MakerLab is a Tunisian tech startup specialized in developing customized embedded systems and mechatronics projects to industrials.
In MakerLab, we believe in the Open Source Hardware philosophy and we want to spread the tech knowledge we gain, with the community so everyone performs itself and benefits from others experiences. And this is why, we made from our little space in Sousse, a TechSpace, open for everyone who wants to work on real projects, finding all what a Maker needs to create his own tech project.
In our TechSpace, many projects were developed and created, even if it is by our staff or by students from different universities across the country, starting from Drones, Internet of Things (IoT) devices, arriving to Robotic Arms and CNC Machines.
Moreover, this 5 Axis CNC Machine, is our first Open Source Hardware Project we made, and which we are so happy sharing it with the community.
You can find more details on our TechSpace in our:
Lien Facebook : https://www.facebook.com/tunmakerlab/
Lien siteweb : https://makerlab.tn/
This 5 axis CNC machine, is part of a big project made by our partners Open Lab Hamburg from the Helmut Schmidt University in Germany, for the benefit and with the collaboration of FABLAB ENIT (National School of Engineering of Tunis), and sponsored by the BMBF.
Being always updated to the latest OSHW projects in the community, we found that there is many 3 Axis CNC machines, 3D Printers and Laser Cutter with a very good documentation, but not enough OSHW 5 Axis CNC machines and not at all for the Head/Head type.
Dimensions 5xm600 : 650 x 670 x 480mm
Working volume 5xm600 : 990 x 780 x 1000mm
Max travel speed XYZ : 15000mm/min (X,Y); 3000-6000mm/min (Z)
Max travel speed BC : 20rpm(C) 20rpm(B)
Motors used : NEMA 23 ( X / Y / Z / B / C)
Linear guides : HIWIN High accuracy Rails and Blocks
Structure material : Anodized Aluminum
Protection : 5mm Acrylic enclosure
Power requirements : 1200W, 220V, 60hz, 13A
Weight : 85kg
Computer interface : USB
Computer requirements : Windows operating system with Mach3
Controller : MACH3 (to be purchased separately from an official vendor)
Software : supports any CAD/CAM software
CNC machines are commonly known that they are nothing more than automated robots, their famous type, is a 3 axis CNC machines, which are considered as 3P robots (robot with 3 Prismatic Joints linked with 4 Links).
But in 5 axis CNC machines we talk about 3P2R robots, because they are composed of 3 Prismatic Joints succeeded with 2 Revolute Joints, and linked with 6 Links.
The Links are named : Frame, Y2X Bridge, X2Z, Z Axis, Swivel Head and the Spindle.
Designed to be easily made, assembled and disassembled, we choose the aluminum profile to be the main structure composition. As it's important that the structure be stiff and robust, we wanted to work with 45 series aluminum profiles.
The Y2X Bridge is the second link in our 5-axis CNC machine, it links the Y and X joints.
X2Z, as its name indicates, do the function of the joint between the two prismatic axis, X and Z. X2Z is an assembly that plays a big role in our 5 Axis CNC Machine, because it assures both, the linear guiding of X axis, Z axis and their transmission organs.
The Z-axis, slides on the 2 blocks installed on the X2Z Flank plates. The motor module installed on its top assures its motion. The Z motor transmit rotation to the ball screw that moves the Z-axis up and down.
The swivel head is composed from the last two revolute joints, C & B. What is special about this assembly, is the fact that it should be the more compact possible. So the two motors, their transmission system and even the limit switches and connectors should all be enclosed in this assembly, and this was the hardest task that we encountered in the whole machine design. While designing the Swivel Head, there was 2 big challenges, the choice of transmission system and minimizing joints offset relatively to each other.
For the spindle motor, we did our best to find small and powerful, and not too expensive ones in the market, but we found none. The main specification needed is a small size, but the most of powerful spindles are so big that you cannot integrate in the swivel head. This is why we designed and fabricated our own spindle composed of a 540W Brushless motor, a bearing housing and an ER11 chuck.
Machine movement along X, Y and Z Axis is assured by 4 motor modules. Containing pulley and belt transmission system between the motor shaft and the shaft.
Installed in an industrial plastic enclosure (400x500x240), the electronics of the CARVER X5 is composed of a set of drivers for each motor including the spindle driver, a USB interface control board, a sensor interface board and two 12v 42A DC Power Supply.
▪ THE PoKeys57CNC control board PoKeys57CNC USB and Ethernet CNC controller is a blend between general purpose PoKeys device and motor controller. The device is targeted primarily for controlling up to 8 STEP/DIR signal driven motors (stepper motors, servo drives, etc.) in various applications with the addition of powerful PoKeys device features.
Download PoKeys57CNC datasheet here.
▪ Drivers TB6600 Stepper Motor Driver is an easy-to-use stepper motor driver, which could control a two-phase stepping motor. It is compatible with Arduino and other microcontrollers that can output a 5V digital pulse signal. TB6600 stepper motor driver has a wide range power input, 9~42VDC power supply. And it is able to output 4A peak current, which is enough for the most of stepper motors. The stepper driver supports speed and direction control. You can set its micro step and output current with 6 DIP switch.
Download TB6600 datasheet here.
▪ The sensor cables gatherer board The need for the sensor cable gatherer board has emerged due to the multiplicity of sensors. And to minimize the number of cables passing through the cables carrier, first, we managed to gather them in a 15 cores VGA cable, then we choose to use 2 DB9 ports and cables, one for Limites (+), and the other for Limites (-).
This board provides the current and voltage needed to all the 10 sensors used in the machine and the toggle switch, and is installed on the Y2X Bridge in between the two cables carrier.
(Board KiCAD)
▪ The sensors interface board
This board will play the role of the interface between sensors signals coming from the first board and the pokeys57cnc board through a little circuit of signal adaptation.
Inductive proximity switches works with 12V power supply, and returns a 12V digital signal, but the pokeys57cnc can only handle 5V digital signal in limit switches inputs.
This is why we used a circuit based on a 470 ohm resistor for current limiting and a 5.1V zener diode to let only the needed 5V pass to the control board for each signal.
▪ Spindle motor Driver As we created our own spindle based on brushless DC Motor, we used its recommended Electronic Speed Controller as a driver. A 60A ESC is responsible of driving the motor at 20 000 RPM at 24V. Product page Link.
One main task we did is the wiring, and it is so important. We used RGB 4 wire Cables for the stepper motors, they are thick enough to carry the needed current. The end stop switches cables were long enough to reach the first interface board installed on the bridge assembly. We gathered all sensors signals in two RS232 cables to facilitate connection. Of course all these cables needed a way to be placed in, so we used 57x25 industrial cable carrier to arrange all wires to the electronic enclosure.
Fusion 360 combines industrial and mechanical design, simulation, collaboration, and machining in an integrated concept-to-production toolset. Fusion 360 is the first 3D CAD, CAM, and CAE tool of its kind. It connects your entire product development process in a single cloud-based platform that work both on PC and MAC.
Download Link.
PoKeys software setup package contains PoKeys configuration tool (also used for firmware updating), USB drivers, manuals, PoBlocks tool, Mach3 plugin etc. After installation, run the PoKeys application to update the firmware of PoKeys devices.
Configuration explanation video Link.
Download Link.
Mach3 turns a typical computer into a CNC machine controller. It is very rich in features and provides a great value to those needing a CNC control package.
Configuration explanation video Link.
Download Link.
The Machine Building Workshop was a great experience to all of us, and it was the first step to sharing knowledge with everybody.
This is a set of photos describing the general atmosphere in which passed this wonderful workshop.
Ice breaking & debriefing around CNC machines and their purposes
Knowing everything about the design of the CARVER X5 and the different steps will do during the workshop
-Workbench and space preparation
-Frame assembly
-Electronic circuit schematic design
-Y2X Bridge Assembling
-X2Z Assembling
-Electronic enclosure Assembling
-Plexiglas enclosure assembling
-Wiring electronic parts
-Presenting the machine and Workshop roll up
The project is still in progress, we finished the design of the whole machine, and the fabrication of the 3 first axis and all the electronic parts. Actually, we are manufacturing the double swivel head and the spindle system. We moved the X,Y,& Z Axis with the Pokeys57 and Mach3, and we are working on the CARVER X5 post processor for FUSION 360. We will update regularly this project in every progress we make, and we hope that this will be helpful for the whole OpenSourceHardWare Community !! Don't forget to interact with us, send your notes or eventually you amelioration ideas !!
Everything has to end, and so did the Open Source 5 Axis CNC Building Workshop! This workshop passed in an amazing way, and was a great success for all of MakerLab's team! The knowledge of one month of machine design, followed by two months of fabrication and assembly, shared with amazing people from all over Tunisia, gathered in FabLab ENIT seeking one unique goal: Learn how to construct Machines! And today, this same knowledge is being shared with the whole DIY & Open Source Hardware community.
This project was launched by Open Lab Hamburg from Helmut Schmidt University, sponsored by BMBF, which we thank a lot for their confidence and the opportunity they gave to us as a startup. This Workshop was hosted by FabLab ENIT, and was successful thanks to the devotion of the participants who are from now on "Machines Makers".
We would like to thank all the FabLab ENIT Team, 4C Center, ENIT administrative staff for their collaboration. Coaches Danielli Ingressia, Hashim Al SAKKAF and Kais ALILA, three great Makers from the Open Source community that we had the opportunity to work and exchange ideas with. All the gratitude and thanks to Babasile Daniel, for his support and encouragement. Special thanks too to our families and friends who supported us in this big challenge (Marouen FAKHFAKH and Rabie TAHRI)
CARVER X5 Designers -Anis TRIGUI - Project Manager, Machine Designer and Coach - CEO of MakerLab -Mohamed MAATOUG - Designer and Pedagogic Certified Coach - MakerLab member Makers of MakerLab Azer KHALED, Alaa MEJRI, Khalil SLAMA, Salem MBAREK, Amine MAHDHI, Jawher MANSOUR, Moez KAZDAGHLI, Yassine CHEOUR Machine Building Workshop Participants ( Green Team) Sinda BESROUR, Eya CHROUDI, Sahar FRIKHA, Mootaz BEN ZINOUBA, Hassen ARBI, Haythem LTIFI, Abderrahmen MELLITI, Youssef SAFER, Seifallah BOUCHOUCHA, Taha ISSAOUI.
And finally, we would like to thank our partners, without their help, we couldn't reach this milestone:
Stay tuned to learn about our new coming Open Source Machine that we are planning to construct.
The development of this machine has been funded by:
German Federal Ministry of Education and Research
Funds implemented by:
OpenLab Hamburg
Helmut-Schmidt-Universität Universität der Bundeswehr
Laboratorium Fertigungstechnik
Holstenhofweg 85
22043 Hamburg
Ce(tte) œuvre est mise à disposition selon les termes de la Licence Creative Commons Attribution 4.0 International.
This documentation will be continuously improved as soon there are updates and/or improvements on the machine.