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The first job was to document the existing wiring, both visually with plenty of photographs as well as by using a multimeter to trace the routing and connections. It quickly became apparent that corners had been cut. For example, with multiple wires soldered to gether , covered with heat shrink and tucked into the trunking.

All wiring and connections were noted down in a spreadsheet for future reference. A second spreadsheet was also readied, to be filled out as the cabinet was rewired. This is an important part of a project as it can save a great deal of time further down the line, avoiding the need for re-checking things as they are removed, disconnected or forgotten.

The top of the control cabinet featured two latching switches that looked as though they could illuminate but in fact did not, and an emergency stop ESTOP switch that was not correctly secured and therefore difficult to operate.

Two intake fans for cooling were mounted on the side of the cabinet, but without any filters. This would allow for dust, swarf and other workshop detritus to be sucked into the cabinet — not ideal when you have high voltages and power present! With everything documented and photographed, the bulk of the control cabinet contents were removed. New parts to be fitted included:. Note that this is not a comprehensive list and just shows some of the new parts ordered.

Before fitting these new components some preparation of the cabinet was required. A blanking plate was made to cover the hole for the wire from the pendant to the original controller interface. Some existing components such as the v filter were relocated to make space for DIN rail, upon which new components could be mounted.

The cabinet sides were also measured and positions for new connectors marked out before holes cut. Drilling and hole cutting was done as early as possible to reduce the chance of swarf causing problems with the new control electronics. With the hole cutting complete, the cabinet was thoroughly cleaned to minimise risk of any problems due to remaining swarf. An Ethernet socket was also mounted closer to the bottom of the cabinet, to keep the network cable out of the way.

The power and ESTOP switches at the top of the cabinet were replaced with higher quality units that were properly secured in place.

An off-the-shelf Ohmic sensor module was installed. This is connected to a tab on the plasma head and provides a way of 'touching off' by measuring the resistance between the head and the workpiece.

Configuration of this will be covered in a future post. With plenty of space on existing and new DIN rails, terminal blocks were installed, allowing the original soldered bundles of cables to be replaced with a safer and more maintainable solution. Each new wire was labelled with wire markers and noted down in the new wiring spreadsheet.

Depending upon requirements, ferrules or other crimp connectors were added to the ends of all new wires to ensure reliable electrical connection throughout. Fuses were also added to the low voltage power supplies to reduce potential damage caused by a fault somewhere within the cabinet. The BBB has sensitive inputs and outputs and therefore requires a separate board to interface it with the other cabinet electronics.

Since the Probotix PBX-BB worked well for our previous milling machine conversion, it was also selected for this project. This protects the BBB from potentially damaging noise and spikes, as well as breaking out the connections with screw terminals. More information can be found on the Probotix wiki. The plasma cutting machine currently has a DC motor to control the height of the plasma head. This could have otherwise been made up on vero board using a H-bridge IC and several other components.

For simplicity, an existing opto-isolated relay board was used to interface the two. These boards were all mounted on an acrylic plate, added to the cabinet and wired up as required. Two homing switches are used on the table, for X and Y axes respectively. These are hall effect modules that require 24V supply and sink up to 50mA when activated. See the illustration below for a simplified control signal diagram, including this homing switch solution.

With the wiring completed it was visually inspected with reference to the new spreadsheet, before each connection traced with a multimeter. The BBB was not fitted during the initial power-on tests, in case of any remaining wiring errors. Following a successful test it was then fitted and a monitor, keyboard and mouse connected in preparation for the first boot.

For convenience and stability, the latest Machinekit image was downloaded from here and written to a micro SD card. For the adventurous, Machinekit can be built from source and is an active project with regular contributions.

Put simply, this allows for re-configuring of hardware inputs and outputs, together with machine parameters through the editing of a t e xt file.

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