Low Cost CAM idea

Crazy idea for a low cost, highly accurate CAM system which can be made without precision tools.

The Inspiration

http://freeandeasy.sourceforge.net

Rough Sketch

Main Shaft:

Uses a long bolt, with a nut holding the head of the bolt to the base plate then a nut followed by a washer (small so it just covers the inner race) and then the bearing, then another small washer and a nut. Repeat that for the second bearing at the top... then between the two, there are large washers with a very large hole that clear the small washer and nut and those washers are drilled and screwed down to the top and bottom of the aluminum box tube. These will probably have to be 4 of the large washers, above and below each of the bearings. Perhaps the main wheel will go between two of these and be a press fit around the outside of the bearing.

Secondary Shaft

This shaft could be the same as the one above or it could use a rotary air joint in order to supply a vacuum vice in the second disk.

http://www.milllog.com/deublin.htm
http://www.tonymachinery.com/jointweb/productshowcase.htm
http://www.carymfg.com/pages/rotary.htm
http://www.carymfg.com/pages/rotary/main.htm
http://www.rotarysystems.com/index.htm

We have :

Qty 4 Astrosyn Bipolar Stepper IBM P/N: 1408666 EC NO: T4906 23LQ-C202-G4V Minebea CO. Ltd (410-09) pulled from a Lexmark 4039 Optra
- http://www.ni.com/devzone/advisors/motion/mineaba.htm
  
  Series 23LQ-C
  
  # of Models in Series 3
  
  Machine Type H
  
  Size (mm) N23
  
  Step Size (deg) 5.0
  
  Best Accuracy (arcmin) 15.0
  
  Cont. Holding Torque (N-cm) 22.6
  
  Rated Current / Phase (A) 1.0...2.0
  
  Nominal Voltage (VDC) 3.4...6.8
Qty 1 Unipolar stepper pulled from an inkjet with pully and belt.
- AstroSyn PN: EM-217 Type: 17PM-K041-P2F NO: T4Y24 (7.0/step?)
  Series 17PM-K
  
  # of Models in Series 10
  
  Machine Type H
  
  Size (mm) N17
  
  Step Size (deg) 1.8
  
  Best Accuracy (arcmin) 5.4
  
  Cont. Holding Torque (N-cm) 14.8
  
  Rated Current / Phase (A) 0.4...1.2
  
  Nominal Voltage (VDC) 3.0...10.0
- 20 tooth pully
- Belt MB5740 B4 K 04232 309 13 teeth per inch, 34" long.
  
  Using http://www.wmberg.com/Tools/BeltLength.html if the pully is .5 inches in diameter, the center line distance between the wheel and the pully will be 9.591"
  
  Using http://www.hoverhawk.com/bcalc.html with the same figures, the result is 10 and 21/64ths.
  
  Using http://www.csgnetwork.com/pulleybeltcalc.html with the same figures the result is 9.58
Qty 1 stepper pulled from a dot matrix printer with pully and belt.
Qty 6 Allegro A3972SB Dual DMOS Full-Bridge Microstepping PWM Motor Drivers
- http://www.allegromicro.com/sf/3972/
Qty 2 high power 16th microstepping controller kits from Roman Black
Qty 8 608ZZ ABEC7 Predator Skate bearings from Sonic Bearing Co. 8mm ID.
- http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=1856558827

We need:

Qty 3 steppers for the second unit.
Qty 4 Shafts (drill rod?)
- http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=42829
- http://www.catalogs.google.com/catalogs?hl=en&lr=&ie=UTF-8&category=Business+to+Business&issue=6122&catpage=776
Qty 2 Center support with two precision holes and motor supports (see picture below) Note: Mount motors offset left and right rather than one on top of the other (as in the picture) so that larger stock can be held on the top wheel without striking the top motor
- http://www.engineeringfindings.com/cat22/cat22pg28.pdf
- http://www.smallparts.com/HTML%20Product%20pages/zstt.htm
Qty 4 wheels
Qty 4 Belts
- http://www.engineeringfindings.com/cat22/cat22pg267.pdf 1/5i Pitch
Qty 4 Pulleys. Size to match stepper shaft and belt.
- http://www.engineeringfindings.com/cat22/cat22pg266.pdf 1/4iID 1/5i Pitch.