Converting and Improving a K40
I have invested an inordinate amount of time converting my K40 to a better cutting and engraving tool. This post concatenates my K40 conversions posts into a build index. I am doing this with the intention of helping others reduce or eliminate their research, design and build time for K40 conversions.
There are many RIGHT ways to convert a K40 but the most often frustration I see from K40 owners is having a clear and as-simple-as-possible, but not simpler, set of build instructions that result in a working configuration.
This build log should have everything you need to know to clone my design including parts. If it doesn't or something is missing let me know in the comments or G+ me at:
+Don Kleinschnitz
My approach in this conversion was to start with a clean sheet of paper and engineer the needed modifications. That means that I am analyzing each subsystem, understanding its operation, specifying a conversion design followed by build and then finally verification of performance.
This post pulls together detailed posts for each subsystem with the expectation that in the end it will give the community a specific configuration that works.
My ultimate intention is for this information to be simple to use for most makers yet detailed enough to satiate an engineer.
Some of this content was designed by myself along with the associated testing and research. However a large amount of content linked in here came from the hard work of others. I just linked things together in a way that made sequential sense to me.
I thank and acknowledge the work of many other members of these communities that contributed in a significant way.
This is a work in progress so expect changes. I will keep this post updated as my analysis/design/build/test and usage evolves.
Donate:
Please consider donating (button to the right of this post).
Your donations help fund additional research, tools and parts that I will return to the community as build and design information and how-to's.
Status
BUILD COMPLETE
Machine in operation testing minor jobs and making repairs and improvements
Machine in operation testing minor jobs and making repairs and improvements
Advantages of this conversion design?
This design adds the following improvements to the standard K40 experience:
- Protocol: GCODE enables a better part design tool chain
- Increased safety: interlocks, mains shutdown, grounding verification
- Documentation: includes ENGLISH schematics and drawings for everything.
- Cutting/engraving performance: Air & vacuum assist
- Robust DC power supplies
- Open source software tool chain: such as: LaserWeb, SketchUp, Inkscape
- Support: a rich G+ community with engineers and experienced laser builders and users willing to help.
DON"T IGNORE THIS!
CAUTION: LASERS AND THEIR HIGH VOLTAGE SUPPLIES ARE BOTH ELECTRICALLY LETHAL AND OPTICALLY DANGEROUS. THEY HAVE THE POTENTIAL TO KILL AND/OR BLIND YOU
STAY AWAY FROM THE HIGH VOLTAGE SUPPLY'S OUTPUT!
WEAR PROTECTIVE EYE WARE AT ALL TIMES WHEN OPERATING A K40!
DO NOT OPERATE A K40 WITHOUT THE PROPER LASER INHIBITING INTERLOCKS INSTALLED AND OPERATING PROPERLY!
BY READING THIS POST YOU AGREE TO USE THIS INFORMATION AT YOUR OWN RISK!
CHAPTER 1: A SIMPLIFIED WIRING DIAGRAM
If you want to get right to the core of the electronics here are the full Build Schematics and below is a simplified sketch of the Smoothie wiring. Pretty one coming soon. The lift table integration is not included on this sketch
CHAPTER 2: THE INTERLOCK SUBSYSTEM
CAUTION! Unmodified K40's are dangerous.
K40's do not come with interlocks however every K40 should have interlocks installed!
The K40 laser is dangerous and can blind you.
Interlocks should be installed on the main cover and the rear laser compartment.
Don't defeat them when your inside the machine. Its not that hard to make an adjustment and close the lid to check the results.
Wear your safety glasses especially if you have defeated interlocks which I just suggested you do not do!
- Detailed build post: http://donsthings.blogspot.com/2016/11/k40-s-interlock-breakout-board.html
- See Build Schematics for details
CHAPTER 3: ADDITIONAL SAFETY IMPROVEMENTS
- Coming soon, keyed Laser enable switch
- Coming soon, mains shutdown
- How to verify K40 grounds
CHAPTER 4: THE CONTROLLER ELECTRONICS SUBSYSTEM
- This Simplified Smoothie Interconnect Diagram shows just the wiring to and from the smoothie.
- Smoothie controller
- My Current Configuration file
CHAPTER 5: CONTROL PANELS
I have elected to use two control panels on my K40-S. The stock panel will server as the "K40-S Operations Panel" and the GLCD will serve as the "Controllers Operations Panel. My reasoning was as follows:
- These two panels have no interconnections with each other
- I needed more real estate than the stock panel could provide
- I wanted to make the smoothie and its interconnects modular so I could reuse the packaging for other CNC projects and test it on the bench.
Controller interface panel
Operations Panel
- Coming soon, redesigned K40 operations control panel
- When your Current Pot Fails
CHAPTER 6: THE POWER SUPPLY SUBSYSTEM
DC Power
AC Power
The Laser Power Supply & PWM
Interfacing to the the Laser Power Supply
http://donsthings.blogspot.com/2016/11/k40-laser-power-supply-control-take-2.html#more
Laser Power Supply Test, Repair & Installation
Engraving and PWM control
LPS Configuration Definitions
http://donsthings.blogspot.com/2017/01/k40-lps-configuration-and-wiring.html
Engraving and PWM control
LPS Configuration Definitions
http://donsthings.blogspot.com/2017/01/k40-lps-configuration-and-wiring.htmlCHAPTER 7: GANTRY SUBSYSTEM
Interfacing to the gantry electronics
Cable management on the gantry
K40 Motors
http://donsthings.blogspot.com/2016/06/k40-s-motors.html
The finder LED
I used a simple approach to implement the finder because I wanted to keep the head bracket simple. The disadvantage of this approach is that the pointer is offset from its true position when the table goes out of the focal range. To date I do not use the finder to locate anything accurately so I am using a single diode vs two with dot or line output. If I do need more accuracy I plan to move the finder so that it enters and exits the light path through the objective lens and therefore totally remove it from the head altogether (more on this idea later).
CHAPTER 9: Z AXIS SUBSYSTEM
How do CO2 lasers work
https://en.wikipedia.org/wiki/Carbon_dioxide_laser
http://www.recilaser.com/en/productInfo/fc9181e840aa427d0140aa55363800f1.htm
- The finder diode is mounted on the head.
- The finder uses a Laser diode that is mounted in a holder. The holder is adjustable with a screw.
Gantry parts
CHAPTER 8: CABINET MODIFICATIONS
Controller packaging
This packaging design mounts the controller outside the K40 and the DC supplies inside.
- Packaging Assembly
- Drawings Coming soon
- Build post coming soon
CHAPTER 9: Z AXIS SUBSYSTEM
CHAPTER10: LASER OPTICS SUBSYSTEM
CO2 Laser Theory and Operation
Basic Principles of OperationHow do CO2 lasers work
https://en.wikipedia.org/wiki/Carbon_dioxide_laser
Laser Specifications
This is the best reference I have found for laser operating specifications.http://www.recilaser.com/en/productInfo/fc9181e840aa427d0140aa55363800f1.htm
Laser tube mounting brackets
- Build post coming soon.
- Tube bracket design work
Mirror mounts and assy. changes
http://donsthings.blogspot.com/2017/01/k40-optical-path-improvements.htmlK40 Optical Systems Modelling for Better Alignment
http://donsthings.blogspot.com/2016/06/k40-alignment-tools.html
Aligning, Cooling, Operating and Protecting The Laser
http://donsthings.blogspot.com/2016/07/k40-k40-s-tips.htmlCHAPTER 11: THE DESIGN TOOL CHAIN
CHAPTER 12: AIR AND VACUUM ASSIST SUBSYSTEMS
CHAPTER 13: K40 & K40-S TIPS AND FAQ'S
http://donsthings.blogspot.com/2016/07/k40-k40-s-tips.html
CHAPTER 14: TESTING YOUR BUILD
Coming soon...
- AC power and grounding
- DC power and grounding
- Interlocks
- PWM
- Endstops
- Steppers
Appendix A: REFERENCE MATERIALS
- Build Schematics
- K40 album
- Coming soon, Testing
Hi,
ReplyDeleteOutstanding results at affordable Laser Hair Reduction Machine . More info about Laser Hair Removal Machine visit elenusmart. Buy Now with best price.
Elenusmart Laser Hair Removal Machine
Order Online Laser Machine
Dr Brahmananda Reddy is established Elenusmart for innovative services to providing medical devices and dermatology machines, beauty machines.
Don, I am currently doing a liteburn AW708c dsp controller upgrade. My K40 has the zte laser myjg40w power supply . will this power supply work with the AW708c controller?.and do you have a wiring diagram for this upgrade?.
ReplyDeletethank you for your time.
Hi Don,
ReplyDeleteI am not sure what to do with my machine. It works properly but I was going to install a ammeter but the neg wire from the tube is attached to the FG position and the ground wire from the machine is attached to the L-. Should I just switch the two wires so that the ground from the tube is attached to the L-? Thanks
My testimony of Getting ex back after breakup
ReplyDeleteMy boyfriend of 4years broke up with me and I was 3 weeks pregnant. I have cried myself to sleep most nights. Sometimes I stay awake almost all night thinking about him and start to cry all over again. Because of this I end up not having energy for my next day’s classes, my attendance has dropped and am always in uni and on time. Generally he is a very nice guy, he ended it because he said we were arguing a lot and not getting along. He is right we’ve been arguing during the pregnancy a lot. After the break up I kept ringing him and telling him I will change. I am in love with this guy and he is the best guy I have ever been with. I’m still hurt and in disbelief when he said he didn’t have any romantic feelings towards me anymore that hurt me faster than a lethal syringe. He texts me once and then mainly to check up on how am doing with the pregnancy, he is supportive with it but it’s not fair on me, him texting me as I just want to grieve the pain and not have any stress due to the pregnancy. I was really upset and I needed help, so one day I came across a website that suggested that Dr. Imoloa can help solve marital problems, restore broken relationships and so on. So I felt I should give him a try. I contacted him and he told me what to do and I did it then he did a spell for me. 2 weeks later, my boyfriend came to me and apologized for the wrongs he did and promised never to do it again. Ever since then, everything is back to normal. I and my boyfriend and I are living together happily again. Dr. Imoloa as it is a place to resolve marriage/relationship issues, do you want to be sure if your spouse is being faithful to you or Do you want your Ex to come back, power to control crowd, happy marriage love spell, unable to get pregnant, Loto Spell, protection spell, traveler spell, job spell, attraction charms, extreme protections and so on. Contact him Via Email-drimolaherbalmademedicine@gmail.com / Whatsapp- +2347081986098. Website- drimolaherbalmademedicine.wordpress.com
Hello, my fuse just blew within the PSU.
ReplyDeleteWhat is the amperage rating for the main fuse?
can anyone show me the circuit trace on x axis optical sensor on a k40
ReplyDeleteIn the bustling city of Surat, businesses of all sizes are constantly seeking cost-effective solutions to streamline their financial operations. Enter Accounting Software for Free in Surat, a powerful tool that empowers businesses in this vibrant Gujarati city to efficiently manage their finances without incurring significant expenses.
ReplyDeleteFascinating! WAY over my head at this point, though.
ReplyDeleteI'm upgrading my 40 watt to a 60 watt and have a Cloudray M60 replacement. The pin outs are compleely different and Ive been trying to find a simplified schematic, wiring from the stock JG 40W to the new M60.
Can you assist me please? I'll be 71 this fall and need all the help I an get!
Many thanks
Laser hair removal in Amsterdam is an excellent choice for those looking to achieve smooth, hair-free skin. With advanced technology and skilled professionals, this treatment offers a safe and effective way to permanently reduce unwanted hair. Whether you’re targeting small areas like the face or larger areas such as legs and back, laser hair removal provides lasting results with minimal discomfort. It's perfect for people seeking a long-term solution to shaving, waxing, or plucking. Plus, in Amsterdam, you'll find clinics offering top-notch care with personalized treatment plans tailored to your skin type and hair texture.
ReplyDelete