02 – Catching Up With China Blue

The Tangerine Tiger Series with Russ Sadler

In this Series, Russ has purchased a new 500 x 300mm, 50W laser machine from eBay with a view to modifying and upgrading it. In fact, he rips out the glass laser tube and high voltage power supply and replaces them with an RF laser source and PSU from Cloudray. Find out how upgrading a Chinese laser machine can improve the performance and accuracy, far beyond that of a standard machine.

In this series you will also learn how the expensive RF laser source compares to a glass CO2 laser tube. So prepare to get your hands dirty!

If you are considering purchasing a CO2 laser machine with an RF laser source from one of the big boy suppliers, I would suggest you check out this series before making a decision!

Contents

(Editor) Russ is upgrading a Chinese laser machine by carrying out some destructive work on his Tangerine Tiger before starting the rebuild to bring it to the same standard as his modified China Blue machine by replacing the belt drive system. First he cuts a side access hole for the stepper motor. Then he replaces the stepper motor bracket and 2nd mirror assembly with an all-in-one assembly that includes a rack and pinion replacement for the drive system. Next up is removal of the cable chain and fitting of the lightweight laser head.

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Transcript For Upgrading a Chinese Laser Machine

Catching up with China Blue

Use the search function at the top of the page to find specific sections of interest.

00:00

welcome to another session with my

00:02

tangerine tiger

00:04

um today we’re going to push on and

00:07

do some more destructive work on the

00:08

machine before we start

00:10

working on it to build it back up again

00:12

there are quite a few things that we’ve

00:14

got to

00:14

modify to bring this up to the same

00:17

standard as my

00:18

china blue over the other side of the

00:20

workshop there and so you know it’s

00:22

pretty straightforward stuff

00:24

some of it but the first thing i’m going

00:26

to do is

00:27

one thing i really wish i’d have done

00:28

early on with my china blue machine

00:31

and let’s get access to everything i’m

00:34

going to put an

00:35

access panel in the side here there is a

00:39

natural divider across here i’ve

00:41

measured it and we’ve got to 295

00:45

millimeters

00:46

roughly and that’s where that piece of

00:49

metal is

00:49

inside and what i’m trying to do i’m

00:51

going to put

00:53

a door in here which i’m going to cut

00:56

out

01:02

and here’s the frame for the door

01:05

okay now the door itself is going to sit

01:08

on that line that i’ve marked there with

01:10

my tape

01:12

and the screws are going to be below

01:15

this panel that’s inside here

01:18

i’ve got to keep the screws below the

01:20

panel because there’s a cable chain that

01:22

runs along and i can’t have the screw

01:24

heads interfering with the cable chain

01:26

and i need these screws up here out of

01:28

the way as well of everything else

01:30

so there are natural obstructions in

01:33

here which define

01:34

where and how i should put this in it’s

01:37

less

01:38

important where this way although

01:41

when i lift this up and move the head

01:43

forward i’ve got to think about

01:45

where my cutting tool is going to go in

01:47

relation to the head

01:49

and the cable chain just to make sure

01:51

things don’t move

01:53

we’ll just tape it in place now i’m

01:55

putting in that i’m locking that in

01:56

place for two good reasons

01:58

first of all i’m going to mark

Transcript For Upgrading a Chinese Laser Machine (Cont…)

02:01

my aperture and secondly

02:03

[Applause]

02:06

now i didn’t waste the piece that came

02:07

out in the middle here

02:09

because now i’m going to put that in

02:10

there

02:13

and just temporarily stick that in there

02:17

[Music]

02:20

we’re going to use a proper drill to do

02:21

the next bit

02:36

now we’re going to start creating some

02:37

dust inside the machine i’m going to put

02:38

dust sheet over everything inside the

02:40

machine

02:41

just to protect all the rails and the uh

02:44

the mirrors and things like that

02:50

[Music]

02:59

[Music]

03:07

[Music]

03:08

this is a weld on there

03:18

[Music]

03:30

clean those corners if they’re the ones

03:33

that are going to show

03:40

these underneath here won’t show

03:51

just remove all the sharp edges and

03:53

burrs

03:57

a five mil hole through here

Transcript For Upgrading a Chinese Laser Machine (Cont…)

04:07

i don’t want to mess up my new machine

04:09

do i look at that

04:11

a little bit of isopropyl alcohol

04:19

restore it to full health back to

04:21

pristine condition

04:24

i’ve invalidated the warranty i’m afraid

04:27

and what warranty was that did i hear

04:28

you say

04:29

okay so here’s the plan we’ve got our

04:31

frame now

04:32

and i’ve remade a separate frame because

04:34

i wanted to cover up this little bit at

04:36

the bottom here which is a bit

04:37

uh a bit rubbish and the idea is i’ve

04:39

put four tapped holes

04:41

in the corners of this frame plastic is

04:43

not very strong

04:44

and not good for putting tapped holes in

04:46

but it’s really only to hold the screws

04:48

in and stop them falling out and we’ve

04:50

got plenty of access into here for

04:53

messing a room with the stepper motor at

04:55

last i can see what i’m doing in here i

04:57

can measure things

04:58

i can get access to things

05:03

just put a cover on there so we can also

05:06

see

05:06

safely into the machine well at least we

05:09

can see what we’re doing

05:10

now so i have to say that this bracket

05:13

is actually substantially stronger than

05:16

the one that i had on china blue machine

05:19

the principle’s still the same but they

05:20

seem as though they’ve made it of 16

05:22

gauge rather than

05:23

18 gauge right so i’ve got the belt

05:25

disconnected now

05:26

but it’ll never go back together again

05:28

until i drill some holes in here

05:30

so that i can adjust the tensioners

05:34

sounds like a bad idea why is that

05:35

screwed in there

05:38

okay so we take that off

05:42

and we can see what’s in here now

05:48

that’s rather alarming news

05:52

yes you can see the bearing block there

05:54

there should be two screws here

05:56

and two screws there well the two screws

05:58

are there over the back

Transcript For Upgrading a Chinese Laser Machine (Cont…)

06:00

but there’s no two screws here so this

06:02

bearing block is only held on with

06:04

two screws this gantry i mean it feels

06:07

secure enough

06:07

don’t get me wrong as i said this is a

06:09

relatively well-built machine

06:11

here’s the bracket that i made for the

06:13

china blue machine

06:16

now i’m pretty confident this will not

06:18

fit on here because

06:19

first of all as you can see the pulley

06:20

won’t actually go through the hole it’s

06:22

a much

06:23

larger pulley on this machine than it

06:25

was on my other machine

06:27

so let’s just have a quick look what the

06:29

heights are like i think the heights are

06:31

going to be okay

06:32

that sits on there and this

06:36

looks as though yeah that will sit on

06:40

there okay that looks perfect

06:42

so that height is correct i’ve got to go

06:44

and design a number two mirror bracket

06:46

that takes the mirror at the right

06:48

height and

06:49

allows this larger pulley to fit in here

06:52

and the bearings have still got to sit

06:55

in there

06:56

and allow everything to run clearly just

06:57

remember that’s why i’ve got this hole

06:59

in the side here so i can get around to

07:01

it

07:02

because there’s a nut in there which is

07:03

difficult to get to

07:13

so we drop the stepper motor down yeah

07:15

we’ve still really got to cut this

07:17

bracket off now

07:19

as there’s only two screws holding that

07:22

gantry on we’ve got this thing to come

07:25

off here

07:29

this sensor is in totally the wrong

07:31

direction as well it shouldn’t be facing

07:33

that way

07:35

so we’ll have this sensor off now i can

07:38

get to the

07:39

bearing screws we’ve got to disconnect

07:42

this cable chain

07:43

and now

07:48

we have a stepper motor bracket in my

07:50

hand

07:52

and i can just go and cut that off there

07:58

okay so i modified the motor bracket and

Transcript For Upgrading a Chinese Laser Machine (Cont…)

08:01

uh i gave it a little coat of paint just

08:03

to make sure that um

08:05

i didn’t invalidate the warranty i’ve

08:06

put the screws back in but hey you can

08:08

see that this

08:09

this motor bracket can be mounted

08:12

anywhere look i can

08:13

i can slide it around forward

08:16

and backwards and wiggle it around

08:20

but even so the one thing i can’t do

08:23

is move it in and out and

08:27

unfortunately that’s the one thing that

08:29

i need to do

08:32

to get this prototype bracket on

08:37

now this is the great advantage of

08:39

having laser machines just now i can

08:40

actually make

08:41

a not a working prototype but a a 3d

08:46

usable model that enables me to check

08:48

that i’ve got everything in the right

08:49

place

08:50

it would appear to fit but the problem

08:53

is it could really do with being

08:56

out there somewhere a little bit further

08:58

out so that i’ve got room

09:00

to get this plugged over the motor

09:03

because of the

09:05

bigger flange everything about it says

09:09

yeah there’s a bit of a problem so what

09:11

i’ve got to do now

09:13

look i’ve got about six millimeter

09:15

difference there

09:17

between where it was so i’ve got to

09:19

redesign

09:20

a motor bracket as well to shift the

09:23

stepper motor out

09:24

it won’t affect the casing here because

09:26

i’m not going to not going to increase

09:27

the size of the bracket

09:28

all i’m going to do is shift the motor

09:30

further away from the gantry

09:32

i’ve got to make a mark ii version of my

09:34

belt drive and

09:36

mirror two holder because mark one

09:40

which was suitable for my china blue

09:43

machine

09:44

is not suitable for this machine

09:48

now there’s quite a few people that have

09:49

asked me can they have

09:52

this unit i think the answer is probably

09:56

no

09:57

because it’s so different than what i’ve

Transcript For Upgrading a Chinese Laser Machine (Cont…)

10:00

seen

10:01

being shipped today

10:04

this machine here i think is more

10:06

typical of the machines that you guys

10:08

might have this one’s got a very small

10:10

drive pinion on it

10:12

and this one has got a much larger drive

10:14

pinion on it and so i’ve had to do quite

10:16

a lot of modifications here

10:18

to get this mechanism to fit into this

10:20

machine

10:21

not difficult but a complete redesign

10:25

i plan to send the mark one and the mark

10:28

ii along with the lightweight head and

10:32

the one piece tube holder with its

10:34

mirror to cloud

10:36

so that they can attempt to create the

10:37

rust spec machine for themselves

10:40

so i’m making it easy for them by giving

10:42

them all the drawings

10:43

and physical parts so that they can play

10:46

with them

10:47

i’ve already had quite a few inquiries

10:48

about when is the rust spec machine

10:50

going to be available from cloud ray

10:52

i can’t answer that question but what i

10:55

can do is pass on your interest to cloud

10:57

ray

10:57

to encourage them to make sure it

10:59

happens sooner rather than later i’ll

11:01

make it completely clear to you guys

11:04

i do all this work for cloud ray for

11:06

free

11:07

it’s not for free because i get the

11:10

major enjoyment out of it

11:11

this is great pleasure for me the

11:13

engineering solving the problem that’s

11:14

how i see this i’ve had the pleasure

11:17

and i’m quite happy to give it away but

11:19

of course

11:20

i’m giving it away to a guy in china

11:24

who has got morals he’s a great

11:26

businessman he’s an entrepreneur

11:28

but he has morals and he sees me

11:32

as a bit of a research and development

11:34

arm so

11:35

he’s giving me this kit okay this is two

11:39

thousand pounds worth of kit here

11:41

which is sent to me to modify a machine

11:45

so stand back from this situation and

11:47

see who are the winners

11:48

me because i’m selfishly getting a

11:51

machine

11:52

which i bought the machine and was

11:54

gifted these parts the expensive bits

11:56

so i’ve got a thousand pounds worth of

11:58

machine and two and a half thousand

Transcript For Upgrading a Chinese Laser Machine (Cont…)

12:00

pounds worth of kit to fit into it

12:02

so there’s an idea just an idea of

12:05

the total value of this package it’s

12:07

somewhat less than thirty or forty

12:08

thousand dollars that you might have to

12:10

pay for a

12:12

proper machine

12:15

we’re gonna see how close we can get to

12:17

the proper machine

12:18

with this venture

12:21

so i think that clears things up i

12:24

bought the machine

12:25

i was gifted some of the stuff i give

12:27

lots of things in return

12:29

and the winners are me mr claude ray

12:33

and you who’s complaining

12:36

right well let’s get back on with the

12:38

job i’m going to be changing the timing

12:40

belt

12:41

in this machine yeah i said timing belt

12:45

because

12:45

that’s what these are these are designed

12:49

for transmitting in one direction

12:53

i’ve mentioned before that these were

12:55

never designed

12:56

for this application cnc machine

13:00

precision movement in opposing

13:03

directions

13:04

the problem with these belts

13:06

particularly this one

13:07

although there’s no stretch in that

13:08

direction the problem is

13:11

these teeth are a bit like a bouncy ball

13:14

when you bounce a ball on the ground it

13:17

absorbs the energy

13:19

and then gives it back to you well

13:21

that’s effectively what these teeth are

13:23

doing

13:24

they’re storing energy up from the

13:26

stepper motor which is doing this

13:28

and they’re at certain speeds they’re

13:31

producing a resonant frequency

13:33

which in a very small way although you

13:35

can’t see it is making this head

13:37

vibrate like this coupled to that as the

13:40

teeth travel around

13:42

the pulley at certain speeds as well

13:45

they will exaggerate this situation so

13:48

we’ve got two things here working

13:49

against us

13:50

when we’re trying to get smooth movement

13:52

out of this head

13:53

to overcome that problem which shows up

13:56

as a curtains problem

13:58

these are lines in the background that

Transcript For Upgrading a Chinese Laser Machine (Cont…)

14:00

actually represent

14:02

the teeth on the belt the teeth on the

14:04

belt

14:05

are actually causing the head to go stop

14:07

start stop start stop start stop start

14:09

and as the head stops the power which is

14:12

constant

14:13

burns deeper and then it runs quickly

14:16

and it burns shallower deeper shallower

14:19

deeper shallower

14:20

so that’s how these patterns develop on

14:22

here and it all comes back to a

14:24

combination of

14:25

the stepper motor which is a minor

14:27

player

14:28

or the belt which is the major player if

14:31

you

14:32

run round playing police

14:35

you can’t have a steppy motion

14:38

so we’ve got a plane pulley that end two

14:41

plane pulleys this end

14:42

and the belt only ever runs around the

14:44

flat side of the belt

14:46

on these pulleys and then what we’re

14:48

doing we’re driving on the outside of

14:50

the belt

14:52

with the stepper motor and the other

14:54

thing is

14:55

i’m changing the belt profile to a much

14:58

stiffer

14:59

belt profile so i don’t get this bouncy

15:02

ball

15:02

effect i’ve had this system working on

15:04

china blue for the last

15:05

nearly three years now and it’s still

15:08

working extremely well

15:10

and i have no hint of resonance now i

15:12

hope that you might be able to see there

15:14

the difference in the belt profile look

15:17

at the tooth look at the profile at the

15:18

bottom here the thickness of the tooth

15:21

the thickness of the tooth at the bottom

15:22

here is wide the thickness of the tooth

15:25

at the bottom there is

15:26

very very narrow so this is made from a

15:28

much stiffer material

15:29

called urethane polyurethane and as you

15:31

can maybe see there it’s got multiple

15:33

steel cores

15:34

in the center so there’s now not much

15:37

more i can do

15:38

at this end of the machine until i get a

15:40

proper

15:41

steel version of this so i’ve got to get

15:44

that away to the laser cutter now

15:46

that design and get them made

15:49

the problem with laser cutting is

15:51

there’s normally a minimum order charge

15:53

which could be anything from 100 to 200

15:55

pounds depending on which

15:56

which which vendor you use um

Transcript For Upgrading a Chinese Laser Machine (Cont…)

16:00

because i use this vendor quite a lot

16:01

for other things um

16:03

i will be able to get i don’t know i

16:05

might be able to get four or five of

16:06

these

16:07

for 100 pounds so that’s what i should

16:09

do i should get a small batch made so

16:12

you know for those few that are really

16:14

interested in trying this

16:16

i won’t sell it to you until you’ve

16:17

checked your machine i’ll give you key

16:18

dimensions

16:20

and if your machine satisfies the

16:22

requirements of those dimensions then

16:23

yes you can go ahead and buy one but

16:25

i don’t want to sell you some scrap

16:27

metal let’s start taking a look at the

16:29

other parts of the machine

16:31

one of the things that we do need to do

16:33

is to get the mass of this head down

16:36

so we know how we can do that with the

16:37

lightweight head there’s another

16:39

problem as well i mean we’ve got

16:42

extra weight down here and we’ve got

16:46

inertia here in the form of this chain

16:49

i mean this is however you look at it it

16:51

is a fairly free running

16:53

i agree with you but this still

16:56

represents

16:56

a load as you move the machine backwards

16:59

and forwards because this is something

17:00

that’s got to be dragged

17:02

all the time okay so

17:05

i can’t get the nozzle out let’s just

17:07

take this brace off here which stops the

17:09

head from

17:09

doing that and if you take it off and

17:11

start running fast

17:13

you’ll get wobbly lines on your scans

17:16

so that’s what this piece of material

17:18

here is for there’s still no arrangement

17:20

on here

17:22

for adjusting the head up and down oh

17:24

they’ve reduced the weight by putting m3

17:26

screws in as opposed to m4 screws

17:28

wow oh and i had several goes at it as

17:31

well

17:31

[Laughter]

17:33

okay so now we’ve got the head off

17:37

as i said one of the most useless pieces

17:39

of tut that they build into this machine

17:41

and i have to say that when i bought my

17:43

first machine i was excited at having

17:45

one

17:46

and that’s this red dot pointer it was

17:48

supposed to be the best thing since

17:50

sliced bread

17:51

uh no let’s put that in the box of bits

17:54

and pieces

17:58

because we shan’t need that again along

Transcript For Upgrading a Chinese Laser Machine (Cont…)

18:01

with that

18:03

and that

18:04

[Music]

18:08

now this thing here is useful for some

18:11

things

18:12

but not on this machine

18:15

so it’s going to come out

18:19

it might seem like a small amount but

18:21

it’s it’s a load it’s a flexing load

18:24

that’s taking place here it’s

18:25

continuously being bent

18:27

you don’t bend things for nothing it

18:29

costs energy

18:31

and it’s mass and what we’re looking for

18:34

this machine to be as fast as possible

18:36

so we’re looking for the smallest

18:37

possible mass that we can get

18:40

in this head

18:48

so we’ve only got one thing left in that

18:52

chain now

18:53

and that’s an airline i think i can do

18:56

something

18:57

to do with that problem basically i’m

19:00

trying to get rid of this heavy old

19:01

chain

19:03

now i’ve seen various people with curly

19:06

cables fixed up the back here

19:08

but but they flop around as they fly

19:11

backwards and forwards

19:13

i don’t want that to happen

19:16

let’s take the cable chain off

19:20

i think we’ll offer up the uh we’ll

19:22

offer up the lightweight head to start

19:23

with

19:24

or at least the the basic framework and

19:26

see

19:27

what we can do with this piece of pipe

19:29

because this represents a small problem

19:32

but it’s an important detail that we

19:34

need to deal with

19:35

more bits for the junk bin but we’ll

19:36

keep that bit because that’s the uh

19:38

that’s the bit to fix the belt on with

19:41

now that’s the miracle of

19:43

acrylic and laser cutting i can quickly

19:46

knock out what’s in my brain in a few

19:49

minutes

19:50

and hey we can try it so first of all we

19:53

need to put a couple of

19:54

m4 nuts in the back there then we put

19:57

our belt plate on

19:58

and fix it to the bearing don’t do the

Transcript For Upgrading a Chinese Laser Machine (Cont…)

20:01

screws up tight

20:05

because they need to jiggle into the

20:06

other holes okay now we’ve got all four

20:08

in we need to tighten them up because

20:12

we’ve got to find out whether this head

20:15

is nice and stiff

20:16

now another m4 nut in the back there and

20:19

one more

20:20

m4 nut in the back there and there we go

20:22

one more m4 by 12.

20:25

tighten everything up right so we just

20:28

lay that in there that will be screwed

20:30

in there but we’ll lay it in there for

20:31

the time being because it doesn’t really

20:33

matter for what we’re trying to achieve

20:37

i put the lens tube in and the butterfly

20:41

clamp

20:42

what we’re really interested in does the

20:44

back corner of that tube

20:46

hit this m4 screw head and the answer is

20:49

no which is brilliant

20:52

because that means i can put a really

20:54

strong fixing on there now

20:55

so we’ll just clamp that in there for

20:57

the moment

20:58

and then we’ll see i’m pretty impressed

21:02

with that

21:03

that is lovely that’s not going to jump

21:05

around that’s really going to work very

21:07

very well

21:08

that’s another major problem all i’ve

21:10

got to do is build this isn’t that’s not

21:11

a problem

21:12

so let’s just take a look at this other

21:14

problem here which is

21:15

this one and have i fixed it with this

21:19

fitting that i’ve put through here well

21:21

i think that

21:24

probably we’ve solved the problem look

21:28

now the only thing that’s going to

21:29

happen is when i push this to the back

21:32

right if i if i happen to be engraving

21:35

along the back there

21:41

it might be forward another 10

21:42

millimeters or so

21:44

but hey look

21:49

we’re not going to have this here anyway

21:51

i’m going to take that off

21:53

and probably mount that underneath the

21:55

gantry here because that’s the right

21:56

place to have light not at the back

Transcript For Upgrading a Chinese Laser Machine (Cont…)

22:10

there

22:22

well with a little bit of patience and

22:23

fiddling i think i’ll probably come up

22:25

with the solution

22:27

now the solution involves making some

22:30

special clamps like this now i’ve made

22:32

these at 10 millimeter

22:33

acrylic but hey they’re not really

22:35

strong enough but they do the job

22:37

to prove the point so i shall have to

22:40

get some probably some metal clamps made

22:42

but not like this um

22:46

and what we’re doing we’re actually got

22:49

the tube here

22:50

and we’re first of all we’re putting the

22:53

tube

22:53

into the clamp now that’s difficult

22:55

because it’s six millimeter tube going

22:57

into a three millimeter slot

22:58

but fortunately this tube is very soft

23:01

and it squashes with difficulty

23:08

but you can get it into the slot like

23:10

that and then

23:12

you can actually slip it

23:15

under the gantry

23:18

so the tube is now tucked underneath the

23:20

gantry not on top of the gantry

23:24

okay and here’s here it is coming out

23:26

just here

23:27

what you need to do now is to take a

23:29

look at this piece of tube

23:31

as i move it from end to end it doesn’t

23:34

touch

23:37

all it does is rotate 180 degrees

23:45

no load on that at all and the because

23:48

this is

23:49

your polyurethane tube it can take all

23:52

sorts of

23:52

um abuse

23:58

neat isn’t it

Transcript For Upgrading a Chinese Laser Machine (Cont…)

24:10

on a hot day like today that’s hard work

24:12

you can see one of my intermediate

24:13

solutions here which

24:14

didn’t really work now all i’ve got to

24:16

do is to find a way of mounting this

24:19

tube so that it comes down the front

24:21

here because the position of the tube is

24:23

pretty crit to get this to get this

24:25

shape that passes

24:27

over

24:30

the head like this

24:35

so we can cut it off and i could

24:38

try plugging it in the front there

24:50

i mean that does work as well

24:55

there’s a little bit of drag on this

24:56

corner now but

24:58

again the euro the polyurethane tube

25:01

will take that

25:06

[Music]

25:07

so that’s a pretty neat solution as well

25:10

it then means

25:11

i can plug that in the back so there we

25:14

go

25:15

another little problem solved taking all

25:17

the weight away from the head

25:18

there’s just the weight of the head now

25:22

and there’s enough pipe in there

25:30

well here we are at the end of a quite

25:32

busy day

25:34

we’ve done actually quite a lot today

25:37

and uh ripped the machine to pieces and

25:39

started putting it back together again

25:41

look this is the latest

25:42

addition the air vent in the front

25:45

hardly shows at all on the lid that’s a

25:47

job completed

25:49

the head is completed the lack of a

25:52

cable chain

25:54

that’s completed we’ve got the belt in

25:57

the wrong way round but that’s a job

25:58

that’s there and now we’re waiting about

Transcript For Upgrading a Chinese Laser Machine (Cont…)

26:00

a week

26:01

for uh the number two mirror holder and

26:03

flexible rack and pinion bracket that

26:05

i’ve got to bolt on the end there

26:07

might be able to get the tube fitted in

26:10

and ready might even be able to test it

26:13

but

26:13

i’ve got other things to do but yeah

26:15

we’ve made good headway in a day

26:17

we’ve designed several bits and pieces

26:20

so at that point

26:21

i think i’ll go and have a nice cool

26:23

shower and

26:24

i’ll see you in the next session

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