ELEKTOR FORUMS

HI!
Here am I with a few more problems!
I have the Profiler since September but only now I had time to explore it.

During board production I have a few problems. I use Eagle as layout editor, I’m not an expert, but I manage to solve some problems.

Here is why I turn to the forum for help: CUT-OUTLINE BOARD; ISOLATION between tracks and COPPER REMOVAL between tracks.

When I produce a PCN, I set the dimension, for instance 30mmx45mm and use Layer 46; then I create a GERBER file, then I go to COLILINER and I draw the polygon around the outline drawn in EAGLE. Afterwards I go the “set contact point” and adjust COLILINER’s polygon to the EAGLE polygon. After this, I set the board milling strategy and select the function “outside the polygon” and I don’t know what happens but the milling cutter always cuts on the line. I’ve tested the other two options and the same happens in the three options! Strange is also the fact that no contour line appears around the polygon as shown in page 17 image of COLILINER tutorial. What I'm I doing wrong?

The other problem I’ve put it in the forum as theme “insulation areas with eagle/coliliner posted by Gralf. Does anyone knows how to remove the copper between tracks and pads? I don’t even know the name of that function in Eagle, or if that removal is done in COLILINER. Please see and example in this link:
http://www.sunequipco.com/PCB/pcb-532006.htm T2 and T3 images demonstrate what I intend to do with the endmill.

Thank you once again my Profiler’s Friends,
David from Portugal

P.S.: Do you know any Portuguese who has also bought a PROFILER?

Hello Ravilez

It’s good to know we live in the same country and very close to each other, I live near Mafra, surely you know.

It seems everyone had to buy a Kress 1050 and I’m very pleased with mine. Although I had a few problems with weight, I managed to surpass them by adding an aluminium part and a spring to counter-balance the weight. Anyway, I find the Z axis very weak to support the milling machine. Anyone had problems already?

As for the MDF working table, I gathered that it wouldn’t be the best solution, so I built a new table, all in aluminium, and on top of it I have a 10mm acrylic part where I glue my A4 PCB’s to double face tape. I would like to point out the relevance of levelling of the bench where the PROFILER is. I only got good results after well levelled!

Regarding the subject that led me to write this topic, I’ll explain it better. I intend to remove completely the copper between tracks and pads. The reason why, is that I have several prototypes in development and all of them work with high tension. Imagine a switch-mode power supply where there’s a tension around 300V and a transistor MOSFET functioning at a 100KHz frequency. How do I make the galvanic isolation between the primary and the secondary? It’s best not to risk!

Fortunately the solution is in the new COLILINER that has enhancements and new options, as partial and total copper removal en PCB. I also hope the problem with the OUTLINE is solved. I only installed it yesterday and I’m waiting for the licence key.

Ravilez, if you’re willing, we can exchange e-mail contacts so we can talk some more about our PROFILER. But I don’t know if we’re allowed to do that here at the ELEKTOR’s forum.

Greetings,
David

I also have the kress 1050 with no problems, no counterbalance stuff.

The only issue is the MDF table as stated by David. I have replaced it with an ordinary shelf at your local wood store.
Then i made a cut with the kress and then measure the diffrens from left to right and is was of by 0.3 mm with is to mutch.
I then compensated under the right side with 3 layer of double sided tape. And did an other round with the kress, voila.

Everything works great.

I also is very intressted in the possibility to remove all copper between tracks and pads. I'am running Eagle and the pcb profiler ULP add on that converts eagle work directly to ColiDrive and skips the coliliner with one press at a buttom, great program.
ftp://ftp.cadsoft.de/eagle/userfiles/ulp/pcb_profiler_v2.0.zip

/ Jonas, Sweden

Hi,

I had a similar problem. When the software is unregistered all the features are available to try (however, you cannot export to Colidrive). When you license the software it switches to a cutdown mode where it will only import Gerber and not NC drill files. I contacted Colinbus and they confirmed that this is the case. This was not explained in the original article. Colinbus support said they would look into it and get back to me but that was several months ago and I have heard nothing !

Andy

Ok. Got an answer from Juraj at Colinbus who says that until you activated Coliliner, you are using a professional version without saving options. Once you get the activation licence, however, the version is reduced to the basic one.
I have been using KiCad, but the profiler plugin for Eagle, thanks for the link Jonas, makes changing software a very attractive alternative instead of forking up for the full Coliliner version.

Richard

Here is part of my first reasonable pcb milled with a Kress and a 36º(0.2mm) groove cutter. Sorry for the poor image quality.

The second image was traced with a 30º normal milling tool and represents a vqfp64 footprint and lines to the piggy-back connectors. The board was ruined earlier, see top right, and I think the results can still be improved on. Any other examples of this sort will be appreciated.

The third is a near success to an experimental pci express x1 cutout with a 2mm router. I tried the 1mm router at too high a speed and it broke off like a drill bit. What is the best router to use for this job and at what speed ?

Hi Zoran,

Is the a document, web page somewhere that shows the name of the versions and details the differences between each version ?

Regards,
Darren

ravilezHi all

I still haven´t mounted the 42mm holder for the Kress which I bought from CNC-Plus, but I can imagine that by adding this additional weight and without cutting its wings, weight problems might arise. It is really very heavy compared to the original Ferm holder and with me winding only tape around the Kress I get very good results. Make sure to get rid of all extra weight.

Hi Ravilez,

The weight of the Kress and the mounting block should NOT be a problem I work with it for 3 months now and it is NO problem. I even have a dust capture device as extra weight and resistance (to move the tube).

I strongly advice everybody to first take care for the best optimized Z-axes alignment you can get. (in fact all axes of course...)
Don't start with corrections if the basics are not in their optimum.
Such kind of compensations do counterstrike themselves now or later

You are right... minimizing the weight is always okay!

Suppose you might call this an auto-reply.
Fits almost like a glove. Board cutout with 2mm router
using Coliliner software. A better tool would be a 1.5mm
router to cut out exactly the 1.7mm pci expess slot separation.

What are the limits of smd engraving ? Experimented to engrave
parts for a low-power quad op-amp, tssop14, and 0603 resistor footprints. Not bad using 30º engraving bit.

The last image is an hpgl imported fom KiCad (sorry ) which is more or less the negative of the isolation contours plus tracks and pads superposed. I produced it using the zone fill operation with no clearance (there is always some, but it aprox. equals that of the isolation gap). The only problem I had was specifying the tool within ColinDrive. I haven't actually milled it, just a dry run, and it took too long using the 0.2mm milling tool. May be the hpgl file could be edited manually to select he right tool ???. Together with the engraving file one might be able to get rid of all the unwanted copper. Note, it's the negataive and real hpgl image must be flipped. Of course, I suppose, one would only remove the copper between isolation tracks where it's really necessary, for example, spikes which can not be grounded.

I am only a beginer.

Yes, there is a english version out now of the "Profiler ULP" for eagle.

Works great !

please contact: gerd_vogel (at) online.de

/ Jonas Hellgren, sweden