Please help me design my new CNC food cutting machine

Thank you forreading this, hopefully you can lend me your experience with your answer.
I apologise inadvance for the lengthy post. (I believe it is necessary to avoid additionalposts to clarify)

I have justpurchased an old CNC milling machine. It has antiquated control and software.
I have managed toget it going with the old software to test the hardware.
Please see video: My new CNC (Part 1) - YouTube
http://www.cnczone.com/forums/attach...d=278084&stc=1


I will be using itas a cutter for my food factory by adding an ultrasonic blade that rotates onthe z axis.
Please see similarmachine in function from Bakon Food Equipment: https://www.youtube.com/watch?v=HBzo5l1LzPo
I have beenresearching CNC technology for about two weeks now.
I think I know whatI want but would like to hear from people with experience and get theiropinion.
I want to upgradeall or most of the electronics to today's current technology.

It has an Isel CNCController C 142-4.1 as a motion controller. (it uses RS232 to connect tocomputer)
https://www.isel.com/fr/downloads/dl...l_complete.pdf

The drivers (UME7008) inside the isel controller may be useful if there is a way of interfacingto them. (any help in this area would be very much appreciated)
https://www.isel.com/uk/downloads/dl...8_hardware.pdf

The three motors ithas are:
X axis
Oriental Motor CoLtd Vexta (PH296-E4.2B)
4.2A 0.46Ohm1.8"/Step
No data sheet existsfor this discontinued motor
Only generic datasheet in japanese http://www.orientalmotor.com/product...601-13JECK.pdf

http://catalog.orientalmotor.com/ite...=prod&filter=0
http://www.cnczone.com/forums/attach...d=278086&stc=1
Y axis
Nanotech(4H8618M1408)
2.4 V 6.0 A 1.8 Deg
http://en.nanotec.com/fileadmin/file...ren/4H8618.pdf
http://www.cnczone.com/forums/attach...d=278088&stc=1
Z axis
Nanotec Munich(4H5618C0408) 3.4V 2.85A 1.8 Deg
http://en.nanotec.com/fileadmin/file...4H5618_L_C.pdf

http://www.cnczone.com/forums/attach...d=278090&stc=1


If there is a way touse the existing drivers and power for the motors it would save me considerableeffort in rewiring all the connections to the stepper motors and also save onpurchasing new drivers and power supply. (by the way they are wired very professionallyalready)


Requirements:

• I will be building a 4 axis machine. 3 for the x, y and z axis and a fourth one to rotate the cutting head.
• I would like to use Ethernet Motion Controller (for various benefits I have read about)
• I will be using touch screen with very simple screen for factory staff to call up 1 of 4 different programs.
• I will be using fixed jigs to place on the CNC worktable to place the 1 of 4 tray sizes to be used. (maybe more in the future by adding jigs)
• I am considering using Mach 4 with customised screen on a touch screen laptop or monitor
• The motions of this cutter are very simple compared to a milling machine and do not need to be as accurate as a milling machine. So I would like the machine to be as fast as possible. (please see video of similar in function machine to Bakon Food equipment video link above)
• I do however need it to be accurate to within a millimetre so it does not accidentally cut the metal tray and damage my very expensive ultrasonic blade. ($6000 still to be purchased)
• I would like the electronics to be best of breed of today's technology and be future proofed as much as possible.

Please comment on mychoice of equipment and where I can buy them from (companies that give bestafter sales support)

Mach 4 software	Should I buy from the developers or is there anyone that does a package deal with the ESS card.
Ethernet Motion Controller	Not sure the best place to buy this from
Power supply for Motion Controller	Is it best practise to have its own power supply if so which one?
Break Out Board to either interface to existing drivers or new ones	From what I read I require one of these to interface to the motor drivers. Is this best practise from an isolation point of view? Is this the most elegant solution? Does it add complexity to the solution? Does it slow down feed rates? I am happy to have one since they are inexpensive. Especially if it saves me form replacing existing drivers / cabling from drivers to motors.
Power supply for Break Out board	Is it best practise to have its own power supply if so which one?
Motor Drivers	If I cannot get the help to interface to existing drivers and power supply that came from the manufacturer https://www.isel.com/uk/downloads/dl...8_hardware.pdf I will need to replace both drivers and motor power supply Not sure which ones to pick? I would like the latest technology if possible. Not even sure what to look for in a good driver. I will however need to buy one additional driver and motor for use as the C axis
Power supply for motors	If I cannot get the help to interface to existing drivers and power supply that came from the manufacturer https://www.isel.com/uk/downloads/dl...8_hardware.pdf I will need to replace both drivers and motor power supply Not sure which one to pick? I would like the latest technology if possible. Not even sure what to look for in a good power supply. I will however need to buy one additional driver and motor for use as the C axis
C axis to mount ultrasonic blade	Possible 4th axis motor and chuck. http://www.ebay.com.au/itm/CNC-Engra...item19fc84273b http://www.cnczone.com/forums/attach...d=278092&stc=1 Possible ultrasonic blade. (still shoping around). I need to determine exactly what parts of the ultrasonic blade can be used for mounting points. http://www.cnczone.com/forums/attach...d=278094&stc=1

Existing driversIsel UME 7008
https://www.isel.com/uk/downloads/dl...8_hardware.pdf
http://www.cnczone.com/forums/attach...d=278096&stc=1http://www.cnczone.com/forums/attach...d=278098&stc=1


I would be veryappreciative to anyone helping in the following areas:

1. High level re design or design refinement.
2. Help with interfacing a breakout board or ESS motion controller to existing Isel Motor drivers
3. Help with choosing the right components

I am happy to postmy progress and photos for:

1. anyone wanting to attempt using a CNC for alternative function (food cutter) or
2. for a newbie to see the choice of components when retrofitting or creating a new 4 axis CNC (hopefully with the insight from various experts on this and other forums)

Thank you in advancefor your help.

AlexanderB

Mach4 & the ESS would be a good choice if you need a control like this, to do what you need, you may be able to use a simple 4 axes index card, to do your whole process no other control needed

Dmm have a really good 4 axes index card that is stand alone, plus servo motors drives, much smoother than what you have, no noise when moving

DMM | AC SERVO DRIVE | AC SERVO MOTOR | ROTARY ENCODER

AlexanderB

Here is their index card stand alone 4 axes control, with simple programing you can make any axes do what you want

https://www.youtube.com/watch?v=4kRd...Uj6f4Q&index=2

Alexander,
Eighteen months ago I bought the same model of used Isel machine. I updated mine with a Gecko G540 controller kit, stepper motors and Mach3. I built the controller myself and used motor cables that were pre-wired with connectors so that part was plug and play. I use a rotary axis for my 4th axis where you would use the knife. The motors just bolted on. I also replaced the couplers on mine because the rubber spider in original ones were getting old. Double check the original limit/home switches. One of mine did not work correctly so I added new switched.

You can get an excellent pre-built setup with Gecko G540 controller, ethernet smooth stepper, cabling, motors, etc. from Dan Mauch at Camtronics. His eBay seller id is "danmauch"

I think the stepper motors would provide plenty of accuracy and speed for the knife cutting operation. A closed-loop servo motor system may provide more speed, but after watching the knife cuter video, I don't see where you would need it.

Bob