G-EDM

The G-EDM is an electrical discharge machine that supports sinker EDM, EDM engraving, EDM drilling and Wire EDM operations. #Drahterodieren

Description

The G-EDM is a fully automated ESP32 based three axis EDM CNC machine that supports different kinds of electrodes like brass tubes or brass sheets and is highly customizable. With the wire EDM extension it is possible to cut high precision parts out of different metals.

It uses 3D printed parts where it is possible and in the future it may support even laser and mill operations. The firmware provides many EDM specific features and is available on Github too: https://github.com/G-EDM/G-RBLevo

The G-EDM pulse generator is a modern buck converter based pulse power supply that does not need a power resistor.

All PCBs use big ground planes, feedback signal traces are fenced with via stitches and in general all ground zones on different layers are connected together with via stitches to get the best possible performance out of it.

https://www.youtube.com/@G-EDM
Contact: goblin-dev@proton.me

Project Logs

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G-EDM EVOIII board - pulse and sensing merged on a single PCB #wireEDM
gedm-dev • 12/02/2024 at 20:54 • 2 comments

G-EDM EVOIII

The new EVOIII board provides a single PCB containing the pulse stage and the sensing stage. It replaces the EVOII pulseboard and the EVOII sensorboard.

The EVOII Cube is a cool looking piece of Art but it is hard to manufacture. To reduce build costs and make it easier to produce the EVOIII PCB was designed. Specs and performance of both versions is the same. There is one difference: The EVOIII uses a single gate driver IC while the EVOII cube has a discrete gate driver circuit. At higher frequencies they don't switch identically and the cube needs a slightly higher duty cycle.

The board provides two isolated analog feedbacks and also isolates the PWM to drive the mosfet gates.
New controlbox
gedm-dev • 11/01/2024 at 01:38 • 0 comments
Ordering the raw boards on your own. Added the links.
gedm-dev • 10/20/2024 at 11:38 • 0 comments

Here are the links to order the boards directly and build them on your own.

All three boards are needed to build a G-EDM.

Pulseboard:

https://www.pcbway.com/project/shareproject/G_EDM_Low_budget_DIY_Wire_EDM_machine_pulseboard_8975f488.html

Sensorboard:

https://www.pcbway.com/project/shareproject/G_EDM_Low_budget_DIY_Wire_EDM_machine_sensorboard_24b74366.html

Motionboard:

https://www.pcbway.com/project/shareproject/G_EDM_Low_budget_DIY_Wire_EDM_machine_34e1e043.html
Cutting text from stainless steel
gedm-dev • 09/26/2024 at 07:06 • 0 comments

The project is almost finished and so far everything works acceptable.
The new concept was able to cut 30mm steel and also 2mm stainless steel.
PCBway helped a lot developing the PCBs and I think they deserve a little fan art for their great work.

The total cut took three hours. This is very slow and based on the feedback shown on the UI scope it should be possible to adjust the settings to make it in 1 hour.

The settings file is the same that made the 30mm cut and seems bulletproof. Not a single issue on this cut except one related to the mechanics.

The X axis belt walked off the idler bearings and finally fully popped off the pulley. That happened at the bottom of the W and from there on the X position is a little off. Shit happens.
I'm doing the recordings with a smartphone and had to swap the clips to the PC multiple times. That is why there are cuts.

Next cut will hunt the max speed.
And a look at the G-EDM EVOII boards. In total there are three PCBs. One to switch the sparkpower, one with isolated dual channel Feedback and one controlboard that runs with an ESP32..
The EVOII cube (pulseboard and sensorboard)

The Controlboard:
G-EDM vs 30mm steel
gedm-dev • 09/13/2024 at 23:11 • 0 comments

The final boss is tamed.
Cutting a 30mm steel block with a cheap DIY wire edm machine is a quest that almost never ends. Almost.
Hot: G-EDM G-RBL EVOII is now on github!
gedm-dev • 09/10/2024 at 12:27 • 0 comments

Start to burn like a pro.
https://github.com/G-EDM/G-RBLevo
So Pulseboard, very motion control, much plug and play
gedm-dev • 06/23/2024 at 00:25 • 0 comments

Fully redesigned the PCBs. The boards now have JST connectors to easy connect them. Wiring the display was the biggest pain in the past. Now it is plug and play.
The ESP board has a few more pins exposed and provides an optoisolated RX/TX UArt interface with a 3.3v to 5v level shifter to control the DPM. Enable/Disable it, change voltage and current etc.
The pulseboard provides bus voltage and high side current sensing. Also fully isolated with linear optocouplers.
New wire module is almost ready for printing
gedm-dev • 05/25/2024 at 23:14 • 0 comments
Working on the new wire extension
gedm-dev • 05/22/2024 at 01:12 • 0 comments

The first wire extension was very specific for the G-EDM tower. It worked very well but with the new router it is time for a new module and add all the improvements possible.
Access to the wire will be easier. The bearings on the spring loaded tensioners are fully exposed to the operator.
Power feed contact is now a real EDM contact that can be shifted to the side to get a new position and it is also spring loaded. This should increase the lifetime a lot.
The internal routing of the power wire and flush hose will end in connectors. A banana jack on top of the module and a push in connector for the water hose next to it.
The flushing nozzle are threaded now and the upper guide has a grip to easily adjust it.
Not finished yet but it starts to get somewhere:
G-EDM EVO II - First cuts
gedm-dev • 05/13/2024 at 22:44 • 0 comments

View all 73 project logs

Discussions

jb333 wrote 12/28/2024 at 17:05

Just placed my order with PCBWay for motion boards! :)

Are you sure? yes | no

gedm-dev wrote 12/28/2024 at 17:29

You need the pulseboard too. Go for the EVOIII board as it is much easier to setup compared to the evoII cube.

Are you sure? yes | no

jb333 wrote 12/29/2024 at 07:00

Of course! :)

I agree with you, the EVO2 cubes are works of art, but the EVO3 boards have to be a lot easier to cool! And, I appreciate the minimal number of connectors; That reduces costs a bit!

See, I'm very poor, minimum disability payment, so I can only afford to do one step at a time; Here's my plan:

1st: I bought a 38-pin ESP32-WROOM-32 with CP2102 USB Interface, a 38-pin breakout board, and rainbow wires with 2.54mm female terminals. Prices = $7, $3, and $0.20, respectively.

2nd: Installed VSCode and the platform.IO extension, then compiled and uploaded the firmware to the ESP32. Price = FREE - Yay Roland! :)

3rd: Bought a 2.4-inch iLi9341 Display with XPT2046 Touch Input. Price = $10

4th: Soldered J1 on rear of screen, then confirmed firmware and touch input, using the breakout board and rainbow wires. Price = FREE - Yay Roland! :)

5th: Ordered motionboards. Price = ~$130 for 20 PCBs.

6th: Acquiring components to solder motionboards.

7th: Order Stepper Motors to confirm motionboards, using power supply I already have.

8th: Order EVO3 pulseboards.

9th: Order components to solder pulseboards.

10th: Order Power Supplies, Wires, Case, etc.

11th: Order 3D-printed parts, including the G-EDM v1 toolhead.

12th: Order an "Aluminum-Foil" Enclosure for RF shielding.

13th: Order gantry plate. (I'm guessing that's the right term.)

14th: Order Aluminum Extrusions.

15th: Build plexiglass tank with filters.

16th: Install extraction fan.

17th: Buy dielectric fluid.

18th: Calibrate Machine and start testing!

I think that's everything! I hope to get this done sometime this Summer, if my budget and health will allow it.

Are you sure? yes | no

gedm-dev wrote 12/29/2024 at 11:14

Sounds like a plan.

Are you sure? yes | no

gedm-dev wrote 12/29/2024 at 12:03

PS: I still like the cube. It feels rock solid while the EVOIII board does flex easy due to the cutouts. But for me they are too much work building compared to the new board. If you want the raw cube PCBs I would give them away for free if you pay the shipment.

Are you sure? yes | no

jb333 wrote 12/31/2024 at 23:03

WOW!!! That's Extremely Generous! :)

I just sent you an e-mail.

Are you sure? yes | no

yfsnd wrote 06/11/2024 at 05:38

Very nice design! I am very interested. Have you shared the circuit schematics and the PCB files? Where can I check them?

Are you sure? yes | no

Mike K wrote 03/13/2024 at 13:31

Amazing work. I am waiting for the PCB files to build and test one myself. I had made an edm machine in the past but my spark wasnt strong enough. Hopefully this board works in my machine.

Are you sure? yes | no

dgourlay wrote 11/22/2023 at 22:44

this is GREAT! I just saw your youtube. Excellent work!

Are you sure? yes | no

gedm-dev wrote 11/23/2023 at 07:41

Thanks. Wish it would be finished soon. But still so much to do.

Are you sure? yes | no

H wrote 10/06/2023 at 00:59

Looks amazing so far! As far as I know there haven't been any other EDM makers that were willing to share their files, so thanks (even though you're not to that point yet)!

Are you sure? yes | no

gedm-dev wrote 10/06/2023 at 02:19

The only thing unreleased are the PCBs and people may be surprised how simple they actually are. The ESP motion controller is jsut a breakout board that makes life easier. The pulseboard is a little more complex but still pretty basic. At some point they will be available.

Are you sure? yes | no

H wrote 10/06/2023 at 23:51

Oh dam I should look more into this. I don't need the motion board since I already have individual drivers + breakout boards that are easy to wire

Are you sure? yes | no

gedm-dev wrote 10/07/2023 at 00:34

The breakoutboard is very useful. It extends the SPI Mosi/MISO/CLK pins and allows to wire the display without hacking 3to1 jumper wires.

Are you sure? yes | no

Jimmy wrote 10/04/2023 at 08:44

Does your GRBL version backtrack on short?

Are you sure? yes | no

gedm-dev wrote 10/05/2023 at 07:26

Yes. The planner of grbl was replaced with one that can move back in history.

Are you sure? yes | no

Piotr wrote 08/10/2023 at 00:00

How feedback circuit looks like? I want to build similar machine and have problem in this part.

Are you sure? yes | no

gedm-dev wrote 08/10/2023 at 01:31

The feedback is just a voltage divider. that outputs between 0 and 2.8v depending on the voltage drop created. Everything else happens at software level.

Are you sure? yes | no

joram wrote 07/12/2023 at 08:48

This looks interesting. Is the esp32 code already in a sharable state?

Are you sure? yes | no

gedm-dev wrote 07/12/2023 at 12:49

Almost. I just need to confirm that the Y axis works too. Currently building the axis. Should be ready soon.

Are you sure? yes | no

G-EDM

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