Titan ReloadingInline FabricationGraf & SonsLee Precision
RotoMetals2ADvertise hereStainLess Steel Media

Page 1 of 5 12345 LastLast
Results 1 to 20 of 88

Thread: Automating the Master Caster - Another way to skin the cat

  1. #1
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394

    Automating the Master Caster - Another way to skin the cat

    I finally finished assembling the machine.

    Based on the work listed in this thread -> http://castboolits.gunloads.com/showthread.php?t=153579

    I wanted to go one step further and make it totally automated.

    My brother Robert (No_1) automated his using timers and hydraulics.
    I wanted to use pneumatics and use a PLC.

    That is the one done by No_1 (my brother).
    The thread concerning that build is here -> http://castboolits.gunloads.com/showthread.php?t=89909
    This is the video of it running -> http://smg.beta.photobucket.com/user...a/003.mp4.html

    I can't afford to do hydraulic like No_1's setup as its very expensive compared to the Air setup and he uses 8 timing relays to control the MC

    My intial setup is the exact same as wymanwinn's but what is going to be different is the controls. I am not doing a manual control. i want it to be automatic like NO_1's is.

    I installed a micro-switch (limit switch) at the base under the handle.
    Everything is based off of that switch.

    Switch closed (input 1) -> WAIT 1 seconds -> start lead pour relay (output 1 for 5 sec) -> boolit dump (output 2 for 4 sec)

    The entire cycle is about 11 seconds from start to finish. Thats about 655 boolits a hour. I have cast 225 grain 41 mags and 115 grain 9mms using the same program with the only adjustment being the lead pour POT.
    Keep in mind that the lead pour adjustment doesn't affect the lead pour relay time. I use a one shot relay that is adjustable so regardless of how long the signal is sent to it, it will only close for the amount of time based on the pot.

    There are 1 PLC, 2 solid state relays (SSR), 1 standard 2 pole relay (t92 style), 2 3-way air switches, 1 timing relay, 1 250K pot (to control lead pour), 2 DC powersupplies (not enough height for 1 big one), and various switches.

    I will make a list of individual parts for anyone that is interested. Honestly anyone that owns a Master caster should at least automate the lead pour. It doesn't take a lot of parts and can be done in a couple hours tops.

    Click the pics for high res








    Enough talking. Here is a video when I was casting 158 gran SWC 38s.

    Last edited by HATCH; 12-03-2012 at 04:34 PM.

  2. #2
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    Also I am willing to provide the PLC program for anyone that wants to set one up.
    My brother Ray wrote the program.
    I have cast 115 grain 9mm's all the way to 250 grain 45 colts with the only change being the lead pour which is adjusted on the front of the control panel.

    Magma list 15 seconds as the cycle time. As of this post the current cycle time is 10 seconds as I have made changes since I wrote the above post (using word a couple weeks ago). So it does 2 boolits every 10.5 seconds.
    Ran it for over two hours last night

    Basic wiring.

    you need to hook 24vdc ground to terminal C0 terminal
    Inputs

    C1 = 24vdc (NEG)
    X1 = Start switch
    X2 = Stop Switch
    X3 = Limit switch

    Outputs

    V1 = 24vdc (POS)
    Y1 = START LIGHT (OPTIONAL)
    Y2 = STOP LIGHT (OPTIONAL)
    Y3 = LEAD POUR TIMER (TERM 3 ON TIMER)
    Y4 = CYCLE AIR SWITCH (POS)


    TIMER

    1 = AIR SWITCH VALVE (NEG)
    2 = 24VDC NEG
    3 = PLC TERM Y3 + AIR SWITCH VALVE (POS)
    4 = LEAD POUR POT RESISTOR (250k OHM)
    5 = LEAD POUR POT RESISTOR (250k OHM)



    CYCLE AIR SWITCH
    POS = PLC Y4
    NEG = 24VDC (NEG)

    LEAD POUR AIR SWITCH
    POS = TIMER 3
    NEG = TIMER 1

    OPTION LEAD POUR SELECT SWITCH (ON-OFF-ON)
    AUTO POSITION 1 = X3
    COMMON = AIR SWITCH POS
    MANUAL POSITION = TIMER 3
    Last edited by HATCH; 12-21-2012 at 11:38 AM.

  3. #3
    Automated Master Caster

    wymanwinn's Avatar
    Join Date
    Mar 2012
    Location
    Solvang, CA
    Posts
    254
    now you've done it Hatch...LOL

    ok, a parts list if you have time....i agree with the 10sec cycle...watching your video is exactly how i "manually" cycle my now "semi-automated" MC....

    really, REALLY nice job....

    wyman
    Solvang Shootist
    SASS 60905-Life
    Frontier Cartridge Black Powder Shooter

  4. #4
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    I am going to assume that you just want the parts you need to automate it. Not the entire setup including the PID.
    PLC x 1
    Air switches x 2
    DC Power supply x 1
    Solid state timer x 1
    250 ohm pot x 1
    knob for pot (I just reused the temp one off my master caster)
    small limit switch


    The heart of the automation process is the PLC. Automation Direct is who I used. -> http://www.automationdirect.com/adc/...nits/C0-00DR-D
    You do not need battery backup as it will retain the programming without battery backup. Battery backup is if you want to retain counters if your program had them but its not needed for our application.

    I use 2 air switches to control the pneumatics. [MAC PART # IS 35a-aaa-ddaa-1ba] I got them from Kele.com , you can purchase them elsewhere. My cost on them were $45 each (plus shipping). I used 24vdc switches because I needed 24vdc to run the PLC. Here is the catalog page -> http://www.kele.com/Catalog/16%20Pne...log%20Page.pdf

    I used two power supplies because I have illuminated lights on my switches that are powered by 24vdc. You should be able to do it with one. -> http://www.kele.com/power-supplies/ps5r-series.aspx
    The PS5R-B24 is the one I would get. My cost on it is around $42.00

    For lead pour you will need a timing relay. I used a Artisan 4300a-3-1. I got it from Allied Electronics. Cost was $35.00 -> http://www.alliedelec.com/search/pro...x?sku=70089149
    You will also need a variable resister. 250K ohm is what I used. -> http://www.alliedelec.com/search/pro...x?SKU=70153330

    You will also need a main power switch (basic on/off) and 2 normally open push buttons for start/stop
    I also forgot you need a small limit switch. I will snap a picture later and add it to the thread.

    I figure you could automate your setup (if its already setup for pneumatic) for under $300.
    I guess I have about $1800 tied up in my automated Master Caster. This includes the cost of the machine (with 1 mold) and then all the parts to automate it.


    wymanwinn because you helped me with your post and with PM information, I am willing to build one If you provide the PLC itself, I will provide all the other parts and build it for you. You basically would just have to hook up the air lines and plug the power in. Also you would have to mount the limit switch. Its not that hard to mount.
    It would be the basic setup. Main power switch, two illuminated push buttons (start/stop), the 250K pot to control lead pour, the air switches, and the rest of the parts to automate it.
    It would not have the fan control or pot control (PID).

    Limit switch video - keep in mind this is a early video before adjustments were made so its basically BANG OPEN and BANG CLOSE. 7 second cycle time I think.
    Last edited by HATCH; 12-21-2012 at 11:36 AM.

  5. #5
    Boolit Master


    mktacop's Avatar
    Join Date
    Dec 2011
    Location
    Hueytown AL
    Posts
    351
    DANG IT.....I sense another project in the works for me.....

    Nicely done HATCH!! I may have to pick your brain on this....
    USAF Retired

    WAR EAGLE!

    "A government that does not trust its law abiding citizens to keep and bear arms is its self unworthy of trust."
    - James Madison

  6. #6
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    I attached a video of the limit switch in action 2 post up.
    its a early version when I was just setting up the cycle time.
    For reference I did have the machine running on a 6.2 second cycle time at one time.
    Yep 6.2 seconds for every 2 boolits. Yeah over 1100 bullets a hr!!!!!!
    I ran into a issue but it wasn't with the cycle time it was just a issue with the design of the master caster itself.
    The Sprue plate covers up some of the boolit when the mold is open.
    I had to grind it so it didn't cover up the cavity any. I haven't increased the time because it is working fine like it is now.

  7. #7
    Boolit Man
    Join Date
    May 2012
    Location
    OKC, OK
    Posts
    146
    Hatch, I have an air assited master caster, designed by Wyman. Would you be able to build the control unit and ship it fora reasonable fee? I like Wyman only need e control unit, the master caster is already pneumatic.
    Fox
    Last edited by HATCH; 07-18-2017 at 10:34 AM. Reason: remove phone #

  8. #8
    Boolit Master


    mktacop's Avatar
    Join Date
    Dec 2011
    Location
    Hueytown AL
    Posts
    351
    HATCH, could you post (or send me) a wiring diagram of your setup? I'm in the planning stages of making this mod to my Master Caster, and a diagram would be very helpful to those of us less electrically inclined.
    USAF Retired

    WAR EAGLE!

    "A government that does not trust its law abiding citizens to keep and bear arms is its self unworthy of trust."
    - James Madison

  9. #9
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    I will make one when I build the next one.
    To be honest the wiring diagram is in my head.
    I just wired it up as I went along and it worked LOL

    I need to say something.
    I have VERY limited free time.
    I will help out with what I can but it may be the first part of the year before I can get all of this done.

    I am going to assume that you want a drawing for just the control part itself.
    I will draw it with 1 DC power supply as that is what mine would of been if I had the room to do it.
    Last edited by HATCH; 12-06-2012 at 06:09 PM.

  10. #10
    Boolit Master


    mktacop's Avatar
    Join Date
    Dec 2011
    Location
    Hueytown AL
    Posts
    351
    Quote Originally Posted by HATCH View Post
    I will make one when I build the next one.
    To be honest the wiring diagram is in my head.
    I just wired it up as I went along and it worked LOL

    I need to say something.
    I have VERY limited free time.
    I will help out with what I can but it may be the first part of the year before I can get all of this done.

    I am going to assume that you want a drawing for just the control part itself.
    I will draw it with 1 DC power supply as that is what mine would of been if I had the room to do it.
    That would be most appreciated. I understand that you are busy, so am I. It will be a few weeks before I can even start ordering parts anyway.
    USAF Retired

    WAR EAGLE!

    "A government that does not trust its law abiding citizens to keep and bear arms is its self unworthy of trust."
    - James Madison

  11. #11
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    Send me a pm with your email address.
    Will send you the Plc program and the points list on where the wires go.

  12. #12
    Boolit Master


    mktacop's Avatar
    Join Date
    Dec 2011
    Location
    Hueytown AL
    Posts
    351

    Automating the Master Caster - Another way to skin the cat

    Thanks! PM coming


    Sent using Tapatalk
    USAF Retired

    WAR EAGLE!

    "A government that does not trust its law abiding citizens to keep and bear arms is its self unworthy of trust."
    - James Madison

  13. #13
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    Put the basic wiring in Post# 2 in this thread.
    I am willing to email the PLC program to anyone that wants it.

    CHARLES

  14. #14
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394

    Re: Automating the Master Caster - Another way to skin the cat

    Shootinfox got his up and running. Maybe he can post up a pic or two...

    I didn't take any of the final panel.

  15. #15
    Boolit Man
    Join Date
    May 2012
    Location
    OKC, OK
    Posts
    146
    Thanks to Hatch. I willtry to post pics this afternoon.

  16. #16
    Boolit Man
    Join Date
    May 2012
    Location
    OKC, OK
    Posts
    146
    Thread posted under its alive.

  17. #17

  18. #18
    Boolit Master
    Join Date
    Jan 2012
    Location
    The Sooner State
    Posts
    256
    Quote Originally Posted by HATCH View Post
    Put the basic wiring in Post# 2 in this thread.
    I am willing to email the PLC program to anyone that wants it.

    CHARLES
    If that offer is still good, I'll take you up on it This is a really neat project, and I think it's great that you guys are sharing your build information to help the other forum members. I'll send you an E-mail address via PM. Thanks a lot !!!

  19. #19
    Super Moderator


    HATCH's Avatar
    Join Date
    Sep 2008
    Location
    Lexington, SC
    Posts
    3,394
    I came across a couple of 110v fans that i am going to be adding one to the back of the MC. It will be used to cool the lead that is in the mold.
    Hopefully it will allow me to increase the cast rate of the HP mold to 720 per hr instead of the 500 it can do now.

  20. #20
    Boolit Mold
    The Oracle's Avatar
    Join Date
    Feb 2013
    Location
    Colorado Springs, CO
    Posts
    8
    Hatch,

    Will you continue to use the front fan or by cooling it from the rear with your new fan will you remove the front fan completely?

Page 1 of 5 12345 LastLast

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  
Abbreviations used in Reloading

BP Bronze Point IMR Improved Military Rifle PTD Pointed
BR Bench Rest M Magnum RN Round Nose
BT Boat Tail PL Power-Lokt SP Soft Point
C Compressed Charge PR Primer SPCL Soft Point "Core-Lokt"
HP Hollow Point PSPCL Pointed Soft Point "Core Lokt" C.O.L. Cartridge Overall Length
PSP Pointed Soft Point Spz Spitzer Point SBT Spitzer Boat Tail
LRN Lead Round Nose LWC Lead Wad Cutter LSWC Lead Semi Wad Cutter
GC Gas Check