Messages

321

Show"N"Tell ( Your Machines) / ATC Pneumatics

« on: December 10, 2009, 10:59:35 AM »

4 Mach3 Outputs are used to drive the Pneumatics Solenoids: 1) Master Air Enable, 2) Tool RAM Extend, 3) Spindle Air Blast and 4) Tool Release.   4 Mach3 Inputs are also used to read the switches for these actions: 1) Ram Home, 2) Ram Extended, 3) Tool Release Home and 4) Tool Release Extended.  A fifth input will be used to verify the pneumatics system has air pressure before the ATC can be initialized.  (I haven’t hooked this input up yet, the BP412 has a pressure switch and it checked out with a DVM…)    A Mach3 Test Screen with macros was created to test/debug the pneumatic part of the ATC.  
The stock 20 years old air filter and air oilier were replaced with a new filter/oilier.  There was an air pump/charge box?  Not sure what is was or its functionality, but it was leaking air like crazy, so it was removed.

This video shows the ATC Ram and Carousel moving with Mach3 using our test screen:

<a href="http://www.youtube.com/v/8tLJ4iP9Ix4&amp;hl=en&amp;fs=1&amp;rel=0&amp;color1=0x006699&amp;color2=0x54abd6&amp;border=1" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">http://www.youtube.com/v/8tLJ4iP9Ix4&amp;hl=en&amp;fs=1&amp;rel=0&amp;color1=0x006699&amp;color2=0x54abd6&amp;border=1</a>

This video shows the ATC Tool Release moving with Mach3 using our test screen:

<a href="http://www.youtube.com/v/o9DrgaQSEAs&amp;hl=en&amp;fs=1&amp;rel=0&amp;color1=0x006699&amp;color2=0x54abd6&amp;border=1" target="_blank" rel="noopener noreferrer" class="bbc_link bbc_flash_disabled new_win">http://www.youtube.com/v/o9DrgaQSEAs&amp;hl=en&amp;fs=1&amp;rel=0&amp;color1=0x006699&amp;color2=0x54abd6&amp;border=1</a>

Below is the Mach3 test screen, Control electronics and pneumatics

322

General Mach Discussion / Re: It's Alive!! It's Alive!!! (Insert Maniacal Laughter Here...)

« on: December 09, 2009, 05:41:12 PM »

Looks great !   What type of Servo Drivers are you using ?

Thanks,
JH

323

Show"N"Tell ( Your Machines) / Z Axis and its Brake

« on: December 09, 2009, 05:34:51 PM »

We knew the ATC was messed up when got the machine as indicated from the previous owner, so I decided to investigate it first.  I needed to move the Z Axis up so the Tool Ram would have clearance to move under the Spindle Nose and we could get access to all ATC parts easily.  A floor jack and some blocks of wood were used to hold Spindle Head while the Z Brake was disconnected.  The Spindle Head moved up and down with ease using the jack. 

324

Show"N"Tell ( Your Machines) / Mach3, Charge Pump, Breakout Board and Power Supplies

« on: December 09, 2009, 05:10:46 PM »

With the all the old electronics removed, it is time to start building up the Basic Mach3 System.  First things first, Breakout Board and Charge Pump.  I really like the Charge Pump integrated in Mach3, this allows for ALL outs to be tri-stated when the system is not RESET.

The only part we kept in the electronics cabinet was the 3 Phase Power Switch.  We ran 220VAC to the switch fused with 40AMP breaker, so we have 110VAC or 220VAC available on the output of the switch.  A switcher PS provides 5VCD and 12VDC, an analog PS was used 24VDC, and a transformer is used to generate 90VAC and 200VAC.  The solid state relays will be used to switch the pneumatics for the tool changer, enable the oilier and the control the Spindle 200VAC Cooling Fan built into the spindle.  A second relay is connected to the charge pump out to enable the 24VDC Z Axis break.

325

Show"N"Tell ( Your Machines) / Remove the 20 Plus year old stock electronics

« on: December 09, 2009, 02:35:44 PM »

The old electronics were working when we picked up the machine, since there is market to sell them, we did.  Some might think it is better to use the stock components and this is a good argument.  However, we want to be able to repair the machine ourselves in the event of an electronic failure, both quickly and at a reasonable cost.  By upgrading to newer components, we can easily interface to Mach3 and keep or energy footprint low.

The goal is the run the BP412 at 220VAC 1 Phase 40Amps

Pictures of the stock parts:

326

Show"N"Tell ( Your Machines) / Re: 1987 Bridgeport Production Center Interact 412 to Mach3 Conversion

« on: December 09, 2009, 01:50:57 PM »

Wow, on that first picture where they unload it from the trailer, it can actually be seen that the structure is bending above the chains. Did you check the bed and slides were Ok?

Daniel

Yea, it looks worse than it is.  On those old 412s, the sheet metal is in multiple parts and is supported only by the legs on the floor, its realy attched to the machine.  The real machine IRON part just sits inside the sheet metal box on the floor all by itself.  So when the machine is moved by the IRON, the sheet metal just hangs like floppy dog ears.

327

Show"N"Tell ( Your Machines) / Re: 1987 Bridgeport Production Center Interact 412 to Mach3 Conversion

« on: December 09, 2009, 12:34:25 PM »

WOW.....looks good Joel.
Keep us posted on the progress.
That's one tough little trailer too !
How well did it tow ?
NICE,
RC

Yea, that trailer is only rated for 6000LBs.  It road fine, we just keep it at or under 55 mph.  Nerve racking to say the least!  LOL

328

Show"N"Tell ( Your Machines) / Sheet Metal Tear Down

« on: December 09, 2009, 12:29:36 PM »

Most of the sheet metal and the coolant pan were removed, so we could get easy access to the servos, belts, ball-screws, tool changer and wiring.  New paint and will added to the skins and some of the IRON when it’s reassembled.  

329

Show"N"Tell ( Your Machines) / 1987 Bridgeport Production Center Interact 412 to Mach3 Conversion

« on: December 09, 2009, 11:26:41 AM »

The BP412 sat on the trailer for about week, as we tried to figure out an elegant why to unload the 5800lb chunk of IRON.  We ended up calling a local wrecker service, one that is large enough to pull crashed semi’s off the road.  They have fork trucks and wreckers,
and are experienced in unloading/loading crazy things from crash sites.

Here are the pictures of them unloading it from the trailer and placing it in the shop:

330

Show"N"Tell ( Your Machines) / 1987 Bridgeport Production Center Interact 412 to Mach3 Conversion

« on: December 09, 2009, 11:10:50 AM »

We pick up this machine about a year ago, and we now starting to dig into it.   This 412 was used in Tech School for most of its life.  Then a machine shop got it next and ran it until it broke.  The tool changer failed and they we having issues with Y Axis. 

Below are pictures of loading it as we prepared for the 425 Mile trip back to my shop: