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Author Topic: Bridgeport Knee Mill Conversion?  (Read 158972 times)

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Offline Hood

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Re: Bridgeport Knee Mill Conversion?
« Reply #230 on: June 05, 2016, 11:37:11 AM »
I think I have about 3 or 4 digital I/O's  spare on the plasma and I too have the MPG module and the IP-S has more than the IP-A.

Hood

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #231 on: June 05, 2016, 11:42:37 AM »
I must have missed some bells and whistles then ;)

I even have it controlling the lamps on the buttons so that the OFF, FEED-HOLD ETC only come on when code is running etc

Having the limits on the power side rather than the control side also saved inputs.

Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Hood

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Re: Bridgeport Knee Mill Conversion?
« Reply #232 on: June 05, 2016, 05:16:27 PM »
No limits via the IP-S either, all hardware and only an E-Stop input.

Just looked and I am using the following I/O (so far)

For outputs I have
Enables for X, Y and Z and just doubled up slave with Y. I could have used one enable for the lot but using three or more reduces the Inrush as there is a delay between enables specifically for that purpose.

I have Fault Reset  buttons for X Y Z and again just shared slave with Y.

I have a Home Z output but that was for the current sensing method so I will not be using that now

I have the Solenoid for the cylinder.

I have 3 used for the THC and may use another for the C Axis protocol if I think it will be worth it.

So all in all I  am using 10 of the 16 outputs but as said could easily free up more if required by using the one enable and even the one reset.


Inputs

I have Z at Home, this again is not used now as it was for the current sensing homing. I am not sure if the cylinder for the touch off I am using has magnets inside, if it does then I will likely fit a reed switch for added safety when probing, so would use this input.

I have X Y Z and Slave  fault signals

X Y Z and Slave Index Inputs (not needed on IP-A as it already has Index Inputs)

E-Stop input

3 THC Inputs

M31 Limit switch input

I have 9 switch inputs

Input for the torch breakaway prox sensor

X Y Z and Slave Home switch Inputs

So 28 out of the 32 Inputs used so far.


Hood

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #233 on: June 06, 2016, 02:14:43 AM »
Of course, its a plasma not mill ;)

So far I have..

Analogues - feed rate override, speed override, vfd1 speed, vfd 2 speed

Digitals ins...
Servo x fault
servo y fault
servo z fault
cycle start
feed hold
stop
E-stop signal
Probe
spindle toggle
Ref Z axis
Home X*
Home Y*
Home Z*
VFD 1/2 fault

*these will likely be left as screen clicks as only used once per session

Digital outputs...
Servos enable
servo's reset
spindle fwd
spindle rev
coolant
relay for button lamps
spindle 2 fwd
vfd 1 select
vfd 2 select

:)
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #234 on: June 06, 2016, 09:22:05 AM »
Revised the safety wiring a little, added some fuses and changed a multiple relay for a single one.

Also sketched up my panel button wiring, the idea is to have the "RUN" relay controlled via a brain or something so it switches as soon as Mach comes out of stop condition i.e. running code or in feed hold - I presume there is a smart way of doing this :)

This relay then controls the supply to the respective buttons and button LEDS - the idea here was that when in stop mode, you can only press the start, ref z and spindle toggle buttons, as soon as you press the start button, the logic changes so that only the stop and feed-hold buttons are active.

NOW, my query here is - is it wise to control the supply to the switches AS WELL as the LEDs or leave the switches permanently live but control the supply to the LEDs only?

Thoughts??
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #235 on: June 07, 2016, 07:56:18 AM »
Pendant turned up today - if anyone is looking for one, this is the first time i have got something from China on eBay and have been surprised at  the quality of it :)

http://www.ebay.co.uk/itm/251989254779?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

It actually 'feels' good - nice clean clicks on the wheel, positive switches, heavy case and a hard wearing cable, will have to lash it up to my test rig and have a play with it ;)

Away for two weeks on thursday so it'll have to wait i think.
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #236 on: June 08, 2016, 04:00:08 AM »
Pendant works perfectly - also has on-off switch so the keyboard jog can still be used :)

I think thats about it for a couple of weeks now as i'm off on holiday tomorrow :)
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #237 on: June 24, 2016, 11:32:15 AM »
Hi all, back again :)

Wasted no time in getting out to the shop, started catching up on customer orders and did some work on the mill.

Seems I have ordered a screw set for the Z axis that is far too long - bum!
Will eBay that one for a few quid - its a 1605 zero backlash unit 360mm long if anyone wants it.

Then i discovered the motor bearings are half-shot, a bit of slack and grumble when spun. It will work ok but not sure having come this far if i should refit or replace with something else - options would be repair, fit a new vfd style motor with shaft extended or throw on a servo motor.

Views?
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Hood

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Re: Bridgeport Knee Mill Conversion?
« Reply #238 on: June 24, 2016, 02:58:41 PM »
You not just chop it down in length?


Wont tell you the way I would go re the spindle, you will already know :D

Hood

Offline Davek0974

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Re: Bridgeport Knee Mill Conversion?
« Reply #239 on: June 24, 2016, 03:07:10 PM »
Hiya Hood,

I'm not 100% certain now, I won't be doing anything until I have the frame for the Z axis machined up and assembled, it might just be that it "seems" too big at present, time will tell on that one.

I can't re-read the whole thread but my guess is you would throw in a servo and go direct drive?

As for the X & Y motor support plates, what thickness ally here - 10mm, 12mm, 15mm ??
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives