Hello Guest it is October 14, 2019, 10:22:56 AM

Author Topic: Bridgeport Knee Mill Conversion?  (Read 160002 times)

0 Members and 1 Guest are viewing this topic.

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #540 on: October 05, 2016, 06:06:23 AM »

Amp draw can be measured if you have a snap around ammeter.

RICH

Ah, no but i know where i can borrow one ;)


Thanks, will ask the sparks that maintain the business in my day job.
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Online Stuart

*
  •  199 199
    • View Profile
Re: Bridgeport Knee Mill Conversion?
« Reply #541 on: October 05, 2016, 07:29:38 AM »
Dave

A quick and dirty calc you would need at least a 25a mcb high inrush one

Run 4 mm T&E

 Make sure you fit a mains filter to the VFD they are dirty what nots your servo drives will thank you

As I have been out of the sparks trade for 20 years I may have over sized things

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #542 on: October 05, 2016, 07:32:29 AM »
Thanks, will have a look for a filter, do have one but is only 14A so will have to come out.


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

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #543 on: October 05, 2016, 08:23:25 AM »
Just had a chat with the supplier and he recommends not fitting an input filter as the Bosch inverter I have already has a good internal filter filter to the input, that is unless there is proof of interference on other components.

Also, peak demand for my motor/drive setup in a balls-to-wall full-load situation would be 22.5A on the supply, above that level the inverter will start reducing speed, prolonged heavy draw will trigger a shutdown - the point at which this happens can be adjusted with the settings.

Now, question is, can a Bridgeport actually USE 3Hp at the spindle without snapping something :)
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Online Stuart

*
  •  199 199
    • View Profile
Re: Bridgeport Knee Mill Conversion?
« Reply #544 on: October 05, 2016, 08:42:23 AM »
Ok. Dave

If the supplier says no filter that's a done deal , but is that a dealer or Bosh themselves


All my experience ( yes I still do a bit and keep up with things) filters are necessary particularly if there are more electronics on the same feed , if you fit one put it next to the VFD

But then I am old school better to be safe than sorry , we all no that CNC machines do some funny things at times

Now back to the play pen ( workshop) to make some small bits on my small CNC mill that I have refitted from the Far East nearly motion controller under mach3 to ESS an mach4 no wiring dia and all wire the same colour with nine limits to sort out is was fun

Take care and be safe

Stuart

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #545 on: October 05, 2016, 08:53:42 AM »
Its a supplier i have used in the day-job for some years and is very helpful/knowledgable so i will go with the advice for now.

Gotta love the far-east wiring colours :)
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #546 on: October 05, 2016, 02:22:47 PM »
Got it running under local control tonight, did an autotune on it, draws a tad over 3A idling.

Question -

When speeding up or slowing down (by twiddling the knob) it overshoots and then stabilises - I *think* this is the sensorless-vector stuff doing its thing.

Now, as it will be running in semi closed-loop when finished, is it best to leave it in SVC mode or switch to standard V/Hz mode ?



Looks like i have usable power from 300 to 3000rpm, 10 to 100Hz
Stopping from 3000rpm in 1s pretty impressive too :)
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #547 on: October 06, 2016, 07:32:26 AM »
Going back to my issue with the odd behaviour and imaginary limit switches triggering, I have just got a reply back from CS-LABS and unknown to me, the controller plugin creates a log file - "CSMIO_IP_A.log" somewhere on the PC, they said it should contain details of what switch was triggered and other stuff.

Will have a look tonight, nearly finished the new drive motor so should be back testing by the weekend hopefully.
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #548 on: October 06, 2016, 01:53:04 PM »
Here we go, the log file is a mine of information :)

It seems the machine started up fine, ran fine until 2016-10-02 | 09:52:21.375 where we get the first "Software limit switch activated!" error - this would be when it sent the Z axis home for a tool-change.

So, as i said, its not a real limit switch thats getting hit, its some sort of software limit.

Its also the Z axis throwing the following ePid fault - 2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(2) : FAULT

Question is - why?

2016-10-02 | 09:17:24.718 -> CSMIO-IP class initialized OK.
2016-10-02 | 09:17:24.734 -> InitUDPSock -> OK.
2016-10-02 | 09:17:24.734 -> piInitControl: Module filename: C:\Mach3\PlugIns\CSMIO_IP_A_plugin.dll
2016-10-02 | 09:17:24.734 -> piInitControl: GetFileVersionInfoSize = 1716
2016-10-02 | 09:17:24.734 -> piInitControl: ProductName: CSMIO-IP-A Mach3 plugin
2016-10-02 | 09:17:24.734 -> piInitControl: ProductVersion: 2.8.5.1
2016-10-02 | 09:17:25.687 -> Our IP address : 10.1.1.1
2016-10-02 | 09:17:25.687 -> Our subnet mask : 255.255.255.0
2016-10-02 | 09:17:25.687 -> Calculated broadcast : 10.1.1.255
2016-10-02 | 09:17:25.687 -> Sending discover message to broadcast.
2016-10-02 | 09:17:26.359 -> All network interfaces checked...
2016-10-02 | 09:17:26.359 -> Discover finished. Found 1 CSMIO-IP device(s).
2016-10-02 | 09:17:26.359 -> Connecting to CSMIO-IP at IP:10.1.1.2
2016-10-02 | 09:17:26.359 -> Connected.
2016-10-02 | 09:17:27.109 -> llComm(c:45): Rx time-out. retry = 0
2016-10-02 | 09:17:27.109 -> llComm(c:45): NAck with nackTRREP received. (no retry).
2016-10-02 | 09:18:05.171 -> Sending reset to idle state request.
2016-10-02 | 09:18:07.218 -> Homing start axis:2
2016-10-02 | 09:18:12.296 -> ClrAxisPos: Axis:2 / DeRef: NO.
2016-10-02 | 09:18:12.296 -> Axis 2 homing ok.
2016-10-02 | 09:18:12.359 -> Homing start axis:1
2016-10-02 | 09:18:15.546 -> ClrAxisPos: Axis:1 / DeRef: NO.
2016-10-02 | 09:18:15.546 -> Axis 1 homing ok.
2016-10-02 | 09:18:15.640 -> Homing start axis:0
2016-10-02 | 09:18:22.515 -> ClrAxisPos: Axis:0 / DeRef: NO.
2016-10-02 | 09:18:22.515 -> Axis 0 homing ok.
2016-10-02 | 09:52:21.375 -> Software limit switch activated!
2016-10-02 | 09:52:58.843 -> Sending reset to idle state request.
2016-10-02 | 09:55:34.437 -> Software limit switch activated!
2016-10-02 | 09:55:42.453 -> Sending reset to idle state request.
2016-10-02 | 09:56:24.625 -> ***********************************
2016-10-02 | 09:56:24.625 -> ePID FAULT! (State = 105)(Alarms=0x00000002)
2016-10-02 | 09:56:24.625 -> (ThreadSt=5) (RTappSt=0)
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(0) : 156
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(1) : 1
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(2) : 681
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(3) : 0
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(4) : 0
2016-10-02 | 09:56:24.625 -> ePID MaxError on Axis(5) : 0
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(0) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(1) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(2) : FAULT
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(3) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(4) : ok
2016-10-02 | 09:56:24.625 -> ePID Fault on Axis(5) : ok
2016-10-02 | 09:56:24.625 -> ***********************************
2016-10-02 | 09:56:34.296 -> Sending reset to idle state request.
2016-10-02 | 09:58:19.750 -> Sending STOP request.
2016-10-02 | 09:58:19.812 -> ***********************************
Bridgeport Mill, Mach3 V062, CSMIO-IP/A controller, AC Servo Drives

Offline Davek0974

*
  •  2,578 2,578
    • View Profile
    • DD Metal Products Ltd
Re: Bridgeport Knee Mill Conversion?
« Reply #549 on: October 06, 2016, 02:12:49 PM »
CS-Labs also stressed that it can be connected with a DRO?

"Even the fact you do not use UserDRO 1001 can be the problem - please verify it."

As far as i can see, the 2010 screen-set does NOT have the DRO1001 on it - "Gage Block Height"

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