Changes

== What works so far ==

== What works so far ==

Almost everything. The table and quill move as expected using the Heidenhain controller and joystick, but not the handwheel. We can create and run simple programs using the Heidenhain conversational programming mode. We have switched the machine over to ISO G-code, and have been able to run programs with this. We have changed the communication parameters to FE mode, which permits transferring programs to/from the machine's memory, as well as drip feeding programs directly.

Almost everything. The table and quill move as expected using the Heidenhain controller and joystick, including the handwheel. We can create and run simple programs using the Heidenhain conversational programming mode. We have switched the machine over to ISO G-code, and have been able to run programs with this. We have changed the communication parameters to FE mode, which permits transferring programs to/from the machine's memory, as well as drip feeding programs directly.

We need to reassemble the machine and make many adjustments as well as establish a CAD/CAM process on a external computer.

We need to reassemble the machine and make many adjustments as well as establish a CAD/CAM process on a external computer.

The only big mechanical task remaining is to fix the bent ball screw cover.

The only big mechanical task remaining is to fix the bent ball screw cover.

The only big electrical tasks remaining are to repair/replace the handwheel and to permanently wire the machine, removing the temporarily installed transformer.

The only big electrical task remaining is to permanently hard-wire its power supply.

== Open Issues ==

== Open Issues ==

Parameters can be accessed by pressing MOD repeatedly until you are prompted to enter a Code, which is 95148. Care should be exercised with machine parameters. In this screen, pressing EXT then NO ENT causes a full dump to serial. Pressing EXT and ENT makes the machine look to read them, but sending them as an ASCII file via a terminal program doesn't seem to work.

Parameters can be accessed by pressing MOD repeatedly until you are prompted to enter a Code, which is 95148. Care should be exercised with machine parameters. In this screen, pressing EXT then NO ENT causes a full dump to serial. Pressing EXT and ENT makes the machine look to read them, but sending them as an ASCII file via a terminal program doesn't seem to work.

Set up the tool chain. Ryan made significant progress hacking a custom post-processor for Aspire. However it is having problems with arcs. We need to investigate other CAM packages.

Set up the tool chain. Ryan has succeeded in hacking a custom post-processor for Aspire. He fixed the previous problem with arcs. However, it seems the machine slows down at the end of each G-code line, so designs consisting of lots of short line segments have a very low effective feed rate. We need to investigate other CAM packages, e.g. AutoDesk products.

'''Electrical'''

'''Electrical'''

Install a 3 phase 240v outlet near the machine. This machine is currently sharing one outlet with 4 other machines.

Install a 3 phase 240v outlet near the machine. This machine is currently sharing one outlet with 4 other machines.

The machine was wired at the factory for 460 volt 3 phase and we use 230 volt 3 phase in our shop. Ed and Dean rewired the motor and controller box, in a temporary fashion, to use 230v. It is currently using a 460 to 230 volt transformer, which will eventually be removed.  

The machine was wired at the factory for 460 volt 3 phase and we use 230 volt 3 phase in our shop. Ed and Dean rewired the motor and controller box, in a temporary fashion, to use 230v. It had been using a 460 to 230 volt transformer. Ryan removed this 6/26/2015 and changed all three transformers to use 230V, and re-enabled the accessory outlets at the rear of the machine. He also moved the Heidenhain power source back to the Bridgeport control. PS:One has voltage approaching 250V, so in some cases the voltages at transformer taps are a bit high. However the Heidenhain power, and the external 120V outlets, appear pretty much spot on.

The Handwheel uses a Heidenhain HR 150.001 5000 F4 controller, Id.Nr. 220 954 01, S.Nr. 1300302 A. It is very fragile, using a glass encoder wheel. We have determined that the light bulb that illuminates the wheel, triggering a signal from the photocells, has burned out. This will either need replacement, or we will need a new encoder. Ryan contacted Heidenhain, who does not repair this, and said "this was a very particular lamp/lens assembly, with the lamp focused through the lens in a particular way – not exactly a flashlight bulb." Heidenhain has a replacement: "ID. Nr. 540940-07. It is the current version of the HR 150. List Price $594.00" At Dean's request, Ryan shipped the encoder to Oracle Encoder Service on 5/6/15 for repair; quote was $290. This repair was completed. Oracle adjusted it with very low friction on the bearing, so the hand wheel wouldn't stay in place. Ryan sent this back to them, they fixed it to increase the friction, and it now works. Ryan re-installed it.

 

The Handwheel uses a Heidenhain HR 150.001 5000 F4 controller, Id.Nr. 220 954 01, S.Nr. 1300302 A. It is very fragile, using a glass encoder wheel. We have determined that the light bulb that illuminates the wheel, triggering a signal from the photocells, has burned out. This will either need replacement, or we will need a new encoder. Ryan contacted Heidenhain, who does not repair this, and said "this was a very particular lamp/lens assembly, with the lamp focused through the lens in a particular way – not exactly a flashlight bulb." Heidenhain has a replacement: "ID. Nr. 540940-07. It is the current version of the HR 150. List Price $594.00" At Dean's request, Ryan shipped the encoder to Oracle Encoder Service on 5/6/15 for repair; quote was $290.

 

'''Purchase'''

 

Computer for design work and to drip G code to the Heidenhain. We already have a monitor.

'''Miscellaneous'''

'''Miscellaneous'''

Dave will order a design computer for the milling machine. The computer will be set up on the desk to the right of the mill. We don't have a network cable run to this area, but it should be easy to add this under the cat walk.

Dave will order a design computer for the milling machine. The computer will be set up on the desk to the right of the mill. This is installed and on the network.

Investigate the air leak at the back of the machine. It appears to be leaking at the filter drain. Could be a missing O ring or a cracked bowl.

Investigate the air leak at the back of the machine. It appears to be leaking at the filter drain. Could be a missing O ring or a cracked bowl.

The mystery of the spindle taper has been solved. NMTB 30. We now have a good supply of tool holders.

The mystery of the spindle taper has been solved. NMTB 30. We now have a good supply of tool holders.

the TNC 151 power supply failed while we were working on the machine. The problem was a bad 220uf 63 volt capacitor, which we replaced.

The TNC 151 power supply failed while we were working on the machine. The problem was a bad 220uf 63 volt capacitor, which we replaced.

One half of a y axis limit switch failed. We swapped it for the other limit switch on the same axis which only needed one half working.

One half of a y axis limit switch failed. We swapped it for the other limit switch on the same axis which only needed one half working.

The default post-processor did not do rapids. In that case, Aspire simulates a rapid as a linear move at 2x the normal cutting feed rate. No obvious config setting or way to impose a maximum limit exists. So if you have a 300 in/min feed (F3000), your next "rapid" will be F6000. The TNC 151 is configured to reject feeds in excess of F5000 so this cannot be executed. Modifying the post-processor to do rapids with <code>G00</code> fixes this, as Aspire no longer generates these 2x problematic "rapids."

The default post-processor did not do rapids. In that case, Aspire simulates a rapid as a linear move at 2x the normal cutting feed rate. No obvious config setting or way to impose a maximum limit exists. So if you have a 300 in/min feed (F3000), your next "rapid" will be F6000. The TNC 151 is configured to reject feeds in excess of F5000 so this cannot be executed. Modifying the post-processor to do rapids with <code>G00</code> fixes this, as Aspire no longer generates these 2x problematic "rapids."

Arcs do not work. They give the error: CIRCLE END POS. INCORRECT Some math seems to show that Aspire has an error greater than 0.006" with the end points and/or center.

Arcs now work. The problem before was using incremental coordinates for circle center I and J, when the Heidenhain was expecting absolute for everything.

Because the Interact Series 1 uses tool holders, not collets, you are supposed to mount each tool in its own holder (which hopefully fixes its length relative to the spindle). You mount your longest tool, touch off the workpiece, call that point Z=0, and designate its tool offset as 0. Then you mount each tool in turn, touch off the workpiece, and store the different Z value (which will be negative) as the tool offset of each other tool. You can define tool offsets in G-code, but Aspire doesn't seem to have that concept. Ryan changed machine parameter 225 to define 25 slots in a central tool table. This is a special Program 0, where you manually key in all your tool offsets and radius values (but that generally isn't used for CAM-generated G-code.) So if T=1 is my zero tool, a cut to Z-0.5 will move the spindle to Z-0.5 and cut a half inch into the workpiece. But if I change to tool T=2 which has a L-1.0 offset, a cut in G-code to Z-0.5 will move the spindle to T-1.5, but since the tool is 1 inch shorter, it will cut a half inch into the workpiece. But it is critical now to check the global tool table before running a job!

Because the Interact Series 1 uses tool holders, not collets, you are supposed to mount each tool in its own holder (which hopefully fixes its length relative to the spindle). You mount your longest tool, touch off the workpiece, call that point Z=0, and designate its tool offset as 0. Then you mount each tool in turn, touch off the workpiece, and store the different Z value (which will be negative) as the tool offset of each other tool. You can define tool offsets in G-code, but Aspire doesn't seem to have that concept. Ryan changed machine parameter 225 to define 25 slots in a central tool table. This is a special Program 0, where you manually key in all your tool offsets and radius values (but that generally isn't used for CAM-generated G-code.) So if T=1 is my zero tool, a cut to Z-0.5 will move the spindle to Z-0.5 and cut a half inch into the workpiece. But if I change to tool T=2 which has a L-1.0 offset, a cut in G-code to Z-0.5 will move the spindle to T-1.5, but since the tool is 1 inch shorter, it will cut a half inch into the workpiece. But it is critical now to check the global tool table before running a job!