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Line 74: + + + + + + + + + + + + + − The head has some unexpected noise. Not from the motor, probably from the Reeves drive. The Reeves drive needs to be adjusted.+ − − X, Y and Z limit switches need to be adjusted. − − Check the tension on the drive belts. Especially for the Y axis. − Y axis ball screw cover is bent and not sliding properly. It should be removed and replaced (or bent straight). Removal is difficult because it is bent. This could require removing the table, which is heavy.+ + + Line 73:
Line 109: − + + + + + + + + + + + + + + + + + − + − + − '''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. 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.+ − Spindle brake does not appear to be connected.+ − Clean up the BP service manual scans and add the document to the wiki.+ − == Closed Issues ==+ Line 118:
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switch to removed
{{Template:EquipmentPage
{{Template:EquipmentPage
|image =
|image =
|model=Bridgeport Interact Series I CNC milling machine
|model=Bridgeport Interact Series I CNC milling machine
|arrived=2014
|arrived=2014
|doesitwork=no
|doesitwork=yes
|contact=Dean Anderson, Elizabeth Koprucki
|contact=Todd Allen, Abel Greenwald, Ryan Pierce
|where=Machine Shop
|where=Removed
|certification=yes
|certification=yes
|hackable=no
|hackable=no
|value=~$2000
|value=~$2000
|weight=2860 pounds}}
|weight=2860 pounds
|hostarea=Cold Metals}}
=Removal Section=
*What is it? - Bridgeport CNC Mill
*Who is sponsoring? - Cold Metals Host - Jim Brink
*Date published to the mailing list and RT- 06/11/2018
*Asset value - $1000
*Suggested method of removal - public sale - Graigslist
*Background notes -
*Resolution of removal -
*Approval -
== Authorization ==
by Todd Allen - email [email protected] to schedule
Prerequisites: authorization on either [manual Bridgeport mill OR Clausing lathe] AND ShopBot CNC router. In other words you must be authorized on one manual cold metals manual machining center (lathe or mill) AND you must have been authorized on the operation of the ShopBot CNC router. You must be comfortable operating both of those prequalifying tools without supervision. The member to be authorized must be able to generate a toolpath in Fusion 360 with a simulated machining time of 2 minutes or less and must be able to provide a piece of stock and a single ended endmill 3/8" or smaller with a 3/8" shank that is appropriate for the toolpath.
== Status ==
== Description ==
== Description ==
A Bridgeport Series I Interact milling machine with a Heidenhain TNC151 controller.
A Bridgeport Series I Interact milling machine with a Heidenhain TNC151 controller.
*[https://drive.google.com/open?id=0B6G4Ywi3OresTDNkcFYyVFE4Zm91UzFqWkNtSE5vUGRqdDEw Programming and Operation Manual]
*[https://drive.google.com/open?id=0B6G4Ywi3OresZVV6OXJRZFNFZ2RfMjBfb2Zud29hRGV4SW5Z Maintenance Manual]
== Capacity ==
== Capacity ==
Kurt D60 vise
Kurt D60 vise
Approximately 13 NMTB 30 tool holders, some collet chucks (unidentified ER style), some with fixed bore.
Approximately 13 NMTB 30 tool holders, some DA type collet chucks, some with fixed bore.
1 NMTB 30 drill chuck.
1 NMTB 30 drill chuck.
== Lubricants ==
== Lubricants ==
The automatic lubrication system uses Vactra #2 oil. If the reservoir gets too low, a sensor will prevent the Power Enable switch from operating.
The automatic lubrication system uses Vactra #2 oil. If the reservoir gets too low, a sensor will prevent the Power Enable switch from operating.
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.
== Working Group ==
A working group was formed to update/complete remaining tasks and to get the machine operational. The group is open to anyone. Help with the continuing maintenance would be appreciated. Please check the google groups and/or calendar for upcoming meetings.
The group is currently composed of:
*Abel Greenwald
*Andrew Camardella
*Tom Judge
*Todd Allen
*Ed Bennett
*Ryan Pierce
*Anna Yu
== Open Issues ==
== Open Issues ==
'''Mechanical'''
'''Mechanical'''
Spindle RPM adjuster controls are reversed. Decreasing spindle speed barely functions and needs more work to obtain satisfactory performance.
Make aluminum spoil plates and clamps to minimize risks of table mounted work.
Check the BP maintenance manual for other adjustments that are required.
Check the BP maintenance manual for other adjustments that are required.
Double-check scaling and backlash machine parameters to verify that they are accurate.
Double-check scaling and backlash machine parameters to verify that they are accurate.
The Y axis ball screw cover doesn't appear to be functioning. You can look in the back and see the ball screw.
'''Software'''
'''Software'''
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 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.
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.
Ryan also succeeded in hacking an Autodesk Fusion 360 / HSMWorks post-processor. This makes far more sense for this machine. Multi-tool jobs are supported, including milling operations and peck drilling canned cycles.
Fast moves can trip an adjustable current limit breaker, need to either adjust acceleration/speed parameters and/or the current limit.
'''Electrical'''
'''Electrical'''
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.
'''Miscellaneous'''
Clean up the BP service manual scans and add the document to the wiki.
== Closed Issues ==
Software limits for X, Y, and Z travel needed to be reset. Current values are determined by running the machine to the e-stop hard limit, recording the position, and subtracting 0.4 mm, except that the X hard limit seems like it isn't positioned properly and may be crushing part of the cover so it was set arbitrarily. Current values are: X: +12 -442.58 Y: +7.29 -300.18 Z: 8.13 -116.55 Note that these must be set both in the machine parameters (#44 - #49) as well as in the user soft limits.
Spindle brake does not appear to be connected. No, it does appear to work. There is a switch to enable or disable it.
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 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 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. 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 head has some unexpected noise. Not from the motor, probably from the Reeves drive. The Reeves drive needs to be adjusted/rebuilt. New bushing suggested
Oil line needs to be replaced.
Motors need to be remounted.
X Axis Table needs to be remounted.
X, Y and Z limit switches need to be adjusted.
Check the tension on the drive belts. Especially for the Y axis.
Y axis ball screw cover is bent and not sliding properly. It should be removed and replaced (or bent straight). Removal is difficult because it is bent. This could require removing the table, which is heavy.
CMOS memory is used to store the machine parameters. the AA batteries that keep the memory alive leaked and caused minor damage to the battery carrier. We cleaned up the carrier and replaced the batteries. The parameters have been reloaded.
CMOS memory is used to store the machine parameters. the AA batteries that keep the memory alive leaked and caused minor damage to the battery carrier. We cleaned up the carrier and replaced the batteries. The parameters have been reloaded.
We installed a Kurt power draw bar. It works fine, but the length of the drawbar should be checked once the controller is running again.
We installed a Kurt power draw bar. It works fine, but the length of the drawbar should be checked once the controller is running again.
Tom fixed the air filter leak by replacing the filter/regulator with another we had on hand. He also fixed the leaks in the drawbar system.
== Reference ==
== Reference ==
* http://faculty.etsu.edu/hemphill/entc3710/nc-prog/index.htm - Discussion of CNC. The document appears unfinished.
* http://faculty.etsu.edu/hemphill/entc3710/nc-prog/index.htm - Discussion of CNC. The document appears unfinished.
* http://www.encoderservice.com/ - Oracle Encoder Service LLC. They still repair ancient Heidenhain encoders that Heidenhain no longer supports.
* http://www.encoderservice.com/ - Oracle Encoder Service LLC. They still repair ancient Heidenhain encoders that Heidenhain no longer supports.
[[Category:CNC]]