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infra:tools:bridgeport [2020/02/12 17:49]
q3k created
infra:tools:bridgeport [2021/05/14 20:23] (current)
radex
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 The mill is made almost entirely of cast iron, weighs about 1500kg and provides a 457x305x127mm (X/Y/Z) working area, adjustable along the Z axis within further 365mm by moving the knee. Major cast parts are shared with the Bridgeport Series 1 CNC mill, which is equipped with a much more advanced control, but lacks handwheels for manual operation. Other mills sharing all or most major parts include Bridgeport BOSS, Bridgeport EZ Trak and early Bridgeport Interact models. The mill is made almost entirely of cast iron, weighs about 1500kg and provides a 457x305x127mm (X/Y/Z) working area, adjustable along the Z axis within further 365mm by moving the knee. Major cast parts are shared with the Bridgeport Series 1 CNC mill, which is equipped with a much more advanced control, but lacks handwheels for manual operation. Other mills sharing all or most major parts include Bridgeport BOSS, Bridgeport EZ Trak and early Bridgeport Interact models.
  
-The spindle is driven by a 1.5kW 3-phase induction motor controlled with an INVT GD10-R2G2-4-B 2.2kW VFD and a Reeves-style continuously variable transmission system. Tools use QuickChange 30 mount, which is a modified DIN 2080/NMTB 30 taper. The milling head/​spindle assembly as a whole is a CNC-specific variant of the Bridgeport 2J2 milling head, mounted on a rigid ram, with a permanently coupled ball screw quill in place of the lever-operated classic Bridgeport quill.+The spindle is driven by a 1.5kW 3-phase induction motor controlled with an INVT GD10-R2G2-4-B 2.2kW VFD and a Reeves-style continuously variable transmission system. Tools use an Erickson ​QuickChange 30 mount, which is a modified DIN 2080/NMTB 30 taper. The milling head/​spindle assembly as a whole is a CNC-specific variant of the Bridgeport 2J2 milling head, mounted on a rigid ram, with a permanently coupled ball screw quill in place of the lever-operated classic Bridgeport quill.
  
 The X (table), Y (saddle) and Z (quill) axes are driven by SEM MT30H4-44 permanent magnet brushed DC servo motors equipped with built-in tachometers and fitted with coaxial Heidenhain ROD 450B 125line/rev sin/cos encoders. The servos drive 5mm/rev ball screws through toothed belts at a 2:1 reduction ratio. Notably, the X and Z ball screws are stationary and the nut, integrated with a belt pulley, is being rotated around them. Additionally,​ the Z ball screw is a part of the quill, with the spindle encased within it. The X (table), Y (saddle) and Z (quill) axes are driven by SEM MT30H4-44 permanent magnet brushed DC servo motors equipped with built-in tachometers and fitted with coaxial Heidenhain ROD 450B 125line/rev sin/cos encoders. The servos drive 5mm/rev ball screws through toothed belts at a 2:1 reduction ratio. Notably, the X and Z ball screws are stationary and the nut, integrated with a belt pulley, is being rotated around them. Additionally,​ the Z ball screw is a part of the quill, with the spindle encased within it.
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       * [M8x1.0 plug]       * [M8x1.0 plug]
  
 +====== Quick change tooling =====
  
 +Tools use an Erickson QuickChange 30 (a.k.a. QC30) mount, which is a modified DIN 2080/NMTB 30 taper.
 +
 +Alas, it's near-impossible to buy used/cheap chinese QC30 tooling. There are [[https://​www.hobby-machinist.com/​threads/​erickson-quick-change-30-tooling-and-sources-resource.43018/​|very few]] manufacturers of QC30 tool holders and the only reasonable option for us is [[http://​www.zmkolno.pl|ZM Kolno (BISON)]].
 +
 +**Here are compatible tool holders we have:**
 +
 +  * Boring bar holder
 +  * Morse taper 2 holder
 +  * 3x DA 200 collet holder (a.k.a. Erickson DA 200 / DA 20 / DK 20), analogous to ER16 (max 10mm tools) -- no collets
 +  * 2x DA 180 (DA18/​DK18),​ analogous to ER32 (max 20mm tools) -- no collets yet
 +
 +**Incompatible holders we have:**
 +
 +  * ER16 holder (modified DIN2080, which does not correctly fit either standard or QC30 spindle)
 +  * D18 holder (same)
 +  * Unknown DIN2080 holder (with some unknown large collet)
 +
 +
 +**What we need to buy**
 +
 +  - Holder na uchwyt wiertarski J6 (0642 153 549 459), ewentualnie J33 (0642 153 549 446) + uchwyt wiertarski 1-16mm od JANGO (trzeba zadzwonić i zapytać o cenę)… Warto też zapytać ZM Kolno czy zrobią holder ISO 30 QC na D18, to wtedy nowy uchwyt wiertarski nie będzie potrzebny
 +  - Holder ER16 - 0642 176 168 618 - 180zł
 +  - Holder ER32 - 0642 176 168 710 - 185zł
 +  - Shell mill holder: 0642 173 309 246 - 223zł
 +  - Zestaw 5 tulejek DA, po jednej do każdego holdera który mamy. https://​sklep.fatpol.pl/​da-erickson - tu są najtaniej jakie znalazłem. Alternatywnie http://​santools.de/,​ wychodzi niewiele drożej. System DA jest gorszy pod każdym względem od ER (nie warto w niego inwestować jako główny system), ale posiadanie wielu tool holderów znacznie zwiększa ergonomię pracy, i możemy mieć ich 5 za niewiele więcej jak cena jednego nowego tool holdera ER.
 +
 +**Someday/​Maybe**
 +
 +typ 2190 - półfabrykat trzpienia, nie ma numerów pod QC30, ale możliwe, że sprzedadzą on request.
 +
 +Morse taper holders:
 +
 +   * 0642 116 798 127 - Mt2 - 143zł
 +   * 0642 116 798 130 - Mt3 - 143
 +
 +Weldon flat holders (sztywniejsze od ER, ale tylko jeden rozmiar):
 +   * 0642 176 218 220 - 10mm - 163
 +   * 0642 176 218 232 - 12mm - 163
 +   * 0642 176 218 258 - 20mm - 163
  
 ====== Manuals and Datasheets ====== ====== Manuals and Datasheets ======
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   - {{:​projects:​bridgeport:​tnc131service.pdf|Heidenhain TNC 131 Service Manual}}   - {{:​projects:​bridgeport:​tnc131service.pdf|Heidenhain TNC 131 Service Manual}}
   - {{:​projects:​bridgeport:​goodrive10_operation_manual_v1.3_.pdf|INVT Goodrive 10 VFD manual}}   - {{:​projects:​bridgeport:​goodrive10_operation_manual_v1.3_.pdf|INVT Goodrive 10 VFD manual}}
 +  - {{ :​infra:​tools:​qc-locknut-instructions.pdf |Locknut adjustment procedure}} 
 +  - {{:​infra:​tools:​qc30qcln_spindle_nut.jpg?​400|Locknut assembly}} 
 +  - {{:​infra:​tools:​erick_qc_procedure.jpg?​400|Grinding flanges to fit QC30}}
  
  
  
 ====== TODO ====== ====== TODO ======
- 
  
   - Buy/trade more QC30 tooling   - Buy/trade more QC30 tooling
   - Buy a spindle with a through hole for a drawbar or have the original spindle drilled through - note that the CNC spindle is longer than a classic Bridgeport spindle, which won't fit   - Buy a spindle with a through hole for a drawbar or have the original spindle drilled through - note that the CNC spindle is longer than a classic Bridgeport spindle, which won't fit
   - Add a spindle encoder using automatic car transmission Hall effect sensors using [[https://​pico-systems.com/​bridge_spindle.html|this guide]] as a starting point.   - Add a spindle encoder using automatic car transmission Hall effect sensors using [[https://​pico-systems.com/​bridge_spindle.html|this guide]] as a starting point.
-  - Rebuild or replace the spindle CVT - it's worn out and damaged, makes the whole machine vibrate 
-  - Replace the Bosch Z15-1A servo drive with 3 separate Copley Controls 423 drives (already acquired) 
-  - Replace/​modify the servo drive power section which currently provides 300VAC with a center tap for Bosch Z15-1A. CC 423 requires a single voltage DC supply instead, preferably 140V to match the maximum voltage of SEM MT30H4-44 servos 
-  - Replace/​supplement the Heidenhain TNC 131 control with Mesa Electronics 7i77/6i25 combo controlled by LinuxCNC. Keeping the TNC 131 as an alternative is prefereable to replacement,​ as it's still quite convenient for quick one-off jobs. 
-  - Repair the oiling system and buy ISO68 way oil 
   - Rebuild the coolant system, add mist nozzle   - Rebuild the coolant system, add mist nozzle
  
  
-====== RS232 link ======+====== Accessing Bridgeport controller computer ====== 
 + 
 +Add your nc files for cutting to ~/​Desktop/​cnc-files/<​your-username>​. You can do it via SMB share: 
 + 
 +    smb://​bridgeport.waw.hackerspace.pl → cnc-files 
 + 
 +SSH: 
 + 
 +    ssh bridgeport@bridgeport.local 
 +    ssh bridgeport@bridgeport.waw.hackerspace.pl # (same thing) 
 + 
 +You must manually copy your ssh public key to Bridgeport'​s `/​home/​bridgeport/​.ssh/​authorized_keys`. 
 + 
 +Bridgeport'​s LinuxCNC configuration is kept on https://​code.hackerspace.pl/​radex/​bridgeport/​ . If you update /​home/​bridgeport/​linuxcnc,​ be sure to commit and push your changes. Ask radex for access if needed. 
 + 
 +====== RS232 link (legacy Heidehein 131 controller) ​======
  
 TNC 131 requires a standards-compliant RS232 link with hardware flow control (lack of DTR/DSR will prevent any communication),​ use a good USB-to-serialconverter. Prolific PL2303 has been tested and confirmed to work properly. TNC 131 requires a standards-compliant RS232 link with hardware flow control (lack of DTR/DSR will prevent any communication),​ use a good USB-to-serialconverter. Prolific PL2303 has been tested and confirmed to work properly.
infra/tools/bridgeport.1581529789.txt.gz · Last modified: 2020/02/12 17:49 by q3k