Bridgeport Series II Boss 6 retrofit

Pictures, plans, gcode, projects, tutorials, ...
All stuff that you do with your machine.

Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 20 Feb 2013, 19:20

Hello all.

I have been using the MK2 and the MK1 for about a year now and am so pleased with what Andrej has put together that I have decided to do a retrofit on a full size CNC mill, the bridgeport series II machine which I purchased about a week ago.
My plan is to interface the MK2 with the original system bypassing the LXI board which is the OEM controller and the ZDI (external device interface) but attempting to keep PSU, ACC controller, Steppers/Drivers, limits and control console. I just got the PoLabs PoKeys56U and the PoExtBus to interface with the original console. Still have a lot of work ahead of me but my hopes are posting here might entice some knowledge exchange :)
Keep you all posted.
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby Andrej » 20 Feb 2013, 23:39

I'm very interested in this.
Andrej
 
Posts: 2489
Joined: 10 Jan 2012, 16:09
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 05 Mar 2013, 19:14

Update 1:
I have had the chance over the last few weeks to clean up the 30+yrs of residual oil and machining chips off the machine. I took apart a lot of the mechanical components to inspect them and clean them up. So far, everything is looking good. All the axes and motors are working properly.
I do however have a problem with the spindle brake…It seems to be ceased, not a big problem but just haven’t gotten around to repairing it yet.
It is time now to supply power to turn it on and go through a diagnostic procedure to see what works and what does not but for this I require a power transformer which I will be picking up tomorrow.
I have learned that the SMD cards which are part of the stepper control system do not take step/dir inputs but inc/dec. I will have to convert these signals with the appropriate logic gates…easy. I will have more soon once I connect power. Looking forward to update 2 
One question I do have is related to rigid tapping…I figure the right settings will allow me to do this from a software perspective but I will need to incorporate an encoder into the spindle.

My question is, What encoder specs should I be looking for? I know it should be on a 5V bus and that I need a quadrature encoder with an index track/output but what kind of PPR will give me the best performance from a controller perspective and machine perspective? 100, 200, ….1024? or higher?

Thank you all again and chat soon.
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby Andrej » 05 Mar 2013, 20:31

For encoder use 100 (or 50) PPR. Don't use higher than 100.
But rigid tapping (G33.1) is currently not implemented.
Andrej
 
Posts: 2489
Joined: 10 Jan 2012, 16:09
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby JerryBurks » 05 Mar 2013, 23:55

Could you abuse the encoder-slaved lathe functionality for rigid tapping? That means treat the tapping process like thread cutting on a lathe?
JerryBurks
 
Posts: 217
Joined: 10 Jan 2012, 20:26
Location: Pasadena, California
Controller: Mk2

Re: Bridgeport Series II Boss 6 retrofit

Postby Andrej » 06 Mar 2013, 08:57

Rigid tapping requires that feed direction changes when spindle direction changes.
This is not implemented but it is planned.
Andrej
 
Posts: 2489
Joined: 10 Jan 2012, 16:09
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 23 Sep 2013, 11:53

Another question that has come up since I have been working away at this project has to do with the limit switches.
My question is can the MK2 handle a condition where the machine/hardware that's its connected to has a set of limit switches on its axes as well as separate homing switches?
The specifics of the hardware configuration would be as such: Say the machine travel is 30"x15"x5" (XYZ) and my 0,0,0 is located at the closest lower left corner of this prismatic shape. The limit switches would be situated say at -0.05", -0.05", -0.05" and the more precise home switches at -0.1", -0.1" ,-0.1".
The controller capabilities I'm curious about are can it rapid (G00) from any position over to the limit switches during a homing procedure where the limits would cause it to go into home speed (from settings) until the home switches are depressed? I would also want the limit switches during normal operation to function as they currently do where they initiate an e-stop if depressed.
One work around I though of is to use a selector switch to change between these sets of switches such that I could use stored positions to get to 0,0,0 and then take the limits out of the circuit electrically and let the controller look at the homing switches and then execute a standard home cycle. If there was some available output either on the outputs or on the i2c, I could do this all automatically.

Best regards !
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby Andrej » 23 Sep 2013, 14:30

Currently this is not possible.
Andrej
 
Posts: 2489
Joined: 10 Jan 2012, 16:09
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 23 Sep 2013, 14:56

Okay, Thank You again for the quick reply.
For the time being, I will make use of PoKeys to handle this until a more compact and elegant solution becomes available.
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 09 Oct 2016, 14:54

Hello everyone, it has admittedly been a long time since my last update regarding this thread but I have to say that it has been a very productive time in absence. I am not sure where to start but I think it’s best to 1st give the credit to exactly where it is due.
Andre, your products both hard and soft are simply incredible to work with! What a delight to be able to have such a diverse set of user features and machine options. The software is simply amazing! Since starting this post in Feb 2013, I have essentially completed my retrofitted Bridgeport CNC and have been using it in an industrial environment every day growing my business here in Canada. I can now say with years of use that NOT ONCE, has anything happened to cause my machine to be out of commission. This is truly an amazing feat since my equipment is operating in close proximity and on the same power lines as 7 welding machines and plasma cutters...MIG, TIG, Stick...not to mention dozens of VFD`s and countless motors. I am just amazed that in all these years of operation, the MK2 controller I have used in the retrofit has not once lost comm`s with the host computer, not once frozen or even missed a single step in operation and not once missed anything I have commanded it to do nor done anything I have not asked it to. Absolutely stable and reliable. In fact, as I type this update, the CNC is running making parts and I am 100% confident that I don`t need to go and supervise it.
In the past, there has been a few times where I have either asked for updates in firmware so that specific features become available or found bugs in published versions and every time, Andre and his team have delivered honest and clear responses/solutions much faster than I would have expected. You and your team are truly devoted and professional. A sincere thank you!
I know that this update might be coming across as a solicited one but I want to be totally clear and truthful with all of you that read this, I am just so impressed with these products that I want to help you all have as much success as I have had by saying that the products here at CNC USB are fantastic. I am writing completely on my own accord.
Here are a few pictures of what I built. I am not going to get into too many technical details since this post is already getting long but if anyone has any, feel free to ask as I would gladly be willing to help.
Attachments
IMG_20130218_123547.jpg
Unloading the original machine
IMG_20130218_123547.jpg (72 KiB) Viewed 754 times
20130913_132414.jpg
Conceptual hardware layout
20130913_132414.jpg (109.05 KiB) Viewed 754 times
20131101_131633.jpg
PCB for interface made by CNC-USB on my 1st home made machine
20131101_131633.jpg (207.34 KiB) Viewed 754 times
20161007_153125.jpg
Final control box. All the electronics.
20161007_153125.jpg (134.85 KiB) Viewed 754 times
20161007_153207.jpg
Another control box view
20161007_153207.jpg (112.35 KiB) Viewed 754 times
20161007_153144.jpg
Controls close-up
20161007_153144.jpg (205.03 KiB) Viewed 754 times
20161007_153227.jpg
Motor driver side of the control box
20161007_153227.jpg (70.78 KiB) Viewed 754 times
20161007_153301.jpg
New V.S. old :)
20161007_153301.jpg (133.01 KiB) Viewed 754 times
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby Support » 12 Oct 2016, 10:56

Wow, thank you for such kind words. Your machine looks and setup looks amazing.
We are happy that you are getting such good results with our controller.

If you can, and if you will have any spare time in the future please post some videos of machining.
Support
 
Posts: 2609
Joined: 07 Apr 2014, 17:39
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 12 Oct 2016, 11:26

Thank you!
Thank you for providing such a fantastic product which allows customers such as myself to feel confident with investing so much time and resources in integrating your products into larger systems. I wouldn't of done all this work if I wasn't 100% certain of the quality/performance and support behind your products.
I will gladly post a video or two of some machining as soon as I have a look at what I have and find something appropriate. In addition to the videos, I will also post some of the finished parts and machines I have built with this CNC using your MK2 and software.
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 14 Oct 2016, 23:21

Hello again, I have taken a moment to look through some of the pictures and videos I seem to have collected over the last little while that have to do with either the machines I have used CNC USB's controllers in, or parts/machines I have made. The truth is that I personally have very limited video editing software and skill so I can't say that the videos look particularly great (looks like I have to upload them to youtube since I can't get them up here) but I have recently done some filming with a professional company in which there are some very nice shots of my retrofitted machine doing it's thing. Here are the links;

https://youtu.be/n0eoQFHbd6o This is my CNC plasma cutter.

https://youtu.be/KECIQVtzTwQ This is my retrofitted Bridgeport mill.

https://www.kickstarter.com/projects/st ... escription

https://www.kickstarter.com/projects/ma ... escription

I don't know if you can click them or if you will have to copy them into your browser but the main machining shots are at 0:32 mins into the puzzle coaster link and at 1:33 mins into the Oristo link.
In addition to these two "home made" and professional videos , look below for the pictures I have put together and make note of the file name at the bottom for a brief description.
More will have to come in my next posts since I am limited to the number of attachments per post.
Enjoy :D

Again a big THANK YOU to Andre and his team for without their efforts to create these products, I would not have been able to make mine. I have truly gained a tremendous, invaluable amount of knowledge over the past few years after I discovered Planet CNC's products. Thank you again and be back soon with more.
Attachments
PhantomLungWallPreMachFull1.jpg
Machining a section of a part that is to simulate a human chest for use in cancer radiology technology
PhantomLungWallPreMachFull1.jpg (166.41 KiB) Viewed 705 times
PhantomLungWallDuringMach.jpeg
Machining a section of a part that is to simulate a human chest for use in cancer radiology
PhantomLungWallDuringMach.jpeg (219.71 KiB) Viewed 705 times
BalsaStart1.jpg
Machining a balsa wood part that is to simulate a human chest for use in cancer radiology
BalsaStart1.jpg (158.13 KiB) Viewed 705 times
BalsaFin1.jpg
Machining a balsa wood part that is to simulate a human chest for use in cancer radiology
BalsaFin1.jpg (141.08 KiB) Viewed 705 times
PhantomAxisMount1.jpg
3/8" 6061 part for the same machine to mount some motors and linear slides.
PhantomAxisMount1.jpg (187.55 KiB) Viewed 705 times
PhantomLungArmMach1.jpeg
3/8" 6061 part for the same machine to hold and align the moving lung sections.
PhantomLungArmMach1.jpeg (98.5 KiB) Viewed 705 times
PhantomMechanicsBase1.jpeg
Base and motion components of the machine during assembly.
PhantomMechanicsBase1.jpeg (142.72 KiB) Viewed 705 times
PhantomMotionSysAssy1.jpeg
A little further along during assembly.
PhantomMotionSysAssy1.jpeg (114.19 KiB) Viewed 705 times
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 17 Oct 2016, 00:48

Hello again everyone. It's the end of yet another great weekend and before its time to call it quits, I thought to post a few pictures of a few parts I have built using Andre's controller on my old Bridgeport. Looks like I will have to upload them in a couple posts. Without further delay;
Attachments
Prototypes1.jpg
These are prototype safety razor heads I made just checking to see if I/my machine could make a great shaving DE safety razor.
Prototypes1.jpg (103.91 KiB) Viewed 705 times
Fixtures1-1.jpg
After some fantastic shaving feedback, I decided to design and mfg these machining fixtures ao I could make a bunch of the razors in a single set up. The tool path that the MK2 was running for this was well over 120000 lines long.
Fixtures1-1.jpg (240.21 KiB) Viewed 705 times
Fixtures2-1.jpg
An additional profiling fixture I decided to add during machining.
Fixtures2-1.jpg (230.16 KiB) Viewed 705 times
FinAnvils1.jpg
This is after deburring/Brushing/polishing and assembly.
FinAnvils1.jpg (230.3 KiB) Viewed 705 times
FinRetainers1.jpg
Also after deburring/brushing/polishing and assembly of the other component.
FinRetainers1.jpg (173.52 KiB) Viewed 705 times
750mmSprocketBlank1.jpg
Set up of a 750mm dia sprocket that I had to cut the teeth in several segments making sure that by the time I reached the starting point, I had not lost my pitch distance.
750mmSprocketBlank1.jpg (136.62 KiB) Viewed 705 times
750mmSprocketMidMfg1.jpg
During machining...don't know yet if things will work out...
750mmSprocketMidMfg1.jpg (126.66 KiB) Viewed 705 times
750mmSprocketFinished1.jpg
Thankfully, it all worked out :)
750mmSprocketFinished1.jpg (124.68 KiB) Viewed 705 times
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby EnGrLiFe » 17 Oct 2016, 00:58

Here's a few more...
Attachments
HydCylRodEndNut6inch1.jpg
Threads have been cut using helical interpolation and a 60 deg cutting tool. The OD is around 6" and the part is a repair job for a 5" hydraulic cylinder.
HydCylRodEndNut6inch1.jpg (92.7 KiB) Viewed 705 times
PuzzleCoasterLayout1.jpg
These are 0.117" thick 304 stainless steel coasters as can be seen in the previous video link. Made a total of 500 pcs.
PuzzleCoasterLayout1.jpg (104.23 KiB) Viewed 705 times
CuDiskChucked-1.jpg
This is a copper disk about 12mm in dia where I used the CNC Mill as a lathe..I have the part chucked in the spindle and the cutters located on the table.
CuDiskChucked-1.jpg (104.1 KiB) Viewed 705 times
CuDiskPolished-1.jpg
The finished copper disk.
CuDiskPolished-1.jpg (156.37 KiB) Viewed 705 times
EnGrLiFe
 
Posts: 16
Joined: 08 Sep 2012, 22:32
Controller: Many controllers

Re: Bridgeport Series II Boss 6 retrofit

Postby pmaeder » 02 Nov 2016, 07:15

Andrej wrote:Rigid tapping requires that feed direction changes when spindle direction changes.
This is not implemented but it is planned.


Rigid tapping...
Any news about this one?
Best regards,
Paco
pmaeder
 
Posts: 47
Joined: 10 Jan 2012, 21:16
Location: BW, Germany
Controller: Many controllers


Return to Various projects



Who is online

Users browsing this forum: No registered users and 1 guest