Johann Posted February 6, 2014 Author Report Share Posted February 6, 2014 2 Quote Link to comment Share on other sites More sharing options...
Emiel Posted February 6, 2014 Report Share Posted February 6, 2014 lol. Quote Link to comment Share on other sites More sharing options...
Johann Posted February 6, 2014 Author Report Share Posted February 6, 2014 lol. (For the record) Quote Link to comment Share on other sites More sharing options...
Johann Posted February 7, 2014 Author Report Share Posted February 7, 2014 Emiel's day off…. 3 Quote Link to comment Share on other sites More sharing options...
NGB Posted February 14, 2014 Report Share Posted February 14, 2014 That's a good bit of work for a day off! Quote Link to comment Share on other sites More sharing options...
Commander Riker Posted February 15, 2014 Report Share Posted February 15, 2014 Loving the color of that car. Quote Link to comment Share on other sites More sharing options...
Johann Posted February 18, 2014 Author Report Share Posted February 18, 2014 Have the R back for a couple of days now. Emiel did a great job. No more interior noise from the missing steering shaft bearing. Alarm is activating. No more noise over the speakers from the phone car kit. (Probably because Emiel removed a bit to much wires and phone kits.. ) Call it a stage 0... Eibachs and the new Monroe's make the car drive like new. Still need to find a way to tame the over assisted power steering. Guess I'm spoiled with the Lexus which has such a nice slightly heavy steering feel. In the mean time not much progress on the 242. Received some parts like a Spec Stage 1 with a BMW spline friction. Fits a TTV 850 flywheel and should be OK for 400 Nm of torque. The real sequential gearbox is mounted to the x-member, shifter assay is made to fit and the cabling and rods in place ready for mounting. AP internal slave installed, Since the last post about the 242 the gearbox tunnel has been changed and the interior painted, (Maybe some is a repost..) The car wiring has been sorted and is functioning. Needs tome tidying still. Nothing EMS has been installed yet. Ordered gauges and machined a mounting plate, Color matching steering wheel, Clutch conversion from cable to hydraulic, For the engine a few things changed. Decided to use an ME 7 intake with a twist. Machined the intake to fit the throttle body on top. And added an old B21T intake knee, Took the engine out again. The intake ports were ported to match the RN port shape. Fabricated a solid oil feed line for the turbo. Removed some material from the top to fit COPS properly and added some wiring to the engine but that was late last year. Hardly touched the project since. 4 Quote Link to comment Share on other sites More sharing options...
Popular Post Johann Posted February 18, 2014 Author Popular Post Report Share Posted February 18, 2014 The last year I have been working, on and off, on an old milling machine. Posted about it >here. It's about the 412. A friend tried to repair the servo system but this didn't work out. Overthinking what to do I had two options. Either install a new Heidenhain compatible servo system and add a new control or retrofit the machine with something simpler. I think I would have preferred the Heidenhain option but besides the huge costs it would become a challenge to make it all work. I chose a cheaper option commonly used on older machines. It's called Mach 3. A control system running on top of Windows. Normally / Originally Mach 3 communicates with a controller though the parallel port. Controller itself often is a simple breakout board. A thing I didn't like. Another thing was that it is often used with stepper motors instead of servo's. After investigating the options I decided to go for an Ethernet based control. For the servo's I used drives from Delta. New pulley, motors and machined new motor plates, Whole machine needed to be rewired... Huge puzzle with the spindle drive but eventually got the darn thing to work. Cleaned and painted the spindle body work, But decided to leave the outside of the machine as old looking as it was. Bodywork was media blasted on the inside only and an industrial coating was put on to bring some light inside the machine. Needed transportation for the bodywork, And eventually had most of the machine back together, Made a panel for the controls, , Used an old touch screen monitor, Which makes it look like this now, Not completely finished but operational. After that it was time to tune the machine and start testing. Slowly getting familiar with the machine and so far it has been performing way beyond expectation. 14 Quote Link to comment Share on other sites More sharing options...
quiksilver Posted February 18, 2014 Report Share Posted February 18, 2014 YES. Can I move into your shop? Quote Link to comment Share on other sites More sharing options...
Emiel Posted February 19, 2014 Report Share Posted February 19, 2014 No more noise over the speakers from the phone car kit. (Probably because Emiel removed a bit to much wires and phone kits.. ) Call it a stage 0... Weight reduction! Quote Link to comment Share on other sites More sharing options...
blkaplan Posted February 19, 2014 Report Share Posted February 19, 2014 (edited) Excellent! That ethernet system looks cool. Hows the speed on it for doing surfacing work with small movements? Did you get it to talk to the lube pumps, coolant pumps, and tool changer? Edited February 19, 2014 by blkaplan Quote Link to comment Share on other sites More sharing options...
Johann Posted February 19, 2014 Author Report Share Posted February 19, 2014 Excellent! That ethernet system looks cool. Hows the speed on it for doing surfacing work with small movements? Did you get it to talk to the lube pumps, coolant pumps, and tool changer? Ran the runner finishing profile at 600mm/min. Spindle can do 4K RPM... Lube pump is working and triggered by the spindle. That is the way Bridgeport did it originally. Coolant running from M8/M13 or screen button. For the tool changer, Not using it yet. The tool changer turret itself is working. It's indexing and counting. From the screen I can turn the turret to a given tool number. Spindel positioning is also functioning. Turret can be moved in and out, also from the screen. Tool release and are blast are functioning. The one thing missing is a proper M6 script.. I need some more confidence before trying. The tool release needs a minimum of 6 bar air pressure to function but only above 6 bar it will function smooth. Precisely at 6 bar is sort of plops the tool out and I'm afraid it might damage the turret. There's a pressure sensor in the air system switching at 6+ bar and it also outputs to the control but need to find a way to incorporate it in to the script. Quote Link to comment Share on other sites More sharing options...
blkaplan Posted February 19, 2014 Report Share Posted February 19, 2014 Ran the runner finishing profile at 600mm/min. Spindle can do 4K RPM... Lube pump is working and triggered by the spindle. That is the way Bridgeport did it originally. Coolant running from M8/M13 or screen button. For the tool changer, Not using it yet. The tool changer turret itself is working. It's indexing and counting. From the screen I can turn the turret to a given tool number. Spindel positioning is also functioning. Turret can be moved in and out, also from the screen. Tool release and are blast are functioning. The one thing missing is a proper M6 script.. I need some more confidence before trying. The tool release needs a minimum of 6 bar air pressure to function but only above 6 bar it will function smooth. Precisely at 6 bar is sort of plops the tool out and I'm afraid it might damage the turret. There's a pressure sensor in the air system switching at 6+ bar and it also outputs to the control but need to find a way to incorporate it in to the script. Does the ethernet system have onboard memory for storage or is it all "drip fed" ? Quote Link to comment Share on other sites More sharing options...
Johann Posted February 20, 2014 Author Report Share Posted February 20, 2014 Does the ethernet system have onboard memory for storage or is it all "drip fed" ? It isn't mentioned which communication protocol is used over ethernet between the motion controller itself and the control software. The operator panel controls are running straight to the motion controller and the safety system is tied in with the main emergency/safety "ring". I'm using a 5 year old HP xw4600 Workstation. Did a fresh XP install, ran the updates and installed Mach 3. Not really bare bones but minimal. No other program's used. Using the internal Ethernet as a dedicated connection to the motion controller and for now I'm using a USB stick to load the file's. The filesystem is XP so you could store the files on the computer for repetitive use. Quote Link to comment Share on other sites More sharing options...
blkaplan Posted February 20, 2014 Report Share Posted February 20, 2014 It isn't mentioned which communication protocol is used over ethernet between the motion controller itself and the control software. The operator panel controls are running straight to the motion controller and the safety system is tied in with the main emergency/safety "ring". I'm using a 5 year old HP xw4600 Workstation. Did a fresh XP install, ran the updates and installed Mach 3. Not really bare bones but minimal. No other program's used. Using the internal Ethernet as a dedicated connection to the motion controller and for now I'm using a USB stick to load the file's. The filesystem is XP so you could store the files on the computer for repetitive use. Thats pretty cool, I'm sure the ethernet is as fast as the onboard memory in my fanuc 10m Quote Link to comment Share on other sites More sharing options...
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