bridgeport series 1 retrofit kit

Transcription

BRIDGEPORT SERIES 1 RETROFIT KIT
Midwest Office
444 Lake Cook Road, Suite 22
Deerfield, IL 60015
Phone (847) 940-9305  Fax (847) 940-9315
www.FlashCutcnc.com
© 1998-2013 FlashCut CNC, Inc.
Table of Contents
THANK YOU .............................................................................................................................................................. 2
PRODUCT SUPPORT ................................................................................................................................................ 2
SAFETY AND USAGE GUIDELINES ..................................................................................................................... 3
SHIPMENT DETAILS ............................................................................................................................................... 4
INSTALLING THE BALL SCREW KIT ................................................................................................................. 6
REMOVING THE ACME SCREWS .................................................................................................................................. 6
INSTALLING THE BALL SCREWS ................................................................................................................................. 9
INSTALLING THE MOTOR MOUNTS ................................................................................................................ 15
PREASSEMBLY OF THE X, Y AND Z MOTOR MOUNTS ............................................................................................... 15
PREASSEMBLING THE X AXIS MOTOR MOUNT ......................................................................................................... 16
PREASSEMBLING THE Y AXIS MOTOR MOUNT ......................................................................................................... 19
PREASSEMBLING THE Z AXIS MOTOR MOUNT ......................................................................................................... 21
PREPARING THE MACHINE ....................................................................................................................................... 23
MOUNTING BRACKETS TO MACHINE ............................................................................................................ 28
MOUNT THE X AXIS MOTOR ASSEMBLY .................................................................................................................. 28
MOUNT THE Y AXIS MOTOR ASSEMBLY .................................................................................................................. 34
CLEANING / MAINTENANCE .............................................................................................................................. 46
REVISION HISTORY .............................................................................................................................................. 47
FlashCut CNC
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Bridgeport Retrofit Kit
Thank You
Thank you for purchasing the FlashCut™ CNC Bridgeport Series 1 Retrofit Kit. It
is powered by our own intuitive, powerful CNC control system for Windows 8,
Windows 7, Vista, and XP. No system is easier to set up and use than FlashCut
CNC. With intuitive controls and real time graphics, it lets you make parts
quickly and accurately on your machine tool.
We are dedicated to the excellence and ongoing enhancement of all FlashCut
CNC products. Feel free to call us with any comments or questions.
Product Support
We are committed to the full support of FlashCut CNC products. We have many
resources devoted to helping you resolve your problems quickly. Please use these
resources in the following order:
1. Web Site: www.FlashCutCNC.com
Our website has product specifications, documentation, and a dedicated
support section containing Troubleshooting Guides and FAQ’s.
2. Dealer Support:
If you purchased FlashCut CNC from a dealer or other machine tool
manufacturer, please contact them as they will have the best knowledge
of your complete system.
3. E-mail: [email protected]
E-mail is the most organized way to convey your issues to our support
staff. In your e-mail, please state your problem completely. Include
your FlashCut version, the processor and speed of your computer, your
version of Windows and your signal generator serial number. Attach
your setup file (usually found in a folder named c:\FlashCut data) and,
when appropriate, the G-Code file with which you are having problems.
4. Phone/Fax Support
In addition to e-mail support, you may call one of our telephone support
numbers. We will normally respond to your call within 24 hours.
Phone: (847) 940-9305 (9:00 AM-5:00 PM, CST, M-F)
Fax: (847) 940-9315
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Safety and Usage Guidelines
When running an automated machine tool, safety is of utmost importance. For
proper and safe use of the FlashCut CNC program and your CNC machine, the
following safety guidelines must be followed:
1. Never let the machine tool run unattended.
2. Require any person in the same room as a running machine tool to wear safety
goggles, and to stay a safe distance from the machine.
3. Allow only trained operators to run the machine tool. Any operator must have:
Knowledge of machine tool operation.
Knowledge of personal computer operation.
Knowledge of Microsoft Windows.
Good common sense.
4. Place safety guards around the machine to prevent injury from flying objects. It
is highly recommended that you build a safety shield around the entire tool
envelope. If your machine came with a safety hood, ensure that the hood is
closed at all times. The machine or spindle should never be on while the hood is
open.
5. Never place any part of your body within the tool envelope while the machine is
online, since unexpected machine movement can occur at any time.
6. Always keep the tool envelope tidy and free of any loose objects. Clean the
machine regularly and remove chips and dust deposits.
7. Be alert for computer crashes at all times.
8. The machine must not be operated in combustible atmosphere.
9. Ensure sufficient ventilation for dust or gas resulting from cutting your parts.
10. Do not use alcohol as coolant (danger of explosion!).
FlashCut CNC, Inc. is not responsible for the safe installation and use of this product.
You and only you are responsible for the safety of yourself and others during the
operation of your CNC machine tool. FlashCut CNC supplies this product but has no
control over how it is installed or used. Always be careful!
FlashCut CNC, Inc., or its affiliates are not responsible for damage to any equipment
or work piece resulting from use of this product. If you do not understand and agree
with all of the above, do not use this product.
IF YOU DO NOT UNDERSTAND AND AGREE WITH ALL OF THE ABOVE,
DO NOT USE THIS PRODUCT.
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Shipment Details
Kit Includes:















(1) X Axis 3/8” Steel Motor
Mounting Bracket
(1) Y Axis 3/8” Steel Motor
Mounting Bracket
(1) Z Axis 3/8” Steel Motor
Mounting Bracket
(3) 30L Pulley
(3) 15L Pulley
(1) 225L Timing Belt
X-axis Bracket Hardware
o (4) 3/8”-16 X 1-1/2” Button Head Screw
o (4) 1/2" OD, 13/32" ID, 1/2" L Steel
Spacer
o (4) 3/8” Washers
Y-axis Bracket Hardware
o (4) 1/2" OD, 13/32" ID, 1/2" L Steel
Spacer
o (4) 3/8” Washer
Z-axis Bracket Hardware
o (6) 10-24 X 5/8” Flanged Button Head
Screw
X Axis Motor Mounting Hardware
o (8) 1/4”-20 X 7/8” Button Head Screw
o (8) 1/4" Washers
o (4) 1/4"-20 X 2” Threaded Hex Standoffs
Y Axis Motor Mounting Hardware
o (4) 1/4" Washers
o (4) 1/4"-20 Serrated Locknuts
Z Axis Motor Mounting Hardware
o (8) 1/4”-20 X 7/8 Button Head Screw
o (8) 1/4" Washers
o (4) 1/4"-20 X 2” Threaded Hex
Standoffs
(1) X Axis Belt Cover







(1) Y Axis Belt Cover
(1) Z Axis Belt Cover
X Axis Belt Cover Mounting Hardware
o (4) 10-32 X 3/8” Button Head
Screw
o (4) #10 Hard Fiber Washer
o (2) 10-32 X 7/8” Male-Female Hex
Standoff
o (2) 10-32 X 2” Male-Female Hex
Standoff
Y Axis Belt Cover Mounting Hardware
o (4) 10-32 X 3/8” Button Head Screw
Standoff
o (2) 10-32 X 1-1/4” Male-Female
Hex Standoff
Z Axis Belt Cover Mounting Hardware
o (5) 10-32 X 3/8” Button Head Screw
Standoff
o (4) 10-32 X 2-1/2” Male-Female
Hex Standoff
(2) 2-1/2” Circular Plastic End Caps
(2) Shaft Spacer, 1” OD, 5/8” ID, 5/8”
L Steel Spacer (X,Y)
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

(2) Shaft Extensions, 5/8” OD, 2-3/8”
Z-axis Driven Shaft Assembly
o 3/16” to 1/8” X 2” L Step Key
o 3/16” X 1” Square Key
o 3/16” X 3/4" Square Key
o 5/8” OD, 0.014” Wall, 1” L Brass Shim
o 5/8” X 3” Steel Shaft with 3/16” Keyway
o 5/8” ID Solid Coupler
o 5/32” Stubby Allen Key
5
L Steel, 1/2-“-20 Threaded (X,Y)
Stepper Control System (additional items):

(1) 3-Axis, 8 Amp/axis Stepper Motor Driver box

(3) Size 42, 2830 oz-in stepper motors

(1) NEMA 42, 3/8” Spacer Plate

(3) 10' stepper motor cables

FlashCut CNC Software and Manuals (CD)
Servo Control System (additional items):

(1) 3-Axis, 12 Amp continuous, 20 Amp peak Servo Driver box

(3) Size 42, 850 oz-in servo motors with

(3) 10' Servo motor cables

FlashCut CNC Software and Manuals (CD)
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Installing the Ball Screw Kit
If you purchased a ball screw kit, start at this point. If you are using your existing lead screws, then
skip this section and go to the section called “Installing the Motor Mounts.”
Removing the Acme Screws
1) First move the table as close to the front of the machine as possible (Y+ direction).
2) Remove the jam nuts, handles, dial retaining rings, dials, and dial holders from the Y
axis and both the left and right ends of the X axis table. The use of a gear puller may
be required to remove the dial holders.
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3) Remove the gib adjustment screw from the front left side of the saddle and slide out
the gib.
4) Slide the table onto a flat, stable surface that is at the same level. You might want to
adjust the knee of the mill so that the table is at the perfect height to slide onto the
surface. CAUTION: The table is quite heavy, assistance is recommended.
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5) Unscrew both the X and Y axis ACME screws form the support housing. The use of
the handle is helpful to accelerate this process, however be careful not to bend the
ACME screw as it comes out.
6) Remove the support housing cap screws and oil lines.
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Installing the Ball Screws
1) Insert the X axis ball screw into the new support housing and secure snugly with (2)
5/16“-24 SHCS. Do not tighten as adjustments will be made later.
2) Place support housing into the same position as the old support housing. Make note
that the ball nut flange direction on the X axis should be on the left side of the support
housing. Also the bolt holes for the Y axis should face towards the back of the
machine.
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3) Insert the (4) 3/8“ SHCS and screw down snugly, but do not tighten as you will need
to adjust the position this assembly later.
4) Rotate the Y axis ball nut towards the un-machined end of the ball screw. CAUTION
do not allow the ball nut to reach the end as there is a risk of the ball bearings
escaping the ball nut assembly.
5) Insert the Y axis ball screw assembly at an angle through the front cutout of the
casting.
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6) Push the ball nut passed the slot in the support housing then angle the screw back up
and into the slot on the support housing. Once the ball screw is seated in the slot on
the support housing pull the screw away from the machine to allow the ball nut to
slide into the slot and allow the ball nut flange to make contact with the support
housing.
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7) Slide the chip guards away from the machine and secure the Y axis ball nut flange to
the support housing using (3) 5/16“-24 SHCS. Access the ball nut flange though the
chip guard opening. Make sure to tighten the screws at this time.
8) Insert oil tubes into the flange of both the X and Y axis ball nuts. Simply push the
line as far into the flange as it will go.
9) Insert a woodruff key onto the Y axis and on both ends of the X axis. You can replace
the keys or reuse the keys from the ACME screws.
10) Replace the Y axis bearing block and handle assembly.
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11) Move the saddle back to the front of the machine, towards you. Slightly snug the (4)
SHCS holding the support housing in place. Move the saddle back and forth
throughout its travel until it settles and the resistance in both directions are
approximately equivalent. Once the assembly has settled completely tighten the
support housing in place.
12) Center the X axis ball screw in its travel.
13) Slide the table back onto the saddle and reinstall the gib.
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14) Reinstall the right X axis bearing block and handle assembly, but only hand tighten
the bearing block screws.
15) Reinstall the left X axis bearing block and handle assembly and again only hand
tighten the bearing block screws.
16) Run the X axis back and forth through the entire travel until the assembly “settles“
and the resistance to move in either direction is approximately the same. Then tighten
down both SHCS on the X axis ball nut flange.
17) Run the table all the way to the left and tighten the right bearing block.
18) Run the table all the way to the right and tighten the left bearing block.
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2) Congratulations you have successfully installed ball screws onto your Bridgeport Series 1
mill.
Installing the Motor Mounts
Preassembly of the X, Y and Z Motor Mounts
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Preassembling the X Axis Motor Mount
1) First attach (4) 2” long 1/4”-20 hex standoffs to the NEMA 42 motor using (4)
1/4”-20 X 7/8” button head screws and (4) 1/4" washers.
2) Slide on the 15L timing pulley making sure the hub points towards the motor.
Do not tighten down the set screws at this point.
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3) Now attach the motor to the motor mount using 4 more 1/4"-20 X 7/8” button
screws and (4) 1/4" washers. Make sure the motor is mounted to the slots on the
motor mount and the screws are not tight to allow the motor to slide back and
forth in order to adjust the tension in the belt later in the assembly.
4) Next install the 10-32 hex standoffs which are used to secure the belt cover to
the motor mount. The (2) 7/8” long standoffs mount to the threaded inserts
opposite the motor
and the (2) 2” long standoffs mount to the threaded inserts closest to the motor.
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5) Insert the 2-1/2” circular end cap into hole which exposes the motor shaft.
This may take a light tap with a rubber mallet.
6) The X axis motor mount is now completely preassembled and ready to mount
to the machine.
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Preassembling the Y Axis Motor Mount
1) Attach the NEMA 42 motor to the Y axis motor mount using (4) 1/4"-20 X 11/2” button head screws, (4) 1/4” washers and (4) 1/4"-20 serrated locknuts.
Make sure the motor is not completely tightened down so it is able to slide back
and forth for tensioning the belt later in the assembly.
2) If installing a stepper system make sure the insert the NEMA 42 3/8” spacer
plate in-between the NEMA42 motor and the motor mount.
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3) Slide on 15L timing pulley making sure the hub points towards the motor. Do
not tighten down the set screws at this point.
4) Next install the 10-32 hex standoffs which are used to secure the belt cover to
the motor mount. The (2) 1-1/4”” long standoffs mount to the threaded inserts
opposite the motor and the (2) 3/4” long standoffs mount to the threaded inserts
closest to the motor.
5) The Y axis motor mount preassembly is now complete and ready to be mounted
to the machine
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Preassembling the Z Axis Motor Mount
1) First attach the (4) 2” long 1/4”-20 hex standoffs to the NEMA 42 motor using (4)
1/4”-20 X 7/8” button head screws and (4) 1/4" washers.
2) Slide on 15L timing pulley making sure the hub points towards the motor. Do not
tighten down the set screws at this point
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3) Now attach the motor to the motor mount using 4 more 1/4"-20 X 7/8” button screws.
Make sure the motor is mounted to the slots on the motor mount and the screws are
not tight to allow the motor to slide back and forth in order to adjust the tension in the
belt later in the assembly.
4) Next install the 10-32 hex standoffs which are used to secure the belt cover to the
motor mount. The (1) 7/8” long standoff mounts to the threaded insert towards
the top right as shown in the picture below and the (4) 2-1/2” long standoffs
mount to the 4 remaining threaded inserts.
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5) Insert the 2-1/2” circular end cap into hole which exposes the motor shaft. This
may take a light tap with a rubber mallet.
6) The Z axis motor mount preassembly is now complete and ready to be mounted to
the machine
Preparing the Machine
1) Remove the left X axis handle assembly and bearing block screws.
a) Remove the 1/2"-20 jam nut.
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b) Slide off the handle.
c) Unscrew the dial retaining ring and slide off the dial and dial holder. Removal
of the dial holder may require the use of a gear puller.
d)
Remove the (4) 3/8”-16 SHCS.
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2) Remove the Y axis handle assembly and bearing block screws.
a) Remove the 1/2"-20 jam nut.
b) Slide off the handle.
c) Unscrew the dial retaining ring and slide off the dial and the dial holder.
Removal of the dial holder may require the use of a gear puller.
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d)
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Remove the (4) 3/8”-16 SHCS.
3) Remove the quill auto down feed clutch assembly
a) Remove the (2) 10-24 bolts holding the auto down feed clutch assembly in
place and slide off the clutch assembly to expose the quill pinion shaft.
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4) Remove the auto down feed speed selector.
a)Remove the (4) 10-24 SHCS holding the auto down feed speed selector plate in
the place and remove the assembly.
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Mounting Brackets to Machine
Mount the X Axis Motor Assembly
5) Place the (4) 1/2” OD, 13/32” ID, 1/2"L steel spacers into the counterbored holes
of the X axis bearing block.
6) Slide the 3/8”-16 X 1-1/2” Button head screws into the 3/8” washers and then into
the (4) mounting holes on the motor mount.
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7) Lift the motor mount assembly onto the machine making sure the 3/8” screws
slide into the steel spacers and tighten the motor mount to the machine.
8) Slide the 5/8” shaft spacer onto the lead screw shaft.
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9) Slide on the 30 L timing pulley making sure the hub faces away from the machine.
Make sure the rectangular key is in place.
10) Screw on the 2-3/8” shaft extension until the extension bottoms out then rotate
back until the 2 keyways align as shown in the picture below.
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11) Slide on the dial holder followed by the handle and tighten down the 1/2"-20 jam
nut.
12) Secure the set screws on the 30 L timing pulley.
13) Slide the 225 L timing belt over both the 15 L and 30 L timing pulleys.
14) Rotate the handle back and forth to allow the 15 L timing pulley to settle into
position and once the 15 L timing pulley looks vertically aligned with the 30 L
timing pulley secure the set screws on the 15 L pulley.
15) Push down on the motor to increase the tension in the belt and tighten the motor to
the motor mount with the previously installed 1/4"-20 X 7/8” button head screws.
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16) Remove the jam nut and handle.
17) Slide the belt cover over the motor and onto the motor mount and secure using (4)
10-32 X 3/8” button head screws and (4) #10 hard fiber washers.
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18) Slide on the dial and screw on the dial retaining ring. Then slide the handle on
and secure with the 1/2"-20 jam nut.
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Mount the Y Axis Motor Assembly
1) Place the (4) 1/2” OD, 13/32” ID, 1/2"L steel spacers into the counterbored holes
of the Y axis bearing block.
2) Slide the 3/8”-16 X 1-1/2” Button head screws into the 3/8” washers and then into
the (4) mounting holes on the motor mount. Make sure the screws face the
opposite way of the motor shaft.
3) Lift the motor mount assembly onto the machine making sure the 3/8” screws
slide into the steel spacers and tighten the motor mount to the machine.
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4) Slide the 5/8” shaft spacer onto the lead screw shaft.
5) Slide on the 30 L timing pulley making sure the hub faces towards from the
machine. Make sure the rectangular key is in place.
6) Screw on the 2-3/8” shaft extension until the extension bottoms out then rotate
back until the 2 keyways align.
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7) Slide on the dial holder followed by the handle and tighten down the 1/2"-20 jam
nut.
8) Secure the set screws on the 30 L timing pulley.
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position and once the 15 L timing pulley looks vertically aligned with the 30 L
timing pulley secure the set screws on the 15 L pulley.
11) Push down on the motor to increase the tension in the belt and tighten the motor to
the motor mount with the previously installed 1/4"-20 X 1-1/2” button head
screws.
12) Remove the jam nut and handle.
13) Slide the belt cover over the motor mount and secure using (4) 10-32 X 3/8”
button head screws and (4) #10 hard fiber washers.
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14) Slide on the dial and screw on the dial retaining ring. Then slide the handle on
and secure the 1/2"-20 jam nut.
Mount the Z Axis Motor Assembly
1) Insert the 3/16” to 1/8” X 2” step key into the 5/8” OD X 3” steel shaft and
position all the way to 1 side.
2) Insert the 3/16” X 1” square key into the 5/8” OD X 3” steel shaft next to the step
key.
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3) Insert the 3/16” X 3/4" square key onto the end of the quill pinion shaft
4) Slide the 5/8” OD X 1” brass shim onto the end of the quill pinion shaft.
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5) Slide on the 5/8” ID solid shaft coupler until it bottoms out in the quill housing.
Secure the set screw on the pinion shaft using the 5/32” stubby allen key.
6) Insert the 3/16” square key end of the steel shaft into the 5/8” ID solid shaft
coupler and secure the set screw.
7) Slide the (6) 10-24 X 5/8” flanged button head screws into the (6) mounting holes
on the motor mount. Make sure the screws face the same way as the motor shaft.
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8) Lift the motor mount assembly onto the machine and tighten the motor mount to
the machine.
9) Slide on the 30 L timing pulley making sure the hub faces away from the machine.
Bottom out pulley on solid shaft coupler and secure the set screws.
position and once the 15 L timing pulley looks aligned with the 30 L timing pulley
secure the set screws on the 15 L pulley.
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12) Push up and to the left on the motor to increase the tension in the belt and tighten
the motor to the motor mount with the previously installed 1/4"-20 X 4/8” button
head screws.
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13) Slide the belt cover over the motor and then onto the motor mount and secure using
(5) 10-32 X 3/8” button head screws and (5) #10 hard fiber washers.
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14) Congratulations! You have successfully installed your retrofit kit. Proceed to the
Hardware Manuals for the Pro-Series Servo or Stepper for instructions on connecting
your controller and setting up the software. (These manuals are on a CD and can be
accessed through the FlashCut CNC Software on the Help Menu.)
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Cleaning / Maintenance
Switch off the main power before any cleaning and any maintenance. Also,
pull the power plug in order to prevent inadvertent starting.
Clean the machine regularly of all chips with a brush, vacuum cleaner, or
compressed air to protect the mechanics against early wear.
Lubricate the ways regularly, and the ball-screws periodically using way oil. Now
that this is a CNC machine, the odds are it will get more use than normal, so be liberal
with the lubrication.
Periodically remove the dust covers to clean out any debris that has found its way
inside.
FlashCut CNC
Revision History
Revision Date
Description of Revision
-
2012.12.28
Draft
A
2013.01.02
Manual Release
47

bridgeport series 1 retrofit kit

Transcription

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