New Machine Build- Looking for CNC Retrofit controller suggestions

[pmitchel75]

I recently had the opportunity to acquire a Bridgeport Series I CNC mill. The price was right because the control is shot. So...I am looking for suggestions on replacing the controller. This machine will be used in a production environment (metal cutting) and will be expected to run 8 hrs/day making production parts. Any suggestions would be appreciated. I know there are many, many retrofit controllers and am looking to use a PC based controller if possible. If you think that is a bad idea, please let me know and why. Thanks!

[polaraligned]

I have one running on Mach 3 via the parallel port. Pretty reliable.
I am currently doing a Series 2 machine with AJAX Mach controller. Quite a bit simpler to get up and running. The AJAX is the DIY version of a Centroid controller. You can also run the Centroid software on it if Mach does not suit your fancy.

[pmitchel75]

Thanks Polaraligned! I have looked at the Mach3 and seen the Centroid controls also. On your suggestion searched for and found the AJAX/Mach. Looks pretty nice. The other control I have looked at is the EMC2. Any thoughts/experience looking at that control?

[Karl_T]

Steppers or servos on the mill???

If servos, I'd look at EMC because it can handle servos and PID control with feedback. Mach has to use a step servo driver with no feedback.

Karl

[pmitchel75]

Karl: Not sure. I looked it over and made the agreement to purchase, but have not gotten it into my shop yet. It was running well when the control went on them, and being a large shop they don't want to mess with it. I will keep your servo/stepper advice in mind when I get it in house and start playing with it. Thanks!

[polaraligned]

If it is a BOSS 6 or earlier it will have steppers. Later models are all servo. I personally would change any steppers to servos, especially if you want to run the machine on more than a hobby/occasional use. Mach 3 doesn't care which one you have. If you want to close the loop a little tighter, use a motion controller such as the Galil or the Ajax controller. While they do not close the loop all the way back to Mach, they are far better than running steppers open. If you want to run a production environment like you say, then no matter what you do, the Series 1 will be the weak link. A series 2 cnc is a HUGE upgrade over the series 1 because of the way it is designed. But you can get a "real" machining center for as little as $5k these days.