BP BTC II Retro

[DennisCNC]

Here are pictures and other info that I have learned about the BTC mill.

This is the picture of the entire machine its big and heavy. It is about 10 feet tall and ~7,200lb.
http://img116.imageshack.us/img116/1109/allmn1.jpg

For now I will stay with old steppers as I need to get it runing ASAP. The screws have ~.001 backlash. For the spindle motor I pulled out the old DC 7.5hp motor and replaced it with a Baldor 6hp AC motor and VFD.

http://img338.imageshack.us/img338/2...anfrontty2.jpg

I kept all the bolts and nuts organised in ZipLoc bags, it took one day to put it all back together!
http://img338.imageshack.us/img338/4213/bagsfv8.jpg

The screws look pretty good.
http://img338.imageshack.us/img338/5...llscrewfl0.jpg

More pics
http://img338.imageshack.us/img338/7112/cleanallau5.jpg
http://img338.imageshack.us/img338/5...eanheadut1.jpg
http://img64.imageshack.us/img64/2117/cleansidepw4.jpg
http://img338.imageshack.us/img338/7...anside2ay5.jpg
http://img64.imageshack.us/img64/9563/cleanxcu6.jpg
http://img103.imageshack.us/img103/6418/cleanx2iy2.jpg
http://img160.imageshack.us/img160/5...eecleanum5.jpg
http://img160.imageshack.us/img160/8...eclean2oi5.jpg

For some reason the quill got stuck and will not go up or down, so I unscrewed the Z ballscrew bracket and used a 4 ton ram to push the quill down untill it fell out of the head. The quill is nice and shinny and smooth and so is the housing. I think the old oil got gummy and was holding it tight. I applied new oil on the quill and it moved up and down like on ice.
http://img128.imageshack.us/img128/7176/quillkg0.jpg
http://img128.imageshack.us/img128/6...housinghe1.jpg


The spindle in this thing is almost 4 feet long and has all the spring drawbar components inside. It has a double drawbar, one that moves the stud gripper down and another to lock the gripper.
http://img128.imageshack.us/img128/2314/spindleva5.jpg




Here is a pic of the tool holder a 40MMT.
http://img106.imageshack.us/img106/3028/toolst2.jpg


Stepper motor.
http://img117.imageshack.us/img117/8703/stepperde7.jpg

[svenakela]

That's a BUTT KICKING machine for a retrofit! I see you're going big.
What's the strategy (drives, screws etc)?

Sven

[rustamd]

Very nice macnine for retro.


Дуже круто

[DennisCNC]

^^ kryto kogda dengi ono budet delat

The strategy is get it done quick. I got a lot of parts to make and everything I make is always one inch too big for the small the BPort that is the background in one of the pictures.
I ran a test with 4 amp 55 volt drive and the table had a max rapid of 65 IPM but I have Parker 8 amp 140 volt drives that I will use.

I took the machine apart to make sure all the oil lines were not pluged. I found the quill restrictor was pluged all the way.
I will keep the screws and bearings as they are but when the machine pays for it self I will get a new set of bearings and the screws reloaded.

[DennisCNC]

Figured out how to get this thing to hold Cat40 tooling:
http://img411.imageshack.us/img411/6291/catml7.jpg


Also washed the control box and pulled all the old brains out. This is only a third of the control boxes. There was one the size of two refrigertors another the size of a home A/C unit and another one was a big 3ph transformer.

http://img181.imageshack.us/img181/5...rolbackbm8.jpg
http://img441.imageshack.us/img441/6...olfrontuf7.jpg
http://img247.imageshack.us/img247/2...linsideeq9.jpg

Old brains out and 4 axis Parker CD80m stepper drives in:
http://img441.imageshack.us/img441/7...sidenewvp7.jpg

I made the drives flip over forward to make it possible to get to the connectors in the back.
http://img134.imageshack.us/img134/1...idenew2gd0.jpg

Took apart the drawbar cylinder to wire down what all the switches do inside the thing.
http://img259.imageshack.us/img259/1...ylinderyt1.jpg

Two switches sense if the fork is in or out, another one to sense if the small cylinder is down and the last one to sense if the big cylinder is down.


Here is picture of the tool changer.
http://img142.imageshack.us/img142/8222/changeram7.jpg

I'm not going to use it for now but if I do use it later I will get rid of the tool change arm that comes out and grabs the tool from the spindle. I will make the carousel move in to the V groove of the tool holder and pull the tool out, index to the next tool go up in the spindle and retract, I hope.

[DennisCNC]

After messing around with the old stepper motors for a while I decided to go with DC servos on the machine I will not be able to live long with 60 IPM rapids. So I got three nema 42 servos from a Bandit controlled mill. They are 110 Volt, I put a 90V to the motor now the thing is moving!! The motors have nice MS connectors and 500 line encodes. I'm still collecting parts to finish this machine.

http://img239.imageshack.us/img239/3305/dcservo1fr7.jpg
http://img237.imageshack.us/img237/8751/dcservo2mb4.jpg

[rustamd]

so how is this project doing?

[DennisCNC]

Finished all the other pressing projects back to the bridgeport now. I bought 3 Viper 200 drives. Here is a pick of the big dc servo with the Viper drive. At idle the motor is at .04 amps and when twisting the pulley as hard as I can get over 20 amps at 85 volts. This thing has a scary amount of power. I have a signal generator connected to the step input just to see how the drives tracks the motor with a 500 count encoder.

http://img267.imageshack.us/img267/3...rvotestya1.jpg

[DennisCNC]

Got the viper servo drives installed wired to the motors. Sorted out all the wiring for the air drawbar cylinder and the speed change gear box. Limit switches installed wired. Using a CNC4PC breakout board. I can get it to jog at about 160 IPM and at 100 IPM the following error is less than 60 couts. The vfd for the spindle is on the way and that will complete the parts circle for this thing, Just need to finish up the wiring in the control box and that will be it!

This is the back of the head:
http://img254.imageshack.us/img254/9...kofheadil3.jpg

Breakout board and relay borad:
http://img225.imageshack.us/img225/3857/breakoutzq9.jpg

Control box (testing stage):
http://img254.imageshack.us/img254/9...trollerml6.jpg
http://img244.imageshack.us/img244/4343/viperswp0.jpg

Air regulators and lube supply:
http://img254.imageshack.us/img254/3093/lubeyw9.jpg

Machine side:
http://img244.imageshack.us/img244/7449/sidezq8.jpg
http://img127.imageshack.us/img127/9996/side2yp7.jpg

5 Solenoid block for: Spindle lock fork, Draw bar release cylinder, Speed change release, Speed 2 and Speed 3:
http://img127.imageshack.us/img127/4...lenoidsag3.jpg

Top of head:
http://img181.imageshack.us/img181/4...pofheadaf7.jpg

[rustamd]

Looking good!!! Need to come by one day and check out the progress

[DennisCNC]

The AC Tech VFD got here today so I installed and wired it.

http://img246.imageshack.us/img246/9973/vfdeu9.jpg

[rustamd]

where did you mount it?