In an Factory there is an Bridgeport Interact 412 where again there is an Problem with the Z Axis. The TC2500 was changed a year ago so the owner asked if we can bring the machine to an Electronic and Software state of Year2013 and saving as much of the machine as possible because the hardware is still in excellent shape.
So challenge was taken.
We did research and had several options in mind we first tried an Stepper solution knowing the speed will be verry slow.
Attachment 215350
We tried that stepper in the Z axis to drive the 350kg did not work. We had a look at different servo options.
The problem on that machine is that the old servos draw an giant amount of Amperes
Then we had the idea to keep the servos find an solution where we change an servo only if it dies.
And we found an solution from finland. Granitedevices.
Attachment 215352 We mounted new Encoders to the Z axis servo Attachment 215354
And connected it for the test
After 2 days of playing with the parameters we moved the 350kg z axis perfect. So we had an solution
We ordered all the parts and waited till all arrived. Then we started big times
We removed the old screen
Attachment 215356 and gave a new touchscreen (we will see later if touch makes sense -
Attachment 215358
Then we removed all cables going to that control station including all electronics

Next step remove of old power supply and controller
Attachment 215360
all the unused cables have to go
we now have the control and amplifiers for sale
Attachment 215362
So then we removed all other unused cables
of the distri board (it is like hart surgery)
Attachment 215364
Result is an clean distri board where we can set the new relays board. Our concept is to reuse the old relays to keep the 110v power for Lubrication, the ATC hydraulics and so on.
Attachment 215366
We drilled a little hole in that orange board where a 24v and the RJ11 bus cable has to go through. Meanwhile the new mountings where done
Attachment 215368
Here you see the 3 Power Supplys already mounted and 3 mountings for the Granite Devices amplifier.
We also made an rack for the pc
Attachment 215370
Then we pulled out all the old cables . to reuse the old protection hoses
Attachment 215372
Then we mounted the encoders on the x and y servos
which was a lot of work
Attachment 215374
And now the search for the pins and cables has begun
Attachment 215376
So for this year the work in the factory is over.
I have prepared an test setup on my private mill to solve Spindle orientation
Attachment 215378
so i did some PCB to reuse the inductive switches of the Carousel and for orientation
Attachment 215380

Next steps is to configure the Carousel do proper the M19 command and then integrate it in the machine