Bridgeport Boss5 stepper to servo

Servo conversion time

Decided it was time to upgrade the mill with better motors to hopefully increase accuracy and repeatability. Plus its a little annoying the old Bridgeport boss steppers will only move in .001 increments at best.

Had 3 different choices when it came to the upgrade.

1. New stepper motors setup from automationtechnologiesinc.com
$99x3 1200 oz/in motors
www.automationtechnologiesinc.com/produc...tkl34h2120-60-4a-key
$69x3 KL driver 80v DC 6.2 Amp
www.automationtechnologiesinc.com/produc...epping-driver-kl8060

-Pulley adapters

2. DMM-tech servo setup.
$500x3 750 watt AC servo setup.

Original path I was taking till I missed the deal on ebay for $500 a axis. Later on I found I could email the company for the same deal. I did design and build pulley adapters for this setup. Small waste of time and money.

3. Yaskawa servo setup. aka money pit so far

$159x3 750 watt motors on ebay
$213x3 SGDV-5R5A01A Analog servopack
$35x3 Servo motor cables
$35x3 Servo encoder cables
$30x3 MDR 50pin I/O interface cable
$159x3 SGDV-5R5A11A MECHATROLINK-II - costly fuck up

This was going to be a decent price setup until I screwed up and ordered the wrong servopack the first time. Linuxcnc does not play at all with MECHATROLINK-II and I didn't pay enough attention to the ebay ad to notice the slight difference between the analog version and MECHATROLINK-II version.

Analog versus MECHATROLINK-II
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On to the build

Pulley adapters. These were the original 14mm shaft ones I made for the DMM tech motors but I remade them for the 19mm shafts on the Yaskawa servos.

Original pulley setup.
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Drill and tapped the original pulleys for mounting to the adapters. 10-24 holes.
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Roughed out the adapters.
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Machine the step in the adapter to seat the pulley.
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Drilling holes in adapters. At this time none of the motors were hooked in the mill so I had to scribe a bolt circle to know where to place the holes. blue dykem and a transfer screw to the rescue.
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Just a matter of matching the bits to the line and then rotating the super spacer 90 degrees each time.
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Here is where the 14mm shaft adapters and the 19mm shaft adapters differed. I could broach the 5mm keyway in the mill but the 6mm required a arbor press.
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Finished pulleys when I was using 14mm shafts
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My massive wiring nightmare. Originally I tried to reuse parts but now I want to do it correct.

Not proud of this mess.
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Ordered new terminal blocks that will allow better power distribution. This will also be used on the top half of the cabinet. Arrives on Tuesday.
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Removing old power transformer to install new servopacks. Weighs about 75lbs and will allow the removal of some massive caps that were used to smooth out the DC power to the gecko drives.
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Marking new hole locations for the servopacks. Using paper to transfer the locations.
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Much cleaner.
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Current setup so I can still use the stepper motors on the mill till I get in the new Mesa 7i77 Servo card and build a new config file to drive them.

Duc wrote: [The teletypewriter is now in the back of the truck for a trip the scrap yard. Screw using that thing.

I don't think that there are many of those left, it is possible that some collector might want it.

andypugh wrote:

Duc wrote: [The teletypewriter is now in the back of the truck for a trip the scrap yard. Screw using that thing.

I don't think that there are many of those left, it is possible that some collector might want it.

I scrapped it about 2 years ago. It was a fun unit to play with but limited the ability of the mill.

Wiring Diagram from the Yaskawa manual
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Mesa 7i77 questions
1. Does the yaskawa need to be single mode encoder setup on the mesa card? Appears to be differential to me.
2. Where does the 7i77 get the 10v power for the analog drives? Little short in the manual to explain this. Does it step down the 24v down to 10v or which Vfield on TB2 needs to have 10v supplied to it?