Bridgeport 4th and 5th axis enabled machines

[JAZZCNC]

I have not worked on the electronics of the interact so cannot say which way to go with the conversion in terms of motion control. They probably have analogue intputs to the servo drives, maybe Jazz can chime in, but once you have installed the motion control, you can then add up to 6 axes in total with Mach3/4.

Often Bridge port interacts come with heidenhien controls and Large DC Brushed servos running off Analog amplifiers(drives). These are notoriously temperamental and difficult to setup. They also like to blow up for fun.!! Hence why they are cheap.!

There are also couple of types of heidenhien controls used on old interacts with either sinusoidal or square wave encoder outputs which makes a difference if you decide to retrofit the controller. In general Sinusoidal type is start again with new every thing.

Square wave then you can just replace the control with Analog Controller like the Cslabs IP-A or Kflop etc and re-use the Amp's and motors. Easy enough really but does require some knowledge regards wiring and setup etc.
One other thing thou often the Encoders on older motors, Often SEM motors on Bridgeports are Single ended not differential so will need either replacing or special circuit to make into differential that modern controllers require.

Often you'll see many retro-fitted with Modern controllers and Large Stepper motors to avoid all this and just use normal Step-Direction controller and cheap-ish drives/motors. This will how ever often come at the cost of performance.

Now personaly I wouldn't go with either route but would instead gut the lot and replace with AC servos from China and use Modern Step-Dir controller like the CSlabs IP-S. The controller you use for retro fit is important because of the I/O it offers and MHz rating.
Better still if the AC servo drives have Encoder outputs and can accept Analog signals I'd go with IP-A controller for the advantages that it feeds back position to Mach3 at all times. (Or Kflop and Linux or Mach3) This gives the advantage of always knowing the axis position even if axis moved by hand when turned off. Think of it like a manual DRO.

Often the I/O used on rest of the machine is 24V so the controller needs to be able to accept 24V signals otherwise your into converting 24V down to 5V which the Controller or BOB can accept. This quickly becomes a pain also 5v is much more open to noise issues and best avoided for this and reliabilty reasons.. . Not to mention sanity.!!


Spindle Motor and the variable speed pulleys are often a problem. Often these are dealt with by removing the variable pulley for speed control and replacing with Fixed pulley and VFD sized to match the motor. The motors are often Dual voltage so with a quick wire change can be used with 1ph 240V VFD.

This IMO is the best most pain free way to deal with a OLD machines using aged technology. Also won't cost anymore in the long run because you'll probably end up doing it anyway sooner or later.!! . . . Or spend more time chasing problems than cutting.!

Your also very much more flexible regards upgrade options like 4th 5th or 6 axis and ATC etc.