Alright.
Based on my research from the last couple of weeks, I've come up with the following plan and list of hardware for the retrofit.
Servos
Replace the dead 611 Simodrive system and associated axis motors. (I would like to reuse the Siemens motors, but refitting the encoders looks like a headache at this stage)
I'm looking at the Leadshine EL7 drives and associated motors. These come in 380v 3ph. Documentation seems good and the prices aren't bad direct from Leadshine.
Run these in via analog +-10v signal. Position feedback via Linuxcnc. Ideally run battery box encoder cables to keep position even when powered off.
Spindle
Retain the original 9/11kw spindle motor. I'll test the poles on it when I'm back, but I see no reason to not reuse it.
I've already got a good deal on a used Delta VFD110E43A. Paid less than 20% of a new one.
I'll have to get a braking resistor for this.
Run the original spindle encoder (or replace it) back to Linuxcnc for rigid tapping and spindle orientation.
Control
Looking at the following Mesa boards:
7i97T to handle analog control of servo drives, spindle VFD and all encoder feedback. Some I/O.
7i84 to handle additional I/O. Tap into the original Bridgeport relay boards to control tool mag, air solenoids etc.
7i73 to handle control panel keys, rotary encoders, MPG etc.
Coofun CK41 Celeron J4125 mini PC
27" ELO touchscreen (got a lead on a cheap one here, might be a little big though)
A few panel buttons, MPG and rotary encoders for the interface.
GMOCCAPY looks like a great choice and reminds me of the Heidenhain control, which I've really learnt to love. I wish my Fanuc machine was more like it!
Other than the drives, vfd and front interface, the plan is to retain as much of the original control and wiring as possible. As previously mentioned, it doesn't look too hard to tap into the original I/O feeds from the Heidenhain. I also spent some time earlier in the year replacing all the capacitive snubbers on these control boards (with ones that don't light themselves on fire!) Fresh contractors in some spots as well.
Retain all the original breakers and transformers. There is a large contactor, breaker and transformer (415 to 380v) for the servo drives which I'd very much like to reuse (and not rewire!)
Let me now if any of this sounds entirely wrong or you have better ideas on how to execute. While I've played with cnc machines for a while now, this will be a my first experience with Linuxcnc feedback loop on servos/spindle and controlling a tool changer.
Many thanks,
J
