Weiler DZ26 Millturn Conversion

Hi,

i have a rather ambitious project on my hand. I need to convert my Weiler DZ26 as of today my old 810T control finally went the way of the dodo.
I´ve put so much time and effort into keeping that old thing running and making it jump through hoops via CAD/CAM and my own postprocessor, but enough is enough.
My plan is to get basic turning functionality working and look into millturn operation later.
In general the machine is a dynamic (20m/min), high acceleration monster(for its time), with a super quick Sauter 12 station toolchanger (all stations driven).
I plan on using the original Siemens drives and motors. Both spindles need to run in high- or low drive modes for A-axis operation and toolchanging modes. Both spindles have two encoders for high rpm operation and low rpm positioning. The Control need to switch a number of accessories like coolant pump, self oiler, solenoids for mode switch of the tool changer and so on...
I will start with a kind of allright office PC to get it up and running and plan on switching to a proper industrial PC later on.
From what i have read over the years if you have a dynamic machine, your better served with PCIE based mesa boards.
My current plan is getting myself a 6i25 and a 7i77 breakout board. Should have enough I/O for my needs and PCIE should keep it rather real time.
Do you have any suggestions and/or questions? I will document my progress over here and definetly need some help every once in a while.
What would be your recommended GUI for a machine like that? I have next to no experience in LinuxCNC, but are pretty decent in all kinds of Siemens controls.

Best,
Lukas


 

Thank your for your suggestions. Doesn´t using Ethernet compromise system performance? If have read that using PCIE offers the higher performance advantage, or is it neglible? An ethernet card would be easier during setup, but my goal is to have everything inside the original spacious cabinet anyways.

It is unlikely that the 7i77 (or 7i97) will have enough I/O for such a machine. You will probably end up with a 7i84 to expand that.

A 7i73 for the user module also greatly simplifies the wirning between the cabinet and the control head.
 

Ah, i´ve been watching your stuff for a while to get a sense for what i am getting into, nice content!
You are using a pretty elaborate control interface on your Schaublin. I am not sure if i want to go down that route though. All i need is some jogging control to set offsets, tool measurements, start stop and feed override. My idea is using a USB pendant, a footswitch for my chuck and everything else on a touchscreen.
For years i have done nothing but adjust tool offsets on the control itself, everything else is straight from cam. And for jogging a pendant doesn´t need to be real time control via the FPGA in my mind.
Or am i totally wrong about LinuxCNCs control interface?

There seems to be a general dislike for PCI-E cards?
In theory i should be less issues in communication between PC and card and almost no jitter/latency between both.

I used the 5i25 +7i77+7i84 on my Maho, as the Ethernet cards were not yet available. Used the 7i95 on my mini lathe, and a 7i92+7i83+7i84+7i85+7i73 on the Schaublin.

As Tommy said, forget performance differences between PCI and Ethernet cards, that wont be an issue.

I hate jogging on a touch screen. You are looking at the part, probe, whatever and reaching to touch a none tactile feedback peice of glass with a greasy finger, trying to tap through pulse by pulse. Same with feed hold, cycle start, coolant start etc. It is a personal choice.

Got a 6i25 and 7i77d in front of me and i am ready get things started.
I got myself an old office PC to get things going and will migrate to a DIN Rail PC with a proper touchscreen once everything's running.
A few questions straight after studying the 7i77 manual and ripping out lots of cables from the machine.
Can i sink solenoid power straight to the 7i77? Does it have some flyback diodes integrated? Is there a max current rating for those sinking inputs? Original Siemens IO cards had direct connection to all solenoids.
Best,
Lukas