Another Mesa card question - Bridgeport Interact

Hi everyone,

Long time lurker, first time poster.

I've bought some mesa cards for my Bridgeport conversion, but it appears I've probably bought the wrong IO card. Having delved into exactly what I want to achieve and having used my Interact with the original Hadenheim TNC145 for a few months I realise that nearly all of the IO would be best on 24v dc, and I have a lot more than I originally envisaged. I'm quite keen to keep a lot of the hardware switches and pots and minimise the use of the mouse.

I have a 5i23 and 7i48 which should give me enough encoders and analogue outs for the planned upgrade to 5 axis, along with VFD spindle control. I also bought a 7i42TA but I don't think I want to use this now, as I'd rather not mess about making PCB's to interface it to the 24v IO.

I need 7 24v outputs

VFD Fwd
VFD Rev
Flood Coolant
Mist Coolant
Brake Solenoid
Axis Enable (part of the E-stop chain)
Lube Pump

I'd like a lot of Inputs (in addition to the Encoders on the 7i48), some of which really ought to be Analogue, specifically

FRO rotary dial (potentiometer)
Spindle Speed override / manual spindle speed (potentiometer)
Manual feed rate dial (potentiometer)
Mode select rotary switch / push-buttons (i'd rather not have to build a diode network or use an encoder chip to save IO), so DAC here would be handy)
Axis select rotary switch for pendant
VFD analogue out (0-10v or 2-10v) for spindle load meter

MPG 100ppr differential, I'd like to avoid tying up an encoder channel on the 7i48 if possible, but happy to leave it for now.

Plus at least 14 standard 24v digital inputs.


So, it looks like I need some combination of remote serial daughtercards (7i66 or 7i84) to give me 8 bit DAC's for the analogue inputs, plus enough 24v digital IO and a 7i44 to interface them to the 5i23. Does anyone have any recommendations for the best / easiest combination?

I can't see a remote 6 channel servo card, which would have made the wiring a lot more convenient if I have to buy a 7i44 anyway.


Many thanks, you can see from the picture I like biting off more than I can chew!





Hugh

For simple 24V I/O a 7I37TA will give you 16 inputs and 8 outputs

If you want analog inputs for things like feed override and MPGs, a 7I84
is probably a better choice, but requires a 7I44 or other RS-422 interface card.
Other RS422 interface options are the 7I52 (6 channels), and a 485X1 connected to 7I42 (1 channel)
The 7I52 option also adds 6 more encoder inputs

Thanks Guys,

I think going with the smart serial is a good idea, it gives me plenty of I/O including analogue inputs and simplifies the control panel wiring considerably. I'm not sure what benefit encoders have over pots, where else can you change the feed / spindle override except from a dial on the front of the console? I don't want to be clicking a mouse if I've programmed an over aggressive cut by accident.

I think the best combo would be (massive overkill)

5i23
7i48
7i52 (smart serial and MPG encoder)
7i66-8 (cabinet I/O + solenoid outputs)
7i84 (control panel I/O)

Is this combination something that Pnconf is going to be able to support? It's not the end of the world, but if not but would make life easier!

Is 2.6 worth waiting for?

I'll start a build thread as I get a bit closer to the conversion, the CAD is coming along for the motor covers and new console

Ahh, small world! I grew up in Saffron Walden and covered all of Essex from Southend - Felixstowe for the EA when I used to work for them.

I'll hopefully get the PC fired up again and give Pncconf a go this weekend.

Cheers