Indramat 3trm2

If you forget the mesa and linux, and just use a multimeter, are the terminals of the Maho showing state changes when your trip the switches?

I'm not sure, I'm understanding your point right. Do you want me to check on terminals 240 to 252 with gnd? If yes, i have checked they work fine. It's something internal from the hal files maybe?

If you have the external switches checked to their terminals, Pick each of the 7i84 pins which you are feeding a gearbox signal. Disconnect it, and now probe it with the muli meter to see if the signal you have on Terminal 24x to ground, is still working at ribbon cable 28x2-xx.

If that works, replace one by one of your Maho signals with a simple switch wired to your 7i84 and test the hal with that.
Mark

Yes i checked this. They work fine. I told you that i checked the TB3 input pins by directly feeding them 24 volts but they don't change their state in halshow.
I think there is something inside the gearbox.hal that's not identifying the signal. The 24x and 28x2xx cable works fine.and also, only the gearbox input pins of 7i84 don't detect anything but all the other pins at 7i84 work fine. That's why i think it's the hal file. 

Have you posted your HAL file? How did you net the pins to the Mesa terminals? In my older version of LinuxCNC, there is a funky bug where you load a comp with an under score _  in its name , but it generates pins with a dash - in their names.

#Gearbox Control
loadrt mh400e_gearbox
addf mh400e-gearbox           servo-thread

# --- GEARBOX CONTROL ---
net sig_return_actual_speed     mh400e-gearbox.spindle-speed-out   => motion.spindle-speed-in
net sig_return_spindle-at-speed mh400e-gearbox.spindle-at-speed    => motion.spindle-at-speed
#net sig_stop_spindle            mh400e-gearbox.stop-spindle        => motion.spindle-on
net set-gear-shift-start        mh400e-gearbox.start-gear-shift    => hm2_5i25.0.7i84.0.2.output-05
net set-reverse-shaft-motor     mh400e-gearbox.reverse-direction   => hm2_5i25.0.7i84.0.2.output-04
net activate-reducer-motor      mh400e-gearbox.reducer-motor       => hm2_5i25.0.7i84.0.2.output-01
net activate-midrange-motor     mh400e-gearbox.midrange-motor      => hm2_5i25.0.7i84.0.2.output-02
net set-shaft-motor-lowspeed    mh400e-gearbox.motor-lowspeed      => hm2_5i25.0.7i84.0.2.output-00 # MAHO calls this Anwahl Mittelstellung
net activate-input-stage-motor  mh400e-gearbox.input-stage-motor   => hm2_5i25.0.7i84.0.2.output-03
net activate-spindle-twitch-cw  mh400e-gearbox.twitch-cw           => hm2_5i25.0.7i84.0.2.output-06
net activate-spindle-twitch-ccw mh400e-gearbox.twitch-ccw          => hm2_5i25.0.7i84.0.2.output-07

i guess , i have found the problem. You have defined the outputs here in the hal file but i can't see any hal inputs defined in  my gearbox hal files. when i defined machine on output in the sim_hal file the 19K1 relay started working. . i tried directly pasting your hall commands in my gearbox sim hal file but it says that ""mh400e_gearbox_sim.hal:10: Pin 'motion.spindle-speed-out-abs' does not exist"". Also i am unable to use hte command ""source scripts/rip-environment"". when i run this command i get an error that says that this directory doesn't exist.can you tell me step by step how to source this rip environment.i am attaching the gearbox hal and gearbox sim hal file. please have a look at them. And guide me how can i edit them or if possible share your complete gearbox component on my mail.regards
sourabh

Sorry, I missed scrolling down to copy and paste the input pins as well:
# --- GEARBOX CONTROL ---
net sig_get_commanded_speed  mh400e-gearbox.spindle-speed-in-abs    <= motion.spindle-speed-out-abs
net sig_spindle_status       mh400e-gearbox.spindle-stopped     <= hm2_5i25.0.7i84.0.2.input-19
net sig_reducer_left         mh400e-gearbox.reducer-left        <= hm2_5i25.0.7i84.0.2.input-00
net sig_reducer_right        mh400e-gearbox.reducer-right       <= hm2_5i25.0.7i84.0.2.input-01
net sig_reducer_center       mh400e-gearbox.reducer-center      <= hm2_5i25.0.7i84.0.2.input-02
net sig_reducer_left_center  mh400e-gearbox.reducer-left-center <= hm2_5i25.0.7i84.0.2.input-03

net sig_middle_left          mh400e-gearbox.middle-left         <= hm2_5i25.0.7i84.0.2.input-04
net sig_middle_right         mh400e-gearbox.middle-right        <= hm2_5i25.0.7i84.0.2.input-05
net sig_middle_center        mh400e-gearbox.middle-center       <= hm2_5i25.0.7i84.0.2.input-06
net sig_middle_left_center   mh400e-gearbox.middle-left-center  <= hm2_5i25.0.7i84.0.2.input-07

net sig_input_left           mh400e-gearbox.input-left          <= hm2_5i25.0.7i84.0.2.input-08
net sig_input_right          mh400e-gearbox.input-right         <= hm2_5i25.0.7i84.0.2.input-09
net sig_input_center         mh400e-gearbox.input-center        <= hm2_5i25.0.7i84.0.2.input-10
net sig_input_left_center    mh400e-gearbox.input-left-center   <= hm2_5i25.0.7i84.0.2.input-11
 

You can always see my full, current  HAL and INI, as theye are attached to the first two posts in this thread.

All the details and source code of the comp is in Github:
github.com/jin-eld/mh400e-linuxcnc

got an error "mh400e_gearbox_sim.hal:45: Pin 'mh400e-gearbox.reducer-left' was already linked to signal 'sig_reducer_left'" although these lines are already in the MH400E.hal file that you gave me. i copied them in gearbox simulator hal file and this error came out.

can i run and check the gearbox directly in gmoccapy? i am unable to access the MDI tab right now, MDI works only after homing? i,m quiet furious about my first homing cycle as it's based on scale index. any tips regarding homing?

You set it to set itself as homed, regrdless of where it is, which I also used initially to test other functions...Look at the first line of the table in paragraph 6 here:
linuxcnc.org/docs/html/config/ini-homing.html

However, the Heidenhain scales include homing indexes. they are quite close to the end of the scale. I home my machine to them.

You need to configure to separate "machines". I set up a virtual machine called MAHO SIM, which had a hal to load the gearbox and the the sim, and test. Whether you load a GUI like Gmoccopy, or just run this hal config from the command line, either should work.

You can not load the SIM into your real machines HAL, as it needs the same pins. Therefore the errors