Brother TC-225 / TC-229 adventure!

alrighty, here's some files

Here is how I think I would attack this.
I would set up the soft limits for the full travel including tool change length. Then for the regular travel length I would set up something using the near component to trigger a user message and machine pause for the 17" travel. Then during a tool change it wouldn't be too difficult to disable the user limit you just created.

Why not setting the limits to the regular workspace? If a tool change is requested the upper limit is increased such that the spindle can travel to the ATC area. After the tool change the spindle goes down and the original limit is restored. Or am I missing something?

youre not missing something, thats exactly what i want, but i have not yet figured the correct method.

im 99% sure what you posted will do it, but i will need to see how to implement.

inside the toolchange.ngc you would need to trigger the z upper limit change. i have to get back into this on the weekend, and try to remember where i left off

but, we still need to tune the drives first, or this is all for nothing.

soooo, i guess noone found any glaring errors in my hal and ini files?

I haven't had time to do any further tuning on my axis. Your P value seems high and there is no I value. My machine is metric (should be 1/25.4 of your values), but anything more than 1.5 for P in X,Y gave resonances in my case.