Thanks
As it turns out i HAVE a 7i84 although i do not know where it is right now. I did not realise it could "be" a keyboard. My keyboard is 71 keys. (your math is right i think, but it would take all the outputs) This could make things interesting. However, the downside is it costs $80usd, and a raspberry pi 2040 mcu is $6 which makes it less ideal for a future product beyond just my personal machine.
As for the layout, this is a very small panel for a very small machine, so it will naturally not have every single button you fond on a fanuc control. That said, my brother machines had almost nothing either. The DDCS has like 12 or 14 total keys. The touch screen is purely for navigation in linux when required in place of a mouse. The keyboard is a "full" 65% board but i will be rearranging various keys. It will be no worse than just using a pc keyboard as far as number of inputs. The overrides are primarily for feeds on this machine. the spindle almost always lives at full speed. A more idiot proof compromise might be a shift key to change it's function to spindle override. Much like the xyza controls have a middle "rapid" shift button.
7" is a pretty standard size on vmc's. Seimens 808d is 7", I think my brothers had 8". Larger screens are pretty but take too much space and cost way more. A lot of this is modeled on the basic features of the 808d actually.
Vertical keyboard is standard on most machines. Almost all. It sucks if you want to write a novel sure, but it is a necessary evil because there is literally no where else to put it. I drew one up with an angle and it was more trouble than it is worth finding a place for it, wiring, pivots and hinges etc. Simple is best here.