Dyna Myte 2400 milling machine retrofit

Here is my ini file data as it was when the alarms occured.


# Generated by PNCconf at Fri May 1 14:06:34 2015
# If you make changes to this file, they will be
# overwritten when you run PNCconf again

[EMC]
MACHINE = Dyna_2400_A
DEBUG = 0

[DISPLAY]
DISPLAY = axis
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
MAX_FEED_OVERRIDE = 2.000000
MAX_SPINDLE_OVERRIDE = 1.000000
MIN_SPINDLE_OVERRIDE = 0.500000
INTRO_GRAPHIC = linuxcnc.gif
INTRO_TIME = 5
PROGRAM_PREFIX = /home/camlab/linuxcnc/nc_files
PYVCP = pyvcp-panel.xml
INCREMENTS = .1in .05in .01in .005in .001in .0005in .0001in
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 0.250000
MAX_LINEAR_VELOCITY = 1.000000
MIN_LINEAR_VELOCITY = 0.010000
DEFAULT_ANGULAR_VELOCITY = 0.250000
MAX_ANGULAR_VELOCITY = 1.000000
MIN_ANGULAR_VELOCITY = 0.010000
EDITOR = gedit
GEOMETRY = xyz

[FILTER]
PROGRAM_EXTENSION = .png,.gif,.jpg Greyscale Depth Image
PROGRAM_EXTENSION = .py Python Script
png = image-to-gcode
gif = image-to-gcode
jpg = image-to-gcode
py = python

[TASK]
TASK = milltask
CYCLE_TIME = 0.010

[RS274NGC]
PARAMETER_FILE = linuxcnc.var

[EMCMOT]
EMCMOT = motmod
COMM_TIMEOUT = 1.0
COMM_WAIT = 0.010
SERVO_PERIOD = 1000000

[HOSTMOT2]
# **** This is for info only ****
# DRIVER0=hm2_pci
# BOARD0=5i25

[HAL]
HALUI = halui
HALFILE = Dyna_2400_A.hal
HALFILE = custom.hal
POSTGUI_HALFILE = postgui_call_list.hal
SHUTDOWN = shutdown.hal

[HALUI]

[TRAJ]
AXES = 3
COORDINATES = X Y Z
LINEAR_UNITS = inch
ANGULAR_UNITS = degree
CYCLE_TIME = 0.010
DEFAULT_VELOCITY = 0.33
MAX_LINEAR_VELOCITY = 3.33
NO_FORCE_HOMING = 1

[EMCIO]
EMCIO = io
CYCLE_TIME = 0.100
TOOL_TABLE = tool.tbl

#********************
# Axis X
#********************
[AXIS_0]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 200
DIRHOLD = 200
STEPLEN = 4000
STEPSPACE = 4000
STEP_SCALE = -101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 6.2
HOME_OFFSET = 0.0

#********************
# Axis Y
#********************
[AXIS_1]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 700
DIRHOLD = 700
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = 101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 5.0
HOME_OFFSET = 0.0

#********************
# Axis Z
#********************
[AXIS_2]
TYPE = LINEAR
HOME = 0.0
FERROR = 0.005
MIN_FERROR = 0.0005
MAX_VELOCITY = 3.33333333333
MAX_ACCELERATION = 15.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 4.2
STEPGEN_MAXACCEL = 18.8
# these are in nanoseconds
DIRSETUP = 700
DIRHOLD = 700
STEPLEN = 1500
STEPSPACE = 2500
STEP_SCALE = -101596.0
MIN_LIMIT = -0.001
MAX_LIMIT = 4.0
HOME_OFFSET = 0.0

#********************
# Spindle
#********************
[SPINDLE_9]

I fixed all of those issues and I have all of the axis motors and limit switches under control. Thank you for the help.

The last issue that I need to resolve is to control the on/off of the spindle. I am using a Mesa 6I25 card in the PC and a 7I76 daughter card. I need to generate a PWM signal for the spindle. The spindle speed is controlled by a manual POT, which is fine considering that the speed range is selected via belt and pully and the machine does not have an automatic tool changer. All I need to be able to do is program spindle on and off. The signal seems to be 5 volts. I have the field IO's powered with 24 volt power supply and the 6I25 is supplying 5 volts from the PC for the signals to the axis motor dirves. The spindle drive is controlled from a 5 volt power supply in the machine and is on a switch at the moment. How exactly can I generate the PWM signal through the 7I76 card?

The driver is the original hardware that came with the machine. We don't have any documentation on the machine so I couldn't begin to describe it. Forgive my ignorance on this subject. I'm a second year mechanical engineering student. I haven't gotten into electrical controls classes as of yet. The electrical engineering student that is working with me verified that the signal is PWM. We orginally attempted to control the spindle using the potentiometer on the 7I76 and the analog signal outputs and had no luck. The nature of the machine's design doesn't really make it necessary to control spindle speed through a program though. All I need is a programable signal to turn it on.

So I think instead of using the existing spindle drive, I am going to replace it with a new spindle drive. We can get a drive from automation direct that I am fairly sure will operate on the analog spindle signal and pot output from the 7I76 card. I just need to verify that It is compatible with the existing spindle motor. Below is a link to the drive. Can you look it over and tell me if it will indeed work with the analog outputs On the 7I76? Thanks.

www.automationdirect.com/adc/Shopping/Ca...en_Frame/GSD4-240-1C

Well, the original control worked as well, but it was old and no longer supported by the manufacturer. The intention of the project was to update the equipment with readily available parts and an operating system like linuxcnc that would enable us to easily integrate all of our machines and robots into a modular manufacturing cell. My professor originally suggested replacing that drive since we had no information at all on it. In hindsight I probably put myself in a corner by ordering the 7I76 card before I had learned enough about what we needed. But it is all a learning experience. Thank you for all of the help. I'll see how this next step goes.