Mazak VQC 15/40 Integration

We completed a successful recontrol of a VMC (a Mazak VQC 15/40, a gantry-style machine) a while back, and wanted to share the resulting project with the LinuxCNC community.

• Mesa ethernet based boards
• Side toolchanger
• Servos with resolvers with original drives
• Original E-Stop logic
• Way lube, pumps, sensors, etc.
• Interlocks, limit switches, etc.
• New Hitachi VFD spindle controller to replace FREQROL spindle drive
• Linux 2.7 userspace install (current at the time)

Note that the HAL files are very modular -- we purposefully kept everything as modular and notated as possible in order to simply later features, debugging, troubleshooting, etc.

There are more details and pictures at the Github project.
We actually built our own computer using a 2-core Intel pentium, mounted it on a custom plate, and installed it in the control box in place of the original computer boards (the Mitsubishi Meldas / Mazatrol controller was a PC card based controller).
Also, we did modify Gmoccapy slightly to provide a 'limits override' input that controlled a physical signal to the controller overriding an interlock preventing motion (useful when necessary to jog into the toolchanger envelope, or if the toolchange cycle errored while in the toolchanger envelope).

Of course, everybody here on the forum was invaluable as they helped guide us through snags here and there, and Peter at Mesa was wonderful to work with and patiently explained a number of intricacies related to the interaction of the Mesa boards, resolvers, and the like.

Hope this helps provide an example to others working with similar features!