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  • NT4Boy
  • NT4Boy
02 May 2025 19:03
Replied by NT4Boy on topic HURCO KMB-1 Control Update

HURCO KMB-1 Control Update

Category: Milling Machines

I think I have the system in control now, and have reached the point where I want to add an encoder to the spindle for rigid tapping and better speed control.
My plan had been to add a toothed wheel with a pair of hall effect sensors, one a few teeth away, but half a cycle out of phase for quadrature, and a third for an index. Then connect these directly into the 7i77 channel 5 encoder inputs. (some biasing resistors maybe required also)
The maximum spindle rpm is 3500. I was proposing 40 teeth, but on say an M6 thread with 1mm pitch, I think that's a possible pitch error of .00625mm, which is pretty small, but I guess 100 would be better. I'd appreciate others opinions on this choice please.
Secondly, because of the belt run and lack of clearance around the belt pulley, putting the index tooth on is a much bigger mission than I was expecting.
Can I simply delete it and use a missing tooth, or pair of missing teeth as the index?
What looks to me like it might not so simply work is the encoder quadrature when it reaches the missing tooth, or am I over thinking this?
Thanks
  • FPM
  • FPM
18 Apr 2025 12:01 - 18 Apr 2025 12:03
Replied by FPM on topic converting a tos/intos fngj 40

converting a tos/intos fngj 40

Category: Milling Machines

I connected the 7i77 to p1 and the 7i78 to p2, i assume this is the correct order.
I've tried to modify the hal so that the z-Axis is the stepper connected to the first interface of the 7i78. The encoder for the z-axis is connected to the 7i77. Is this more or less done correctly? (hal is attached).
Since the 7i78 has no enable signals for the steppers, is it possible to use the enable pin from the spindle, since i am not using this? and how do i need to mod the hal?
Thanks! 

File Attachment:

File Name: intos.hal
File Size:10 KB
  • workshop54
  • workshop54
23 Mar 2025 20:11 - 23 Mar 2025 20:29
Replied by workshop54 on topic Retrofit: Maho MH400E to LinuxCNC

Retrofit: Maho MH400E to LinuxCNC

Category: Show Your Stuff

Got the Mesa 7i94T and 7i77 boards powered up today, and it’s great to finally see the pins show up in LinuxCNC.


 


Also managed to remove the tool holder that had been stuck in the spindle since I got the machine — definitely satisfying to get that out of the way.I’ll shorten the IDC25 ribbon once the board layout is finalized. For now, I’ve ordered breakout boards to avoid cutting cables too early: three for the Heidenhain DB15s, two for the Indramat DB9s, and two for the IDC40 ribbons.


The original Philips 432 hardware is completely gone. I briefly considered replacing the whole cabinet to avoid upgrading the mains fuse, but in the end I’m likely going for a proper electrical upgrade: increasing the main connection from 25A to 40A and switching from a B16 to a C25 breaker (still waiting on the electrician to confirm this setup).Once the wiring takes shape, I plan to capture everything neatly in EPLAN to avoid spaghetti later on. Slowly but surely, things are coming together.
  • tommylight
  • tommylight's Avatar
20 Mar 2025 21:15
Replied by tommylight on topic 7I97T joint following error

7I97T joint following error

Category: General LinuxCNC Questions

Use PncConf to create a basic minimal config for 7i92 with 7i77, then we can modify it to fit the 7i97T and give it a try.
Simple 3 axis config, no spindle, no I/O, no MPG, nothing else.
Also upload one of the existing configs that run so we can get the card addresses.
  • UrKibin
  • UrKibin
13 Mar 2025 09:52
Replied by UrKibin on topic CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

Category: Milling Machines

I tried using MesaCT to generae the ini and hal files but upon loading in linuxcnc, it produces an error.

Debug file information:
Note: Using POSIX realtime
./main.hal:31: Pin 'hm2_5i25.0.7i77.0.4.analogena' does not exist
2243
Stopping realtime threads
Unloading hal components
RTAPI_PCI: Unmapped 65536 bytes at 0x7f0b2d806000
Note: Using POSIX realtime

I do not know how to proceed. Kindly advise.

For information purposes,
Drive 0 - x axis
Drive 1 - y axis
Drive 2 - z axis
Drive 5 - Spindle

Regards,
Kelvin
 
  • PCW
  • PCW's Avatar
08 Mar 2025 02:24 - 08 Mar 2025 02:31
Replied by PCW on topic CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

Category: Milling Machines

Normally the basic configuration is created by one of the two configuration utilities:
pncconf or MesaCT. These are GUI programs where you enter the intended interface hardware and
basic machine specifications (dimensions, encoder scaling etc) and I/O connections
(limit/home switches spindle controls etc)

Note that the analog out pins are AOUTn. The ENAn+ and ENAn- pins are a switch to enable the
drives (on when enabled)
 
  • UrKibin
  • UrKibin
08 Mar 2025 01:45
Replied by UrKibin on topic CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

Category: Milling Machines

Hi Andy,

Good day. From what i have gathered in the user manuals available in the internet and checking the existing connection from the servo controllers to the non-functioning acramatic 2100 controller,

each servo controller (X, Y, Z, and Spindle) has
1) +-10V inputs (i assume to drive the servo motors)
2) An A & /A, B & /B, and Z & /Z encoder outputs.

I was thinking of connecting the +-10V servo inputs to the 7i77 by its TB5 outputs namely, ENA0+-, ENA1+-, ENA2+-, and ENA3+-.

Then connecting the servo encoder outputs to the 7i77 by its TB3-TB4 inputs namely, QA0 & /QA0, QB0 & /QB0, IDX0 & /IDX0, for all axes and the spindle.

If that is correct, my only problem now would be the configuration under linuxcnc which I have no idea where to begin.

As I have already purchased the Plug-N-Go Kit (7i77 + 6i25) from Mesa, I would like to use them. But will look into your suggestion since they have more pins. Also, it would be generally hard for me to purchase additional boards since I am from the Philippines.

Thank you very much for your assistance.
  • UrKibin
  • UrKibin
07 Mar 2025 07:20
CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC was created by UrKibin

CINCINATTI MILACRON ARROW 500 (BDS4 + VFS5) WITH MESA 7i77 + 6i25 WITH LINUXCNC

Category: Milling Machines

Hi,

Good day. Newbie here. Would just like to crowdsource and steer us to the right direction with regards to retrofitting a milacron arrow with BDS4 axis servo controllers and VFS5 spindle servo controllers.

Any inputs and directions will be greatly appreciated.
  • rainbowkoala49
  • rainbowkoala49
24 Feb 2025 06:31 - 24 Feb 2025 06:42
Which combination of mesa cards should I use? was created by rainbowkoala49

Which combination of mesa cards should I use?

Category: Driver Boards

I have an existing SBZ 130 i want to retrofit by keeping the original motors+drives, the motors all (3 axis and spindle) are AC 3PH servos with integrated 2 pole resolvers (6 wires - sin, cos, excitation pairs) for their feedback, aside from that I have about 42 inputs and 36 outputs as per the machines original schematics, but I might not use every single one. Moreover, I also want to add a separate rotary milling head for chamfers at different angles later down the line, so how would I go about adding/changing the combination of mesa cards.
The same machine I've seen a successful retrofit using combination of 6i25 7i77 7i70 7i71 7i74, but that system all the motors had absolute encoders
Mine is slightly different model (1998, mine is 2001) and I was recommended from a different person to go with 6i24 (do i need 6i24-16 or 25 and whats the difference??), 7i49 for the resolvers and controlling the drives with 10v analog, but would this work? I'm a complete beginner to this field so I'd like to know before purchasing any hardware. Moreover, do I need the other cards as well? (7i70 7i71 7i74) I understand the first two are for extra I/O digitals but im not sure what the 7i74 does, if someone can explain I would greatly appreciate it.

Edit : I just found out that the 6i24 has about 70 I/O pins, I think that covers my need so I dont need the extra 7i70 and 7i71 right?
  • JT
  • JT's Avatar
18 Feb 2025 14:08
Replied by JT on topic Replacing Anilam 5000M - Recomendations?

Replacing Anilam 5000M - Recomendations?

Category: General LinuxCNC Questions

I converted my BP knee mill from Anilam 1100M to EMC (now LinuxCNC) years ago using 5i25 and 7i77. I ditched everything except the drive boards and DC power supply for the drives IIRC. I put an Automation Direct GS2 drive for the spindle using the GS2 component.

JT
  • tommylight
  • tommylight's Avatar
20 Jan 2025 18:23
Replied by tommylight on topic Rando hal component collections

Rando hal component collections

Category: HAL

Had i known it would be such a big deal i would have posted hal parts for monitoring Yaskawa servo drives i did when retrofitting the Hurco, used all 4 of 7i77 analog inputs, drives had a 3.3V output for 100% and i think it was 5V max for 150%, worked like a charm, had sliders with changing colors depending on load so i could see from across the shop if any drive or spindle is overloaded. Unfortunately had to change the drives as one was DOA and another one failed during testing. Changed the drives to Argon and changed the config that is attached on the Hurco retrofit page here on the forum but has no feedback.
-
if and when necessary, i will delete this post to keep it clean.
  • lukin1156
  • lukin1156
13 Jan 2025 21:42
Replied by lukin1156 on topic Carousel with analog servo drive

Carousel with analog servo drive

Category: Advanced Configuration

I tried using the speed mode, but it didn't work. So I went back to the original control. By manually rotating the carousel, I determined the number of pulses between the individual pockets. The automatic tool change works quite well, sometimes there is just a problem with homing the carousel. If the carousel goes to the same side at the home position, it is fine. However, if the carousel goes to the other side after homing, there is a small error in the position. I tried using rotation in only one direction, but there is another problem that the error in the number of pulses between the individual pockets adds up over time.

Here is short video from tool change.

youtube.com/shorts/BAgzHO6OKA0?si=I7e9RTFSHqlaFPUl

 #  --- automatic tool change ---

loadrt carousel pockets=6 encoding=index dir=2
addf carousel.0        servo-thread
setp carousel.0.scale 1666
setp carousel.0.home-offset -70

net spindlenot <= halui.spindle.0.is-on => not.0.in
net spindlenotout <= not.0.out => and2.2.in0
net toolunlock <= motion.digital-out-00 => or2.1.in0
net toolunlockkey <= hm2_5i25.0.7i84.0.2.input-07 => or2.1.in1
net toolunlockout <= or2.1.out => and2.2.in1
net toolunlockout1 <= and2.2.out => hm2_5i25.0.7i77.0.0.output-00

net carouselup <= motion.digital-out-01 => hm2_5i25.0.7i77.0.0.output-01
net spindleair <= motion.digital-out-02 => hm2_5i25.0.7i77.0.0.output-02
net orient1   <= motion.digital-out-03 => hm2_5i25.0.7i77.0.0.output-12
net orient2     <= motion.digital-out-04 => hm2_5i25.0.7i77.0.0.output-13
net toolisunlock   <= motion.digital-in-00  => hm2_5i25.0.7i77.0.0.input-04
net toolislock        <= motion.digital-in-01  => hm2_5i25.0.7i77.0.0.input-05
net carouselisup     <= motion.digital-in-02  => hm2_5i25.0.7i77.0.0.input-06
net carouselisdown  <= motion.digital-in-03  => hm2_5i25.0.7i77.0.0.input-07
net spindleinposition <= motion.digital-in-04 => hm2_5i25.0.7i77.0.0.input-24

net carousel-index carousel.0.sense-0 hm2_5i25.0.7i77.0.0.input-03-not
net carousel-pulse carousel.0.sense-1 hm2_5i25.0.7i77.0.0.input-02-not
net carousel-enable <= motion.digital-out-05 => carousel.0.enable
net carousel-pocket <= motion.analog-out-00 => conv-float-s32.0.in
net carousel-pocket-out <= carousel.0.pocket-number => conv-float-s32.0.out
net carousel-finish <= motion.digital-in-08  <= carousel.0.ready

# PID carousel

setp   pid.c.Pgain     [SPINDLE_2]P
setp   pid.c.Igain     [SPINDLE_2]I
setp   pid.c.Dgain     [SPINDLE_2]D
setp   pid.c.bias      [SPINDLE_2]BIAS
setp   pid.c.FF0       [SPINDLE_2]FF0
setp   pid.c.FF1       [SPINDLE_2]FF1
setp   pid.c.FF2       [SPINDLE_2]FF2
setp   pid.c.deadband  [SPINDLE_2]DEADBAND
setp   pid.c.maxoutput [SPINDLE_2]MAX_OUTPUT
setp   pid.c.error-previous-target true

net c-index-enable  =>  pid.c.index-enable
net machine-is-enabled    =>  pid.c.enable
net c-vel-cmd       =>  pid.c.command
net c-pos-fb       =>  pid.c.feedback
net c-output        <=  pid.c.output

# ---PWM Generator signals/setup---

setp   hm2_5i25.0.7i77.0.1.analogout3-scalemax  [SPINDLE_2]OUTPUT_SCALE
setp   hm2_5i25.0.7i77.0.1.analogout3-minlim    [SPINDLE_2]OUTPUT_MIN_LIMIT
setp   hm2_5i25.0.7i77.0.1.analogout3-maxlim    [SPINDLE_2]OUTPUT_MAX_LIMIT

net c-output     => hm2_5i25.0.7i77.0.1.analogout3
net c-vel-cmd    <= carousel.0.counts-target

# ---Encoder feedback signals/setup---

setp    hm2_5i25.0.encoder.03.counter-mode 0
setp    hm2_5i25.0.encoder.03.filter 1
setp    hm2_5i25.0.encoder.03.index-invert 0
setp    hm2_5i25.0.encoder.03.index-mask 0
setp    hm2_5i25.0.encoder.03.index-mask-invert 0
setp    hm2_5i25.0.encoder.03.scale  [SPINDLE_2]ENCODER_SCALE

net c-pos-fb               <=  hm2_5i25.0.encoder.03.position
net c-vel-fb               <=  hm2_5i25.0.encoder.03.velocity
net c-pos-fb               =>  conv-float-s32.1.in
net c-pos-fb-out             => conv-float-s32.1.out => carousel.0.counts

net tool-changed    <= iocontrol.0.tool-change  => iocontrol.0.tool-changed


 
  • MacKaye
  • MacKaye
24 Nov 2024 18:34
Weiler DZ26 Millturn Conversion was created by MacKaye

Weiler DZ26 Millturn Conversion

Category: Turning

Hi,

i have a rather ambitious project on my hand. I need to convert my Weiler DZ26 as of today my old 810T control finally went the way of the dodo.
I´ve put so much time and effort into keeping that old thing running and making it jump through hoops via CAD/CAM and my own postprocessor, but enough is enough.
My plan is to get basic turning functionality working and look into millturn operation later.
In general the machine is a dynamic (20m/min), high acceleration monster(for its time), with a super quick Sauter 12 station toolchanger (all stations driven).
I plan on using the original Siemens drives and motors. Both spindles need to run in high- or low drive modes for A-axis operation and toolchanging modes. Both spindles have two encoders for high rpm operation and low rpm positioning. The Control need to switch a number of accessories like coolant pump, self oiler, solenoids for mode switch of the tool changer and so on...
I will start with a kind of allright office PC to get it up and running and plan on switching to a proper industrial PC later on.
From what i have read over the years if you have a dynamic machine, your better served with PCIE based mesa boards.
My current plan is getting myself a 6i25 and a 7i77 breakout board. Should have enough I/O for my needs and PCIE should keep it rather real time.
Do you have any suggestions and/or questions? I will document my progress over here and definetly need some help every once in a while.
What would be your recommended GUI for a machine like that? I have next to no experience in LinuxCNC, but are pretty decent in all kinds of Siemens controls.

Best,
Lukas


 
  • PCW
  • PCW's Avatar
23 Nov 2024 22:43
Replied by PCW on topic Mesa, Linuxcnc with step direction servo's for axis and analog servo spindle.

Mesa, Linuxcnc with step direction servo's for axis and analog servo spindle.

Category: Basic Configuration

if (when linuxCNC is running) you run

halcmd show all  | grep 7i77

You can get all 7I77 sserial pins and parameters


 
  • mjones@welfab.ca
  • mjones@welfab.ca
23 Nov 2024 22:16
Replied by mjones@welfab.ca on topic Mesa, Linuxcnc with step direction servo's for axis and analog servo spindle.

Mesa, Linuxcnc with step direction servo's for axis and analog servo spindle.

Category: Basic Configuration

HaHa Don't I feel stupid. I guess that's how my day has gone. It didn't even occur to me that [] meant put in your own value
Now to look even more stupid. How many channels does the 7i77 have, and how do I know what is on each channel. Is it a channel per drive or just i.o on one, drives on another, encoders on another and so on. until earlier today I didn't know there was more than 2 and I didn't really know they were channels of the card I just thought that was the address of the whole card.
I have alot to learn.
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