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ok guys, overwhelming responses!! Thank you all for the awesome support!!

I do have a spindle, z, and x encoder, all attached to servo drives. I do not have the drives powered right now because I do not want to attach anything else for fear that I've done something wrong in the config/pin out. I can afford to replace an MPG, I cannot afford to replace a drive...

The original MPGs that came with the machine (Fryer ET18) are labeled as OLM-01-2AD by Maxmar Controls Inc. I presumed (as unlikley as it was) that both MPGs were bad because they both (X and Z) would crash the computer if they moved even one pulse.
The replacement MPGs are no-name Chinese, but are also 6 wire, 5VDC differential encoders. Pictures of those are in my previous posts. It doesnt appear to matter though, the new encoders make the machine behave the same as the old encoders. I am unable to find an official spec sheet for these, but the google claims they are standard quadrature A/B rotary MPG 5VD.

Hi all,
Hoping this is the right place for a conversation about machine controller conversions. I'm a hobby user, not a production shop. I've got a  Mazak VQC 20/40 mill with M2 control, it's a nice fully functional machine with good tolerances for it advanced age. It's lack of memory is a real pain point. Programming in Mazatrol CAM M2 was probably great back in the day, not so much now. I can send G-Code files to it, but hit file size limits rather quickly. It's not capable of drip feed. I think I'm ready to go for the Mesa upgrade. With AI help I've input all the info I can think of, this is where I'm at... realistic? reasonable?

Servo Motors & Drives:
X-axis: Mitsubishi HD-81-12 DC permanent magnet servo motor with analog drive accepting ±10V command (terminals: AX, BX, G1X, G2X, G)
Y-axis: Mitsubishi HD-81-12S DC PM servo with analog drive (terminals: AY, BY, G1Y, G2Y, G)
Z-axis: Mitsubishi HD-101-12 DC PM servo with analog drive (terminals: AZ, BZ, G1Z, G2Z, G)
All three drives are MELDA-8 or similar Mitsubishi analog cards that accept ±10V command signals—these are REUSABLE
Position Feedback:
X-axis: Magnescale SR-921RH linear encoder (outputs quadrature signals directly) + MS3100B 20-29P tacho generator
Y-axis: Tamagawa Seiki resolver (MS3108B 20-29P, pins: RS1, RS2, RC1, RC2, RO1, RO2) + tacho generator
Z-axis: Magnescale SR-921RH-450-R-0 linear encoder + MS3108B 20-29P tacho generator
Spindle:
Mitsubishi AC motor SE-EV-FV with FREQROL FR-SX VFD controller
Already accepts 0-10V analog speed command and direction signal—fully LinuxCNC compatible
Tool Changer:
20-tool carousel ATC with CAT40 tooling
Nachi proximity sensors for position detectionMesa Hardware StackCore Cards 
7i92H  - Ethernet-based motion controller, main brain
7i77  - 6-axis ±10V analog outputs + encoder inputs + 48 I/O points
7i49 - 6-channel resolver interface (for Y-axis only)
7i73 - Pendant/operator panel interface

Servo Drive Connections:

Existing 24VDC power supply (HR-11F, outputs P24 and G24) remains in service:
Mesa 7i77 I/O is 24V compatible
Existing Contactors (3S-1, 3S-2, 3S-3, 3S-4):
Control servo drive enable sequencing
Spindle power control
Lube/coolant pump control
These stay and get controlled through Mesa 7i77 I/O outputsATC IntegrationInputs to LinuxCNC:
Tool-in-position sensors (Nachi proximity switches)
Carousel rotation feedback
Gripper open/close confirmation
Drawbar clamp/unclamp sensors
Outputs from LinuxCNC:
Carousel motor control (forward/reverse)
Gripper solenoid
Drawbar solenoid
Air blast control

more photosThis hydraulic system really stumped me until i asked a friend (thanks Gordon if you see this)
It has a accumulator so what you do is you turn the pump on and then wait until the pressure switch triggers and turn pump off.  This machine only needs oil when toolchanging so it’s a great idea really and allows me to not need a pump running all the time.  Once I worked out how it worked it is great  and very easy to setup in classic ladder

 


next thing i need to talk about is how i am handling homing currently

this is just copied and pasted from the email user list.  great place to get fast answers to questions btw

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Hey guysthanks for the replies the homing is a interesting issue I had a bit of a play and made a copy of my config that i hacked.   What i found was that if i combined my original 2 PID loops into 1 loop and used the scale for position and used the motor velocity on encoder for velocity all in one PID then homing to index enable worked perfectly. but doing it that way the motor tuning was not as good.  backlash is a constant of 0.1mm and the motor just jumped across that backlash whenever it moved.  in practice that meant that the absolute scale position hovered by +-0.01 or so. this was not bad and totally usable.  If i had done this option first i would have called it good and just used it.  but the movement was much louder and less smooth than the two PID loops which get run through a sum component.  As the original two PID loops was much much smoother, it was perfect and once i come to a stop the drive rapids to within 0.01 or 0.02 and then creeps the last 0.02mm (using the integral value which takes about a second)  and ends up in the right place within 0.005mm or less.  basically perfect every time with no dithering. It is now my most accurate machine.  and really nice also the homing when homing I home all axis at the same time.  X and Y get homed to index enable like normal. and the Z value i trick the home switch by checking the joint state.  How this works is the Joint2 switch state goes form 7 when searching for switch the first time to 12 when latching on to switch slowly the second time so in classic ladder i set up two compare functions that basically choose whether to listen to the main home switch or the z axis motor encoder Z index pulse.  (this is different to the index enable pulse and this is possible to miss when only checking in software not hardware.  but at a slow speed i haven't found any issues yet, and when testing with a dial indicator i can't see any changes between homing.  I can rehome linuxcnc up the top of the travel beside the home switch and then rapid down to the table which is about 1m away and the dial indicator is definitely within 0.01 each time.  i can't really see any movement on it.

photos show the classic ladder stuff might help someone

     So pretty happy all in all would like to fix the index enable issue in the future but for now it's working fine. this is a 40 year old machine and weighs 12 ton.  and when i got it the backlash was 0.40mm.  I replaced all the thrust bearings and changed from reduction gearbox to a nice mazak flexible coupling and direct drive.  The timing belt was T8 timing belt so not even HTD profile which has more backlash which didn't help.  The FIL factory actually got the location of the Z axis 2nd ballscrew mount out by 2.4mm which i was shocked by.  i double checked measuring against the slideways at the top and bottom of the screw and yeah it was out 2.4mm from factory!  so that is why all the thrust bearings were stuffed. anyway just about to get it running into production.  this machine will be running like 16 hrs a day shortly probably.Lastly just have some photos of the control cabinet.  I wasn’t sure if I would post these.  My wiring is never that clean and currently machine is mid progress so wires everywhere.  But enjoy The system has 7i92m 7i77 7i84 mesa cards And yuhai Chinese servo drives 3.5kwPlus 11kw spindle vfd.  Which I might get another one for the horizontal spindle.The machine was actually working when I got it.  But it took me 30 min to just work out how to turn the 40 year old software on.  And it had old dc brushed drives and 40 year old servo motors and I just didn’t want to have to deal with it.  I run a machine shop in New Zealand full time and work for a lot of larger customers making money and time is money..  so definitely not a hobby here anymore.  we have like 60 tons of CNC gear here (7 machines currently) all running linuxcnc apart from one fagor controlled lathe i haven't bothered yet. So I just didn’t want to deal with issues.  I want a machine that just works for the next 10 years.  I have machines that have worked flawlessly for 6 years so far and keen to run the same system.  You turn it on and make parts.  That’s it.

 
 
 

new spindle motor i fitted.  nothing fancy had it laying around. 



and lastly spindle gearchange setup.  you can buy a 400watt VFD for like 30 usd on aliexpress currently.  so i use those instead of contactors.  so i get nice overloads variable speed. electrical braking and easy wiring all in one.  plus cheaper:)   

Hey, folks here literally saved my ass from a disaster so I'm passing it on.

I have a 7.5hp old Columbo spindle that I know little about besides:
(a) Resistance is 1.8ohm consistent across all 3 windings.
(b) Its from 1994ish, and serviced in 2004.
(c) Manual change, and the mechanism to hold the spindle works.
(d) CAT40, insides look good, threads look good.
(e) 18000rpm (I think)
(f) About 80 freedom weight units (says so on the maintenance invoice from 2004).

Free.

You pay shipping. Its located in southern New Hampshire in Freedomland. 
I will post runout or vibration numbers once I get set up to measure everything.
Do request any info you need, and I'll update it here as I measure stuff.

I'm trying to set up linuxcnc on an old motion master bridge. Reusing the brushed servos and 4 amp. drives. Adding 4 pulse train Yaskawa servos/drives (this is the upgrade) to swivel head and rotaries. I'd very much appreciate someone willing to take a few calls and guide me along so I can get help or quick opinions when in a pinch. I've so far managed to covert a 480V machine to 220V. 

Something I'd love is a 7i77u board (just borrow it for a few weeks if you have one to spare). I just don't know enough to understand if I can use 7i77 boards that are immediately available. That's my immediate next step.

They are out of stock and I'm hard up for time. Wife gave me permission to start a project with a machine that is the size of a room, and then, a few weeks later, tells me the whole family is moving to a place that not much bigger than the room the machine is filling up. FML. 

Make stuff and prosper.

 

I just wanted to register that this solved the same issue for me on 2.9.7. There are older solutions on the forum, for example " Automatic pause when spindle is started " from 2015, but they don't reflect current pin/signal names. Modified default spindle control HAL section below, two lines commented out and six more required.

My spindle VFD is connected as follows for simple "run" operation with no feedback:

I might not be the best person to reply to this as i absolutely enjoy retrofitting and bringing back to life old machines, so i may be a bit on the "trigger happy" side, but:
-i would try to use the existing drives and motors and VFD/spindle
-seems like those are analog drives, so a Mesa 7i97T would do perfectly fine if you can find one, if not a 7i92T with 7i77 is the same thing, or if those are also scarce a 7i96S with 7i85 and 7i83 should do the same job.
-if you still want to replace the drives, you have two choices in general: EtherCAT or Mesa with normal step/dir or analog servos (do not bother to look at steppers and close loop steppers)
-You will be bombarded by others to choose EtherCAT, i am still avoiding them due to some fuzzy communication issues, but i will test them for sure the fist chance i get.
-For the Mesa/new drives, i would look for "position and velocity" mode drives (analog +-10V and step/dir) and also with encoder outputs (all have encoder inputs or absolute encoders, usually serial ones) so the loop can be closed in LinuxCNC with both types of control, makes life easier during use. Given the choice between analog and step/dir, choose step/dir.

No, I was just setting up. I have a couple toggle switches working on gpio but that’s it. I was just getting excited I could see it talking through halshow. No servo/spindle drivers yet.
I figured the MPGs should have been the next easiest thing to do

Hi all,

I'm planning a gantry router build for machining composite panels into cabinet components. Looking for advice on machine choice and stack.

Material

- Sandwich panels: 1mm aluminium skins on both faces, polyurethane foam core
- Total thickness: ~60mm nominal, but varies ±1mm across a batch
- Panel size: up to 1500x3000mm

Parts and operations



- Cutting outlines
- Pockets and step joints on panel face
- V-scoring the aluminium skin to create precise fold lines (score-and-fold)

These operations require multiple tools in a single job (end mills for pockets and joints, V-bit for scoring), so automatic tool change (ATC) is a hard requirement.

The step joints are the critical operation: they create mechanical overlap between mating panels so cabinets assemble with tight joints. A 1mm thickness variation in the stock translates directly into a gap.

Workflow

probing → generate Z map → process map (Python) → adjust G-code geometry (XY and Z) → send corrected G-code → machining

- Fusion 360 CAM produces nominal G-code
- Before cutting, I probe a grid of Z points across the panel surface
- A Python script reads the probe map and rewrites the G-code: step depths and joint profiles are adjusted to the actual measured local thickness — for both the panel being cut and its mating counterpart
- This is not just Z surface compensation: XY profiles are modified based on the probe map so that mating joints match regardless of thickness variation

Why LinuxCNC

- Workflow already tested with LinuxCNC + MESA cards (7i96/7i77) on an entry level router.
- Plan to use the Python socket interface for probe data collection and G-code rewriting — tight integration between probing and post-processing is central to the workflow

My questions

1. Are there manufacturers selling new gantry routers with these specs who ship with LinuxCNC, or sell mechanics separately from the controller?
   - Working envelope: ~1600x3200mm
   - HF spindle: 18k+ RPM
   - Integrated vacuum table with independently switchable zones
   - ATC (tool magazine or rack)
   - Probe input

2. For a retrofit path: which used industrial gantry platforms have the best LinuxCNC community experience?
   - Main concerns: ATC integration and vacuum zone management via MESA I/O

3. Any experience with probe-map-driven G-code modification beyond simple Z surface mapping?
   - Currently planning G38.x + Python
   - Is there a better pattern for this use case?

Thanks

 

Much thanks to iforce2d for this implementation and write-up. I just deployed a slightly tweaked version of it to my 4x10' router that has a 40 watt laser as second spindle. 

I had to modify the component to force zero power output when there was no motion. It looks like the original first line of code can result in a NaN and then my machine was ending up with a 50% PWM output in that state. So I force NaN to zero. That worked okay in my testing at a fixed z height. But when running an actual program I retract Z between parts and I was finding that Z only motion was leaving the laser stuck on. So now I also force zero power output when X and Y motion are essentially zero.

I use a bunch of MESA cards including a 7I77 and a 7I76. And then some additional IO boards linked via serial. I never figured out how to get a hardware PWM output. So I am using software PWM for driving the laser. Here are the relevant sections of my custom.hal file showing how it all goes together:

Hello,I am currently retrofitting a Biesse Rover 336 with LinuxCNC.The machine is controlled with a Mesa 7i77, and I am using EtherCAT modules distributed throughout the machine for the I/O.Originally the machine had a Control Techniques Unidrive VFD, but I was unable to change the required parameters, so I replaced it with a Danfoss VFD, which is now working well.At this point the machine is mostly operational:

• Homing works
• XYZ motion works
• Spindle runs correctly
• The toolchanger sequence is mostly prepared

So I am approaching the final stages of the retrofit.I am using Probe Basic as the interface.Machine configuration

• Toolchanger: 7 tools
• Vertical drills: ~25
• Horizontal drill (X axis): 1
• Horizontal drills (Y axis): 3

My current plan is:

• Tools 1–7 → spindle toolchanger
• Tools 101–130 → drill bank (fixed tools)

Questions about tool offsetsFor the drill bank I need to determine the XYZ offsets relative to the main spindle.I am unsure what the best way to handle this is.Options I am considering:

1. Store the offsets in the tool table (like normal tools)
2. Apply the offsets inside the M6 tool change routine, since these drills are fixed and it may reduce the chance of mistakes.

Do tool table offsets work correctly for horizontal drills, or is there a better recommended approach?Fusion 360 questionI also created a test piece in Fusion 360 to test the horizontal drills.However I get the following error:
 Error: Function 'positionABC' can only be used with multi-axis machine configurations.
Error at line: 2040
Error in operation: 'Drill2'I suspect this may be related to how I defined the horizontal drilling operation.Is there a recommended way to program horizontal drilling for drill banks in Fusion when targeting LinuxCNC?Any advice from people who have implemented drill banks or horizontal drills on router-style machines would be very helpful.Thanks!

I am using a optocoupler (from amazon) between my 7i77D output and a solenoid valve for a spindle break in the sinking configuration, the output is over-temperature faulting for some reason.
using TB8 OUTPUT0. Field voltage is 24Vdc and driving the relay with the same 24 power supply. 
I set up the opto relay on the bench and it only draws 2.2ma on the input in low position.
I'm kind of at a loss, the manual says the outputs can take up to 350ma.

Please advise
John V.
 

I've ended up fighting the hal loader.

#

---

# M19 ORIENT – single driver / multi‑sink form
#

---

loadrt orient count=1
addf orient.0 servo-thread

loadrt pid names=pid.o
addf pid.o.do-pid-calcs servo-thread

loadrt mux2 count=1
addf mux2.0 servo-thread
loadrt or2 count=1
addf or2.0 servo-thread

# --- Orient PID tuning ---
setp pid.o.Pgain 0.05
setp pid.o.Igain 0.0005
setp pid.o.Dgain 0.0002
setp pid.o.maxoutput 60
setp pid.o.error-previous-target true
setp orient.0.tolerance 0.05
setp orient.0.angle 0

# --- One signal name, declared once and fanned out ---
net orient-bit spindle.0.orient => orient.0.enable
net orient-bit => or2.0.in1
net orient-bit => mux2.0.sel
# separate signal drives the encoder’s index enable input
net orient-arm-index orient-bit => hm2_7i92.0.encoder.05.index-enable

# --- Run enable OR gate ---
net run-enable or2.0.out => hm2_7i92.0.7i77.0.1.spinena
net spindle-enable => or2.0.in0

# --- Orient angle / feedback wiring ---
net orient-angle spindle.0.orient-angle => orient.0.angle
net spindle-revs hm2_7i92.0.encoder.05.position => orient.0.position

# --- Orient PID loop ---
net orient-cmd orient.0.command => pid.o.command
net orient-fb hm2_7i92.0.encoder.05.velocity-rpm => pid.o.feedback
net orient-out pid.o.output => mux2.0.in1

# --- Normal spindle path and output switch ---
net spindle-output pid.s.output => mux2.0.in0
net spindle-vfd-out mux2.0.out => hm2_7i92.0.7i77.0.1.analogout5

# --- Completion flag back to controller ---
net orient-done orient.0.is-oriented => spindle.0.is-oriented

#Error in file ./spindlecontrol.hal:
# Pin 'orient-bit' does not exist
#Shutting down and cleaning up LinuxCNC…

I replaced the spindle motor VFD, three phase outpout and the speed signal is 0-10v.
I notice that the speed varies in a random way and at say 1000 rpm, I get steps of 15 to 30 plus and minus.
The fuzzy line is an oscilloscope trace of the analogout5 pin on the 7i77.
The lower halscope trace is the same pin also nominally at 1000, offset and magnified to show what I can hear.
I have started the spindle using MDI with M3 S1000.
Any ideas what maye be going on?

I am trying to configure the spindle as a C-axis, but I am having a problem and cannot find a solution.
Could someone please take a look at my configuration and the video and give me some advice?
I was not able to post this in the original lathe thread.





#########################
# AXIS C JOINT 2
#########################

setp  pid.c.Pgain     [JOINT_2](P)
setp  pid.c.Igain     [JOINT_2](I)
setp  pid.c.Dgain     [JOINT_2](D)
setp  pid.c.bias      [JOINT_2](BIAS)
setp  pid.c.FF0       [JOINT_2](FF0)
setp  pid.c.FF1       [JOINT_2](FF1)
setp  pid.c.FF2       [JOINT_2](FF2)
setp  pid.c.deadband  [JOINT_2](DEADBAND)
setp  pid.c.maxoutput [JOINT_2](MAX_OUTPUT)
setp  pid.c.error-previous-target true

net c-index-enable    =>  pid.c.index-enable
net c-enable          =>  pid.c.enable
net c-pos-cmd         =>  pid.c.command
net c-spindle-pos-fb  =>  pid.c.feedback
net c-output          <=  pid.c.output 

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

268 net c-output            =>  hm2_7i98.0.pwmgen.00.value
269 net c-pos-cmd           <=  joint.2.motor-pos-cmd
270 net c-enable            <=  joint.2.amp-enable-out
271 # enable _all_ sserial pwmgens
272 #net c-enable            =>  hm2_7i92.0.7i77.0.1.analogen

276 net c-spindle-pos-fb    <=  hm2_7i98.0.encoder.02.position
277 net c-spindle-vel-fb    <=  hm2_7i98.0.encoder.02.velocity
278 net c-spindle-pos-fb    =>  joint.2.motor-pos-fb
279 #net c-index-enable     joint.0.index-enable <=> hm2_7i92.0.encoder.06.index-enable
280 net c-pos-rawcounts     <=  hm2_7i98.0.encoder.02.rawcounts

282 # ---setup home / limit switch signals---

284 net c-home-sw           =>  joint.2.home-sw-in
285 net c-neg-limit         =>  joint.2.neg-lim-sw-in
286 net c-pos-limit         =>  joint.2.pos-lim-sw-in


[AXIS_C]
MAX_VELOCITY     = 360
MAX_ACCELERATION = 500
MIN_LIMIT        = -900.0
MAX_LIMIT        = 900.0

[JOINT_2]
TYPE             = ANGULAR
HOME             = 0.0
FERROR           = 1000.0
MIN_FERROR       = 500.0
MAX_VELOCITY     = 360
MAX_ACCELERATION = 500

P        = 0.0000001
I        = 0.
D        = 0.
FF0      = 0.98
FF1      = 0
FF2      = 0
BIAS     = 0
DEADBAND = 0.1
MAX_OUTPUT = 10

ENCODER_SCALE    = -40
OUTPUT_SCALE     = 10
OUTPUT_MIN_LIMIT = -10
OUTPUT_MAX_LIMIT = 10

MIN_LIMIT = -1000
MAX_LIMIT = 1000

HOME_OFFSET   = 0.0
HOME_SEQUENCE = 1

No, Mesa 7i80 does not go with 7i77 and 7i85, the Mesa 7i92TM goes with those. 7i80 is 50 pin, 7i92 is 25/26pin.
There are other options also, the 7i77 is hard to find so a bit more searching is needed, on the 50 pin stuff i can not help, but for 25 pin stuff i used a lot, here are some options:
-7i97T it is roughly the same as 7i92TM with 7i77, with 7i85 or even better with 7i74 as this needs plain LAN cables to wire the 7i70 (48 inputs) and/or 7i71/7i72 (48 outputs sinking or sourcing), or 7i84 (32 in and 16 out)
-7i92TM (notice the M, makes it directly plugable into 7i77 so no need for IDC26 to DB25 cable and adapter), with 7i85 OR 7i74
-7i96S (step/dir and spindle) with 7i83 (analog outputs) and 7i85 (encoder and SSerial) for 7i70/7i71/7i72/7i84
-
I think there is also 7i93 IRC should have 3 of IDC26 headers, but not sure, should be same as 7i92 with more IO. Again, do double check this.