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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


 

if (when linuxCNC is running) you run

halcmd show all  | grep 7i77

You can get all 7I77 sserial pins and parameters


 

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.

[card_ip_address] = Mesa FPGA card IP address, so likely 192.168.1.121 or 10.10.10.10

If you don't get analog output, (and there is some non zero aout value),
its likely appropriate analog enable is not true.

Note that the 7I77 has a common enable for analog  channels 0..4 and
separate enable for channel 5.
 

I managed to get the addressing working for the spindle analogout but spindle doesn't work still. Keep plugging away.
Address is hm2_7i76e.0.7i77.0.3. I never thought of a three until I asked for a error report and it showed me the pins.

I think the analog sserial channel will be 3

To check:

mesaflash --device 7i76e --addr [card_ip_address] --dbname2 7i77 --readhmid
 

I have finally managed to get my 4 step/dir axis working, but still having trouble with the analog servo spindle drive. I get errors for addressing for the output
hm2_7i76e.0.7i77.0.1.analogout5 I have tried with .5. I have tried 7i77.0.2.
it keeps saying anything with that address doesn't exist,

The attached control circuit will disable the spindle and servos of the machine if an Estop push button (PB) is pressed or change tool is requested. The arrangement is combination of both software and external hardwired circuit.

To stop any movement of the machine, the approach uses estop and reset pins of the halui component and redundant hardwired external circuit to disable any movement of the machine. The interface between the software and the hardwired circuit is done through digital I/O (2 or 3 inputs and two outputs).

Operation of this system is follows:
If an Estop PB is activated or tool change is requested machine will go into an Estop state.

• If only Estop is activated, operator is required to press push button reset to enable spindle and servos
• If tool change is requested, operator is required to change the tool, press tool changed PB (either hardwired or UI) and press reset PB to reset the estop and continue operation. (I know operators don’t like to press two buttons sequentially in certain order, but for their hands and fingers sake the extra mental challenge makes it worthwhile, I think!.

On the left side of the sheet is the electrical schematic. Showing use 5 relays. If you decide to use this circuit you need to determine the number of contacts normally open and normally closed before ordering the relays. The MCR contacts connection to servos and VFD are hardware dependent (if you need help with this part of the diagram ask)

On the right side is a postgui block diagram reflecting net listing of hal file see below.

 

#

---

# Load realtime Components and their counts

loadrt and2         count= 2
loadrt flipflop     count= 1
loadrt or2          count= 1

#

---

# Add functions to threads

addf and2.0                   servo-thread 
addf and2.1                   servo-thread 
addf flipflop.0               servo-thread 
addf or2.0                    servo-thread 

#

---

# Connect Pins with Wires

#     signal/wire                 connected Pins
#--+

---

+

---

net estop.activate.sig     halui.estop.activate  and2.1.in1  flipflop.0.out  
net estop.is-activated.sig halui.estop.is-activated  and2.0.in1  flipflop.0.reset  hm2-7i92.0.7i77.0.0.output-00  
net estop.reset.sig        halui.estop.reset  and2.0.out  
net external.reset         and2.0.in0  hm2-7i92.0.7i77.0.0.input-01  
net external=estop         flipflop.0.set  hm2-7i92.0.7i77.0.0.input-00  
net t.prepare.loop         iocontrol.0.tool-prepared  iocontrol.0.tool-prepare  
net t.xch.done             hal_manualtoolchange.changed  iocontrol.0.tool-changed  
net tool-changed           or2.0.in0  
net tool-xch.request       hal_manualtoolchange.change  iocontrol.0.tool-change  hm2-7i92.0.7i77.0.0.output-01  
net tool.changed           or2.0.out  and2.1.in0  
net tool.changed.button    hal_manualtoolchange.change_button  and2.1.out  
net tool.number            hal_manualtoolchange.number  iocontrol.0.tool-prep-number  
net ui.tool.change.pb      or2.0.in1  

That's analog servo (7I77) setup
if you make a (different name!) pncconf configuration for a 7I76E
it will make a step/dir setup as an example

This is what my hal shows for one of my axis servos, should be stp/dir. Does this look like a step/dir or analog code.

#*******************
# AXIS X JOINT 0
#*******************

setp pid.x.Pgain [JOINT_0]P
setp pid.x.Igain [JOINT_0]I
setp pid.x.Dgain [JOINT_0]D
setp pid.x.bias [JOINT_0]BIAS
setp pid.x.FF0 [JOINT_0]FF0
setp pid.x.FF1 [JOINT_0]FF1
setp pid.x.FF2 [JOINT_0]FF2
setp pid.x.deadband [JOINT_0]DEADBAND
setp pid.x.maxoutput [JOINT_0]MAX_OUTPUT
setp pid.x.error-previous-target true
# This setting is to limit bogus stepgen
# velocity corrections caused by position
# feedback sample time jitter.
setp pid.x.maxerror 0.000500

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

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

setp hm2_7i76e.0.7i77.0.3.analogout1-scalemax [JOINT_0]OUTPUT_SCALE
setp hm2_7i76e.0.7i77.0.3.analogout1-minlim [JOINT_0]OUTPUT_MIN_LIMIT
setp hm2_7i76e.0.7i77.0.3.analogout1-maxlim [JOINT_0]OUTPUT_MAX_LIMIT

net x-output => hm2_7i76e.0.7i77.0.3.analogout0
net x-pos-cmd joint.0.motor-pos-cmd
net x-enable joint.0.amp-enable-out
# enable _all_ sserial pwmgens
net x-enable hm2_7i76e.0.7i77.0.3.analogena

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

#setp hm2_7i76e.0.encoder.01.counter-mode 0
#setp hm2_7i76e.0.encoder.01.filter 1
#setp hm2_7i76e.0.encoder.01.index-invert 0
#setp hm2_7i76e.0.encoder.01.index-mask 0
#setp hm2_7i76e.0.encoder.01.index-mask-invert 0
#setp hm2_7i76e.0.encoder.01.scale [JOINT_0]ENCODER_SCALE

net x-pos-fb <= hm2_7i76e.0.encoder.01.position
net x-vel-fb <= hm2_7i76e.0.encoder.01.velocity
net x-pos-fb => joint.0.motor-pos-fb
net x-index-enable joint.0.index-enable <=> hm2_7i76e.0.encoder.01.index-enable
net x-pos-rawcounts <= hm2_7i76e.0.encoder.01.rawcounts

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

net x-home-sw => joint.0.home-sw-in
net x-neg-limit => joint.0.neg-lim-sw-in
net x-pos-limit => joint.0.pos-lim-sw-in

pncconf can setup step/dir and analog servo systems (they end up being very similar at the hal level)

That is, if you select a 7I76E in pnconf, the axis/joint setup is all step/dir as a 7I76E by
itself only supports step/dir motion.

If you setup say a 7I92+7I77 configuration, it will setup an analog servo system

Not sure what the easiest path is here but I see a couple options:

1. With pncconf, make a normal step/dir 7I76E configuration and a normal 7I77 configuration and merge them

2. Use pncconfs discover option

the 7i64 is connected to the 7i77 through tb6 i believe it is. They need to make the printing bigger for us old guys.

The 7I64 could be connected to either the 7I76E or 7I77

(it would be channel 1 on the 7I76E or channel 4 on the 7I77)

that sounds about right doesn't it. Im guessing the 7i64 is connected to the 7i77