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Good afternoon eveyone!
First the video of what i have been working on and dealing with, smashing my head against the wall, too much coffee and a lot of thinking but the results are spectacular!

youtube.com/shorts/jgv-_DtneDw?si=rTl5A_pSrwuul9d2


Time for the photos:
 
 
 

Now the description:
We were presented with a blown $iemen$ controller and our customer wanted drivers + cnc fully replaced. Machine is a huge vertical lathe, 1200mm chuck with automatic chuck changer, real C axis (with cartesian mapping and cylindrical mapping functiones needed), X and Z axis with tool changing system for lathe or mill tools. 16 tool magazine and tool probe system. To all off this add low pressure and high pressure coolant, hydraulics, tool clamp/release system, gearbox for main spindle and tool spindle, c axis brake, gearsbox oil chillers, lube system for guides and a bunch of other systems. Also dont forget the alarms and conditions for all this systems!!!
So, in summary, he complexity was not on cnc side as most of the functions we have already solved BUT the plc logic was a no go with the actual classicladder we have been using, we needed a more robust and scalable solution. What you can see on the video is what we got!

Now to the internal workings!
First needed to solve the communication with the cnc<->plc, i wanted something similar to $inumerik where a DB exist for the NC, then DBs for each channel, each axis, each BAG (mode group) and so on...Thats exactly what was done.
After that a way to send this 1500 bytes and receive 1000 bytes from the CNC, the way i found is using Codesys NVL (network variable) system. A udp based way of sending/receiving data amongs codesys plcs, nothing that a little reverse engineer cannot solve and make it communicate with PC<->PLC. 
Next problem: linux network stack, to slow for handling upd message burst so solution was given by Xenomai and RTNet! Not much info about it on the net but after some nights, coffee and wall-head-hitting, eveything went smooth.

So now i got this arquitecture:
 


Best regards,
Franco

G'day,

Since I updated from 2.7 to 2.9 on the lathe, with the latest GMOCCAPY, I can't enter lathe tool angles anymore. 


Any suggestions appreciated.
Cheers,
Mark

240VAC line rectified and filtered via DC capacitors to 340VDC to power a ~200VAC motor via inverter should be fine as long as the parameter(s) for setting motor rated voltage and v/f ramp (if applicable) are set accordingly. You just can't run such a motor across the line with a switch or contactor.

The few times I have seen this done using VFDs or servo drives, it was working well. I am not familiar enough with stmbl to tell you whether they have the same capability.

1. First confirm your 220VAC power. In my area our 220VAC usually measures around 240~244VAC, just make sure you're not using something like 380VAC.

2. The basic idea for your DC bus is AC through appropriately sized fuses or circuit breaker into the AC side of the bridge rectifier, the DC terminals of the rectifier feed the DC capacitor bank.

3. In practice you will also need a precharge circuit and a discharge resistor.

4. For the bridge rectifier I might use a GBPC3510 or comparable. It has to be bolted to an aluminum or copper heat sink, the required size of heat sink will depend on the ambient temperature and quantity of airflow. It is possible to calculate the heat sink requirement but there are so many variables, I simply use what I think and monitor the temperature during the first runs. If it gets hot the heat sink is too small. An IR temperature gun works great for this. For an application this size I might simply attach the bridge rectifier to the back or sub-panel of the steel electrical box housing the project.

5. I tend to size my capacitor banks by looking at comparably sized (Kw) VFDs or servo inverters and using about the same total uF. It can also be calculated using formulas. I keep calling it a capacitor bank. You might just need one single capacitor for this size project.

6. For the precharge circuits there are three popular ways. If your 220VAC power source has a high enough resistance you might do without the precharge circuit but I would not try that.

6.1. The cheap simple way is to insert an NTC thermistor in series with the AC input or DC output of the bridge rectifier feeding the capacitor bank. I have not attempted doing it this way but I see it a lot on mass produced inverter motor drives. The catch is appropriately sizing the NTC. I would tend to buy a couple different sizes so I can try each, measuring the start-up surge and running temperature. These WILL run HOT by design, probably over 100C.

6.2. I always install a single pole contactor or relay on one AC power lead for the bridge rectifier. An on-delay timer powers this contactor coil. A power resistor across the contactor points trickle charges the capacitor. After a few seconds the timer activates the contactor, allowing full power flow.

6.3. A third precharge method worth mentioning which I consider out of scope for a project of this size is the active rectifier.

7. A relatively high ohm resistor across the + and - of the capacitor bank will suffice for the discharge resistor, to ensure the capacitor is discharged in a few minutes after power is removed.

看看这个https://kcjengr.github.io/probe_basic/debian_13_trixie/extending/custom_ux_hacking.html

Another small milestone:

There is now a PRV32 (PicorV32/RISC-V) plugin that allows one or more soft cores to run in the FPGA.
A few tweaks still need to be made, but it’s already good enough for tinkering

* Up to 16 GPIOs
* Multiple 32-bit variables for data exchange with LinuxCNC
* Serial support
* GCC support
* tested on TangNano9k, ICE40up5k, ICE40hx8K

TODO:
* Add I2C and SPI master support
* Add PWM support
* 1-bit variables for LinuxCNC
* Adding support for use as an interface plugin
* Testing and optimize for more platforms

At the moment, I don’t have a practical application for it yet, but one will come along. (Anything that’s too cumbersome in Verilog, or for those who know C)

Furthermore, there’s also a SERV (World’s Smallest RISC-V) plugin,
which is considerably more resource-efficient but currently only offers assembler support and 3 output pins.

Only because I have been having strange issues.......

I notice at the end of your .ini file you have [PROBE]
USE_PROBE = basicprobe

Yet in the first post you say you are using Versaprobe.
I believe (without checking the destructions) that you "should" change that line from basicprobe to versaprobe, have you tried this?

Replying as much to help myself as you

Been busy finishing and commissioning a router i built, sorry for the lack of updates.

You need ~300VDC for a 210 VRMS AC output

That's an excellent question, the reason I think I need 210VDC is because my motors data plates show 210 as the rated voltage. Here's the info from the big Z axis motor:

Industrial Drives Brushless Motor
Model BRB3-2104-3027-A
Cont. 7.2A RMS Peak 26A
Rated RMS Volts Line to Line 210
Max speed 3900 RPM Freq. 195Hz
Rated Speed 3900 RPM Rated HP 3.1

It's been a while since I posted last. JetCad3 is a parametric CAD/CAM
package I've been building solo for machine shops — plasma, fab, router, laser,
mill — cross-platform on Windows, macOS, and Linux. Lots has landed. This has been in active development for just over 12 years now.

The QtPlasmaC post is fully built out and tested — native G2/G3 arcs (not
linearized unless you want them, it's a post option), material blocks, [spot]
small-hole spotting, M62/M63 THC envelope, M67 hole-velocity reduction. Also
bundled: a plain LinuxCNC Plasma post, Mach3/Mach4, FLCNC/FangLing, ProMach
StrikeCommand, FastCut G7. No post for your controller? An AI Import & Convert
turns a SheetCAM .scpost or Fusion .cps into a JetCad3 post.

Next step is deeper: JetCad3 as a DISPLAY in your LinuxCNC ini — full
CAD → CAM → control in one window. Our GcodePilot workspace already does this
for GRBL/FluidNC (live DRO, Z probing, wireless pendant, mid-cut Run-From-Here,
virtual plate squaring, firmware AVTHC). LinuxCNC is where it goes next — and
I'm looking for LinuxCNC plasma test users. My only LinuxCNC machine here is a
VMC, not a great plasma proxy. If you run QtPlasmaC and want to help, reach out.

THE SUITE — ALL LIVE TODAY

---

  • Design — 2D vector for signage and machine prep. Unlimited free, no account.
  • Drafting — full parametric 3D modeling with editable history, plus built-in
    Sheet Metal: base → flanges/hems → EZ Bend hand-fold reliefs → true flat
    pattern → auto-nest → post plasma/laser, all in one program. No DXF
    round-trip between four packages.
  • Plasma — top-down sheet CAM: DXF/SVG/SheetCAM import, genetic auto-
    nesting, Common Grid shared-line arrays, geometry-based cut rules, live sim.
  • Router — 2.5D nesting-first CAM; GRBL and MASSO posts.
  • Laser — palette-driven cut/engrave; G-code and Ruida output.
  • Mill — Fusion/HSM-style setup milling: high-speed dynamic clearing and
    new stock-aware rest machining. Posts GRBL, FluidNC, LinuxCNC.

Also built in: 2,000+ copyright-free fonts (live previews, offline cache),
straight/arc/circle layout, ready to cut or engrave.

Free/Hobby needs no account and follows the SheetCAM scheme — up to 500 lines of
G-code per post. That's the main gate, and it covers a lot of real hobby work
for free. Every workspace and tool is in the free login; I'm not gating
features. The ask is simple: if you're making money with it, support the project
so I can keep improving it. A free online account (for filing issues/requests on the community forum)
and an unlimited hardware HASP license are also available if you don't like monthly or yearly subscriptions (I don't like them, I'd rather own the software. Lifetime Updates are included with Unlimited Licenses, no version freezing like many other systems)

ROADMAP

---

  • Bevel cutting for Plasma
  • LinuxCNC control integration (DISPLAY in the ini, JetCad3 becomes the interface like Gmocappy or QtPlasmaC for Plasma, Mill, Router, Laser, etc)
  • Internationalization / multi-language
  • HVAC library + 3D-sketch wire-based duct builder in Drafting
  • Tube/rollcage: auto pipe coping + unbend, inline scribing (bend lines,
    orientation) straight to the pipe cutter
  • Rotary Jet Cutting workspace for tube notches — with "NotchMaster," a
    conversational tool that builds 3D tube notches ready to cut

Feedback from this forum has been some of the best I've gotten. Keep it coming —
and if you're a LinuxCNC plasma operator up for testing, please reach out.

 

Why do you need 210 VDC?

Normally you would use rectified 220V for the DC bus to run for 220V  motors

Are the motors 150 VAC?

I'm hoping to catch the eye of some of the experienced retrofitters here so I can learn some things. I'm in the process of retrofitting a Deckel FP4a with STMBL drives and LinuxCNC, it was originally 3 phase, but I want to run it on single phase 220, but not being an electrical engineer, I'm stumbling on the power supply for the drives.

I know I need to supply my motors with ~210VDC via a capacitor-smoothed DC bus, I'm just trying to find the best, safe option of doing so without breaking the bank, causing a fire, or killing myself and all my equipment, so I need to learn more.

From what I understand I have 3 options:

• An isolation transformer to drop the 220VAC to 150VAC, rectified to ~210VDC, but this needs an odd ~5KVA transformer that is likely very expensive and may be hard to source. I have the original, monstrous 3 phase transformer, but I have my doubts that it would work effectively in a single phase capacity.
• A skookum switch mode power supply that can handle the load of the 3 axis motors (2x 1.5KW, x1 1.75KW) and spindle (1.5KW). This is also likely to be expensive and hard to source.
• Direct rectification of the 220VAC to ~310VDC, very simple, but potentially quite dangerous, though I don't fully understand the risks and potential failure modes.

How are others handling this situation for their machines?


For a little background, the machine came to me free in a broken state, the original drives were questionable and the controller was non-functional, the machine is physically in great shape. I chose the STMBL drives because they can handle the resolvers in the stock Industrial Drives brushless axis motors and spindle motor, I couldn't find a decent, off-the-shelf drive that was cost competitive and they seemed like the ideal solution, provided I can power them.

I use DeskCNC for toolpathing, and it does do that for circles, but I do so many repetetive shapes, although not necessarily the same amount each time, that I simply write my own code I can reuse just by changing the number of repeats. I love it this way cause i can change stuff in seconds, but when it comes to circles in 4-axis mode, it's tougher

For the 7I97/7I97T, you need to set offset mode true for all PWMgens:

setp hm2_7i97.0.pwmgen.00.offset-mode 1
setp hm2_7i97.0.pwmgen.01.offset-mode 1
setp hm2_7i97.0.pwmgen.02.offset-mode 1
etc
also dither should be enabled:

setp hm2_7i97.0.pwmgen.00.dither 1
setp hm2_7i97.0.pwmgen.01.dither1
setp hm2_7i97.0.pwmgen.02.dither 1
etc
 

I've finally got my 7i97T running and I am at the point to test driving the spindle of my Lathe. The Simodrive 611 LT Module expects +-10V for running the spindle cw or ccw at certain speeds.
im not sure about my wiring, since I always get -10V and the spindle only turns one direction at full speed.

On TB3 analog0 i have enable +- on the first two pins. Then 10v+- on the third and ground of my 24V Powersupply on the fourth pin.

I did similiar retrofitting before and every time i ran into this, problem is: I cant remeber the solution.

I read somewhere about "spindle mode" and dithtering etc. Where can I read that up and how would I know what to look for ?