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Thanks!

Servos will be delta adsa-b3. I need to read all the specs now.

The spindle itself has no encoder, and no easy facility to add one. Will need to see what it possible to cook up. Its really only for a safety shut down. (program 60k, see the spindle has bogged to 50k, you know something is wrong, shut down). Spindle load is not always a precise indicator on these high speed spindles it seems (see my steel cutting video where it is varying between about 18000rpm and 14000rpm)

Good point on the IO. I have an ek100 here somewhere. that plus one 16 in and one 8 out might be all that's needed and only $300 or so and open to easy expansion. also beckhoff has a local rep that's visited me before, so easy support.

It doesn't have to be really 'good' the machine is a Seig X2 I have heavily modified it, but still I don't think a super nice spindle package would be worth it on this mill maybe my next project.

I was just looking for something better than the stock Brushed DC motor they ship with. at the moment the stock motor still works so I'll run that to begin with but I know the control boards for them are known to blow and its cheaper to get a Chinese servo set up than a new brushed control board (That will most likely break again)

Thanks again for the help guys this forum is amazing!

4. That one would be easy enough, either mcu that reads values and hits a pause button, a python script that does the same. Sure you could make a half component do that as well.

3. Figure a simple induction or ultrasonic sensor could read if the tool is occupied. Don't think this one would be easier with an mcu.

5. Should work fine. Don't think probing cares what the tool setter is. But don't have much experience here

2. Might be able to get rpm with a simple 1 point sensor,. If not find a vfd that has closed loop control such as SV (Sensorless vector) which monitors the rpm with extra circuitry (gs20)

1. If everything is ethercat then go that route. I bet you could figure out a wauly to use the IO of the servo drives. Most have 3-4 of em.

If not then mesa and step dir is hard to beat from a simplicity and reliability side.

6. Not sure on this one

I can't answer all your questions but:

1. Ethercat has always just worked. It just how much work there is between just and works has reduced . If your drives are CIA402 compatible, its easy as there is now a generic driver here at the official driver repo github.com/linuxcnc-ethercat/linuxcnc-ethercat/tree/master

1.a Some people have used absolute encoders. Homing might be a work in progress. I am waiting for a bit of hardware to test my repo github.com/rodw-au/cia402_homecomp home_offsets and gantries are not supported at this stage.

2. My modbus spindle shows accurate RPM and also load. Finding an affordable encoder input is problematic outside of beckhoff.
This one www.icp-australia.com.au/product/ecat-2074a/
And this Chinese one is interesting  and would cover your IO too.But you would need to build a generic driver for it. www.icp-australia.com.au/product/ecat-2074a/

For cheap I/O, Rtelligent has one I use that includes some PWM outputs (16 in, 16 out). There is also one by Deiwu. I have built generic drivers for both. XML are in here github.com/rodw-au/linuxcnc-cia402

Limits and home switches (if needed) can be attached to the drives and then you home internally so IO will be limited don't discount Beckhoff.

I'd try an install of Wheezy, it'll have 2.7 but should be able to be made to work.

I'd be wary of AI and the like, you know with "d1v3r5ty is strength" mumbo jumbo. If it finds enough information saying the sky is Cheddar Cheese that's what it'll tell ya.

On a side note, has anyone seen "AI sign language", think about it, how often does AI get hands right ?

Contact details are on my gtihub page.
github.com/ozzyrob

Yeah I'd be spending money on on an upgrade to some Mesa motion hardware control before a spindle, and a good spindle package isn't going to be cheap.

Would try pwm and two output pins. One with run stop and another for fwd/rev

Are you using a RIP or a installed version of linuxcnc?

Sorry didnt mean to post the ini as a reply

ok

Tried a third cable this morning with similar results.

cornholio,
Thanks for the kind offer, I will send a PM.

John.

edit:
Well, PMs don't work.
How can we get in touch ?

John.

Can you post your current hal and ini files?

Thank you for being willing to try to help me, I also looked in the pins and didn't find anything, I also looked in the documentation to see if there was anything that could be added to the ini for this, but to no avail.

Take a look at the ini file spindle section,
MAX_OUTPUT and OUTPUT_SCALE parameters