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Not sure as it was a long time ago, but i am pretty sure you can have everything working with just:
7i92TM plugged directly to 7i77 and a 7i84 connected with a cut in half LAN cable.
That is 64 inputs and 32 outputs, should be more than enough.
I did it the way i did as i am a control freak and like to have everything at a glance so 7i70 and 7i71 having LED for each IN/OUT helps with that. And if you look at my retrofits, all have every IN/OUT on screen ... yeah freak!

Yes and yes.
LinuxCNC is an Open Source project, and so is Inkscape.
And i have to ask, why use SolidWorks for 2D?

  Attaching the nvmpg .bin I was able to extract from my unit. Hope this helps debug what's going on with the TFT/display oddities!

Sorry for the late response. Truth is I found the replies quite daunting and so turned my attention to trying to get the software running. After repeated attempts I finally managed to get the exe file off the floppy disk and on to the harddrive. Once that was accomplished and DOS commands jogged from memory I managed to get it all running, well almost all. There's also a rotating axis which can run on one of the one of the three axises and which I think I'll wait a bit with. The DOS program is all in German which doesn't help a lot.

A newer kernel might help indeed, my N100 mini pc without rt kernel, just preempt has a ping of 0.5 ms to the router. This is with kernel version 6.9.0 rc4.

Thanks, it works fine this way.
I only changed the settings for "max_velocity_override" so that it took the max speed from the "MAX_LINEAR_VELOCITY" value
        FACTOR_VELOCITY_OVERRIDE = float(INFO.get_error_safe_setting("DISPLAY", "DEFAULT_VELOCITY_OVERRIDE"))
        DEFAULT_VELOCITY_OVERRIDE = float(INFO.get_error_safe_setting("DISPLAY", "MAX_LINEAR_VELOCITY", )) * FACTOR_VELOCITY_OVERRIDE * 60
        ACTION.SET_MAX_VELOCITY_RATE(DEFAULT_VELOCITY_OVERRIDE)

Try qtdragon with the ability to stretch to 3840x3840

Thank you for the quick replay as always!

Yes that is maybe a little overkill.

When having a further look at it a 7i92tm directly connected to a 7i77 (EUSurplus did have this in stock), a 7i74 and 7i70 and 7i71 for IO:s would also work fine as I can understand it and it will be a little cheaper as well

Great, thank you for the info. Can I use solidworks and get the file into Inkscape from there? (Save as a 2D dxf file and import it into Inkscape)

Also is LinuxCNC free?

I have more questions, in the case of only using limit3 and pid+stepgen how could I establish the limit switches for each axis? This is within the motion control if I'm not mistaken, well I hope for fresh ideas hehe, greetings

Why 2 of 7i92? Why 7i80?
I used a single 7i92, 7i74, several 7i70 and 7i71, and 7i77.
Since there is no easy to find 7i77, i would use 7i92TM plugged directly into a 7i85, then a 7i83 for the analog outputs, and add 7i70 inputs and 7i71 outputs as required.
All of those can be easily found, well if there is no 7i92, get a 7i96S, adds another sserial and some inputs and outputs, and some stepgens you probably have no use for, but will come handy if you ever have to change drives, new ones can do step/dir, most of them.

I have several foam cutting machines in daily use for many, many years, controlled by LinuxCNC, so if you are asking
Can LinuxCNC run a 2 axis machine?
Yes it can, from 1 to 9, each can have several joints, and much more if not assigned as axis.
And yes it can run a foam cutting machine, be it 2 or 3 or 4 or 5 axis.
For CAM use Inkscape, it is free and can output gcode directly usable by LinuxCNC. It can not do 4 axis, but does 2 axis easily.

Update of the Hurco retrofiting.
Did run it today with  the old controller. It i runs but have issues with UI freezes up and going in to sleep in middle of programming.
So the new controller solution is needed before could use it to any serious jobs.

Regarding this ordered the mesa boards the other day but EU-Surplus did not have the 7i80 in stock, neither does Mesa them selves.

So the question is now should i wait for a 7i80 card or would it be possible to issue the like of two 7i92 instead?
I have read somewhere here on the forum that the real time UDP controller cards should be directly connected to the PC and not through any switch.
So with a setup of two 7i92 instead of a 7i80 then I need to use a switch in between. Would this work and is there risk to use such a setup instead?

I really have no real urgency in getting the machine ready so waiting a couple of months is okay as it is right now.

Hello, I am looking for controller software that will run a 2 axis (horizontal and vertical axes) foam cutting. I see forums like  these  discussing this 2 axis software issue, but no one comes to a concrete solution.
This machine is meant to cut airfoils for formula racecars, so no need for 4 axes.
https://lh7-us.googleusercontent.com/v2mEQDZu6rNEEwdOJjn_bqSS542OCyz9Hb--cdkY-NKJMqVhxI6ZeEZjKNL3_-AGZNIkmkwFVAzFDNMzs8zBoPqbQ6XiDlCgkUH5jxiVCtE_odPuoLfngF4SgqBucfGOXqd4j5oGwJjjcRGlOD77W4bZWQ=s2048

I managed to get the drive to OP state when starting LCNC, but only when I uncomment all PDO adresses in the xml.

Its done in the hal file when motmod is loaded:

loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[KINS]JOINTS

It's done this way typically with ini file macro substitutions but can be done directly in the hal file without
any reference to the ini file at all...