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Yes, mainly the UI does the gear size / depth calculations and gives you a span measurement to run a quick test that the tooth depth is correct.
It could be more aesthetic:

Where did you find engraver-1.py ? It doesn't seem to appear in this thread....

I think that using HAL to read the multiplexed inputs is likely to be the easier solution.

But, yes, you probably _could_ create a custom component that uses the hotmot2 raw interface to read register values directly and interpret those into HAL pins.
linuxcnc.org/docs/stable/html/man/man9/h...t2.9.html#Raw%20Mode

In fact, if it is a single address that needs to be read, it might be possible to do it all in HAL, by "setp" the register address to read from, and using "bitwise" on the read data to toggle individual HAL pins.

Not sure 'cutting edge' is the right term, but I understand if you're not interested in something slightly experimental.  You can always have a go at caxis.comp later.

As far as creating a second configuration goes, there are (at least) a couple ways.

First, you can simply make a copy of your current config and then hand-edit the INI and HAL files.  But you mentioned that HAL isn't clicking for you, so that may be a bit of a stretch.

Second method would be to use Mesact to create a new configuration from scratch, but this time you tell Mesact that your spindle is a step & direction type.  I think you've got the 4th axis connected to stepgen.04 and are using a 6:1 belt ratio, yes?  Include those values in the new config via Mesact, along with an appropriate max speed and estimated max accel for the 4th axis.

Leave out the 'real' spindle settings, and put everything else (axes & IO) the same as your existing config and then see what Mesact comes up with.

That should give you new INI and HAL files which you can use to create a merged/blended configuration that has both spindles and no 4th axis.

I find that using VSCode makes things easy to read/edit (there's a LCNC/HAL file plugin).  I'd set up all three HAL files across two monitors and look at the differences.  Things to look out for:

• Dont forget to comment out or delete the A-axis/joint 3 section
• The new spindle needs all pins to be named 'spindle.1.nnn', and the signal names need to be 'spindle1-vel-cmd-nnn' (or similar).

INI file must be edited, too, especially these:
[DISPLAY]
GEOMETRY = xyz

[KINS]
KINEMATICS = trivkins coordinates=XYZ
JOINTS = 3

[TRAJ]
COORDINATES = XYZ
SPINDLES=2

[AXIS_A] - remove this entire section
[JOINT_3] - remove this entire section

[SPINDLE_1]
(put the 4th axis spindle stuff here)

Have a go and see what you come up with.  Assuming it doesn't work - these things are rarely perfect the first time - and you get an error trying to start LCNC, make sure to screen capture the error and report back here.

Thanks for your reply.
The XYZ servo drives seem to use +/- 10V analog signal to control the DC motors.
The resolvers are the default Fadal resolvers.
For the VFD I don't know as I'm looking for a new VFD to replace the current Baldor VFD. I did see people succesfully replacing the Baldor either by Yaskawa GA500, Yaskawa V1000 or Hitachi WJ200 VFD.

Can the 7i97T output +/-10V signals and take the input of the resolvers?

Oh and a generic question: can someone share the Fadal Model 914 / VMC15 (1994) wiring diagrams / electrical schemetics?

I think you identified to problem By trade I'm a power electronics engineer... so my programming skills are... well they can only be improved