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Do the encoders not match any of the Mesa absolute-encoder types?

linuxcnc.org/docs/stable/html/man/man9/h...%20Interface%20(SSI)

The manual turret looks like a prime candidate for motorisation...

Or get an industrial robot arm to operate the manual tool changer for you.

Look at the pins supplied by halui.

linuxcnc.org/docs/html/gui/halui.html

You might need to force home-sw-in high, so that it always thinks it's on the switch, and then it will set the index-enable.

ie, in the HAL file:
sets joint.0.home-sw-in 1

Hi Andy, I've been running a 25,000ns relatively successfully. Which is why I've been scratching my head so much. However, actually thinking out loud on here had me thinking it had to be electrical. So I dug out the oscilloscope and probed the signal. The cheap Chinese sensors had a 20k pull up resistor which was far too strong and was causing the pulse width to be way too long. So at 1900 the signal went from a pulse train to just "on".

I've swapped out the resistor and now getting good clean pulses read by the Pi with a stable speed reading up to 4000rpm.

Thank you for your suggestions as they have pointed me in the right direction. I'm in the process of modelling up a mount so i can mount two sensors to create a encoder that will do direction as you suggested.

I think you are suggesting that you could supply "fake" commutation signals from LinuxCNC to the drive, and that might be enough to persuade the drive to start working?

This is what I'm thinking. I will try it as soon as I have time and report back.