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M65 P0  working ok
Today try to run orient with several or2 but not lucky...with spindle orient start must start to;
spindle-cw       hm2_5i25.0.7i77.0.0.output-01
net spindle-enable             <=  spindle.0.on
For the tool change connected all today and when start M6 T5 for example;
Z axis go to Z-50
Arm go out
Relase tool
Z axis go to Z0
Arm go in
Carousel start turn going to Index and stop not going to T5 and not give any error
Spindle is 2,2kw ATC water cooled bt30/iso30 with encoder and spin from 100rpm to 12000rpm  is capable to tapping M12 in steel with 100rpm Think to start produc this spindles in this year.


   

 

I start to add atc for my mill.Setup mesa 5i25 and 7i77 and linuxcnc 2.8.4For now I have two cuestions.1.First need spindle orient. Read some topic with orient i make my setup but when in mdi make M19 past some time and get error spindle dont turn.In halmeter I see orient start. My spindle need one Input for ON  and Fwd/Rev and dont see in halmeter servo on signal when start orient.Encoder working and rigid tapping to.2. For M6 routine  for yesterday  try with only connected Arm out and without connected sensor for arm out The arm going to position and get error (not sensor conected) and abort. And cuestion is the output 5 in my config after abort is still up. Try to press Esc and nothing. Try to press F2 servos stop working but output is still up. The output5 only disconnect when I clouse linuxcnc. Is normall?         

I was called to fix this, again!
It looks grim for now, 7i92 was taken by someone last year, this year they lost the 7i77 as it was inside the Elumatec for testing a while back, and they lost a whole motor with coupler! Damn, some people have no respect for machines at all. The amount of metal dust on it was huge.
Ordered some Mesa boards from www.eusurplus.com and 2 of 7i96S from www.welectron.com so in the meantime i might yank out the 7i92 and 7i77 from my Mazak. Also ordered a 750W china drive and motor and a 15KW cheap china VFD.
The existing Yaskawa spindle drive does not turn on at all on first try, but it does on second try, sometimes with F600 error and sometimes it just works and jogs happily.
The PC and power supply are also dead but the monitor works.
Tomorrow, most probably, changing the PC, testing the state of Argon drives, jogging the spindle since i forgot how to run if from the panel.
Oh joy ...

scda wrote:

...
A brake disc with a notch milled out is used to created the "index" for the index impulse (see pic) on sensor. Maybe the size of the notch is not optimal (round instead of square edges).

How do other people create the index impulse on a lathe (if not using an encoder with Z pulse)? Is an optical sensor better?

 

I'm wondering if this could also be related to the rise/fall time of the specific sensor you are using as some are awfully 'slow'. Maybe it just can't catch-up at 'higher' rpm? Also, inductive sensor have a sensing range that can vary a lot from one model to another. I see that your notch is not very deep, (neither very wide) if it's not deep enough to be outside of the sensing range this could also cause this kind of issue.

This being said, I'm not an expert since I've chose to go with an optical switch instead. Specifically model OPB932W51Z. Some reasons for this specific choice are: Totem pole output  (full swing from gnd to 5Vcc). Inverted output; since I'm spinning a 'tab' instead of a notched/drilled disk. It then connect directly to the encoder Z input (of a 7i77) without the need of anything else (pull-up/down resistor, capacitor, etc) Also, that thing is damn fast with a rise and fall time of 70ns. Main drawback: This is a very easy to destroy plastic little thing. YMMV

May i suggest:
7i96S and 7i84 = 5 stepgens, spindle with encoder, and plenty of IO, mixed mode IO so 5V and/or 24V as 7i84 has two separate supplies and easy to wire with a cut off CAT5/6 cable.
or lately i am aiming for 7i96S and 7i77 as it is the definitive "be all, end all" combo, and it can be readily found.
And keep in mind that 7i96S can have many more stepgens/PWM/encoders on the IDC26 headers.

Isn't the 7i77 only for analog motor interface?
The thing is that in this case a step/dir card is needed for the axes motors so buying a 7i77 just for the spindle may be a bit excessive.

5i25 is PCI, 6i25 is PCI-E, 7i92 is ETH, they are the same functionaly.
Finding those is quite hard lately, still, see if you can find 7i97 as that is both 7i92 and 7i77 in one place/board, easier wiring.
If you can not find 7i97 or 7i92, you may find 7i96S for a bit more money and with 7i77 you end up with all of the above plus 5 step/dirs and another spindle/encoder. And more IO.

Not much to suggest since the chip shortage, but Mesa 7i96S and Mesa 7i77 can still be found.
If you can stretch for that, it is the most versatile combo for now, with plenty of IO, 5 step/dir and 6 full +-10V, another spindle, 7 encoders, etc etc.
As for drives, i have no clue, sorry.