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  • langdons
  • langdons
Today 20:05 - Today 20:07
  • Aciera
  • Aciera's Avatar
10 May 2025 16:14 - 11 May 2025 19:17

Planning to Retrofit a Mazak Integrex200Y Mill-Turn Machine

Category: Advanced Configuration

Here is the promised sim config:
 

File Attachment:

File Name: mazak-inte...-dev.zip
File Size:111 KB


To test:
1. unzip
2. 'halcompile --install' the enclosed 'mazak_integrex_200y_kins.comp'
3. start 'mazak-integrex-200y' config and run the preloaded gcode program


If you have any questions, which is likely, just ask.

Text from the enclosed README file:

Experimental simulation of a 5axis Mill/Turn machine (eg MAZAK Integrex 200Y)

Implemented Gcodes:

- 'G67 B':          Moves the B-axis to the 'B'-word position and activates 'HALF TCP Lathe' mode.
- 'G68 B (X Y Z)':  Moves the B-axis to the 'B'-word position then defines and activates a work plane perpendicular the this current tool orientation with the origin at the current WCS (optionally offset by any [X,Y,Z]-Words). This will change WCS to 'G59' where the transformed work offset values have been written to (ie the prior values stored in G59 will be lost!).
- 'G68.1 (X Y Z)':  Defines and activates a work plane perpendicular the the current tool orientation with the origin at the current WCS (optionally offset by any [X,Y,Z]-Words). For change to WCS see 'G68'
- 'G69':            Cancels the work plane set by 'G68' and (currently) switches back to 'G54'.

NOTES:
- This config defines the work-spindle as '$0' and the tool-spindle as '$1'. Example: 'M19 $1 R90' will orient the tool-spindle to 90°. (For real hardware it is recommended to use the spindle encoder-position instead of using 'spindle.1.orient-angle'.)
- 'HALF/FULL TCP MILL/LATHE' modes include tracking of tool-spindle rotation.
- 'HALF TCP MILL/LATHE' modes do not track the work spindle rotation, this is intended behavior.
- 'FULL TCP MILL' mode will track all rotations.
- Tool-offsets must only be changed in 'Identity' mode as it may cause sudden joint movements otherwise.
- Lathe tools must only be used in 'Identity' or 'HALF TCP Lathe' mode.
- Mill tools must only be used in 'HALF/FULL TCP Mill' or 'TWP' mode.
- Due to easier abort handling we currently restrict the use of twp to G54 as LinuxCNC seems to revert to G54 as the default system.
  Abort behavior can be handled by using a subroutine defined in the ini file under [RS274NGC]ON_ABORT_COMMAND'.
- The TWP remap code in this config does not implement virtual rotations (ie no optional 'R' word).
  • langdons
  • langdons
21 Mar 2025 15:52 - 21 Mar 2025 15:55
Replied by langdons on topic Hardware advice

Hardware advice

Category: Computers and Hardware

"www.omc-stepperonline.com/ys-series-3-ax...ower-supply-3-clys90
* Given the age of the steppers, many people are stating that they are likely weak - due to the age of their magnets and the type of magnets they used."

Also, while the stuff from stepper online looks nice and has nice aviation connectors, it has 3 switching power supplies.

Linear (Huge and heavy) are generally recommended because they are better suited to the spikey, noisy, intermitten current draw that stepper drivers exhibit, though either will do.

What magnets?

I'm 99.9% sure stepper motors have no permanent magnets.

Anyways, that can't be true; stepper motors are brushless.

Brushless motors should not, and generally do not, wear out.
  • rainbowkoala49
  • rainbowkoala49
24 Feb 2025 06:31 - 24 Feb 2025 06:42
Which combination of mesa cards should I use? was created by rainbowkoala49

Which combination of mesa cards should I use?

Category: Driver Boards

I have an existing SBZ 130 i want to retrofit by keeping the original motors+drives, the motors all (3 axis and spindle) are AC 3PH servos with integrated 2 pole resolvers (6 wires - sin, cos, excitation pairs) for their feedback, aside from that I have about 42 inputs and 36 outputs as per the machines original schematics, but I might not use every single one. Moreover, I also want to add a separate rotary milling head for chamfers at different angles later down the line, so how would I go about adding/changing the combination of mesa cards.
The same machine I've seen a successful retrofit using combination of 6i25 7i77 7i70 7i71 7i74, but that system all the motors had absolute encoders
Mine is slightly different model (1998, mine is 2001) and I was recommended from a different person to go with 6i24 (do i need 6i24-16 or 25 and whats the difference??), 7i49 for the resolvers and controlling the drives with 10v analog, but would this work? I'm a complete beginner to this field so I'd like to know before purchasing any hardware. Moreover, do I need the other cards as well? (7i70 7i71 7i74) I understand the first two are for extra I/O digitals but im not sure what the 7i74 does, if someone can explain I would greatly appreciate it.

Edit : I just found out that the 6i24 has about 70 I/O pins, I think that covers my need so I dont need the extra 7i70 and 7i71 right?
  • cakeslob
  • cakeslob
18 Jan 2025 00:57
Replied by cakeslob on topic recommended controller board

recommended controller board

Category: General LinuxCNC Questions

but a Raspi 5 combined with Remora is an option. This uses an SPI bus to communicate with a microcontroller that does the step generation, but it still needs a low latency communication channel to exchange data with a servo thread. Apparently it's untested or not supported to attempt to use an SPI bus from another SBC then the Raspi 5.

SPI is supposed to be unavailable on regular PC's, but as far as I know it's often available on the TPM module, together with the LPC bus. But I have not seen any hint of LinuxCNC being able to work with those communication channels.


The drivers are made specifically for the RPi3/4 and 5, so they dont use spidev and wont work with other sbc. It wont work on a PC with TPM unless someone makes some kind of hardware driver. If you dont want to use an Rpi, you can try out the remora ethernet board
  • User_paulvdh_42
  • User_paulvdh_42
17 Jan 2025 21:06
Replied by User_paulvdh_42 on topic recommended controller board

recommended controller board

Category: General LinuxCNC Questions

I'm also pretty new regarding LinuxCNC, and in the process of orienting for the direction to control my machine.
A quick search:
duckduckgo.com/?t=h_&q=Unimat+SL100+&iax=images&ia=images

SL1000 (with three zero's) is a hobby level lathe.

Do you already have a PC for controlling your machine?
LinuxCNC needs a specially crafted OS with a real time kernel and quick I/O capabilities, because it does all calcualtions on the PC side. If you want to use USB, something like GRBL may be more appropriate. With GRBL, you send the G-code to a microcontroller, and the microcontroller does all the real time stuff. This makes the communication between the PC and the controller very tolerant of timing issues, the PC also does not need to meet real time performance, and any PC can be used. Have a look at the GrblHAL project, where you can choose from quite a lot of different microcontroller families.

For LinuxCNC
Parallel ports are mostly obsolete as PC hardware, but there are still motherboards where an LPT port is available on an internal header, but does not have a connector on the outside of the PC.

The lowest cost option (except the 2nd hand PC from the attic) for LinuxCNC is probably one of those SBC's I once had a working machine with machinekit on a Beaglebone Black, but it was headless and X-forwarding over SSH was atrociously slow (about a 2Hz display update rate. In the meantime Machinekit has mostly died too, but a Raspi 5 combined with Remora is an option. This uses an SPI bus to communicate with a microcontroller that does the step generation, but it still needs a low latency communication channel to exchange data with a servo thread. Apparently it's untested or not supported to attempt to use an SPI bus from another SBC then the Raspi 5.

SPI is supposed to be unavailable on regular PC's, but as far as I know it's often available on the TPM module, together with the LPC bus. But I have not seen any hint of LinuxCNC being able to work with those communication channels.
  • Hakan
  • Hakan
05 Jan 2025 09:08
Replied by Hakan on topic First time configuring ethercat

First time configuring ethercat

Category: EtherCAT

There isn't a stepconf or pncconf equivalent for ethercat so what I do is to configure the machine using one of these tools and then replace the connection to hardware. Editing by hand. Can be a bit of a handful for a first tine linuxcnc project.
Here is what other people do, including a link to rodw's example ethercat config. forum.linuxcnc.org/ethercat/51016-what-d...recommended-hardware
 
  • blazini36
  • blazini36
03 Jan 2025 22:46
Replied by blazini36 on topic Arduino IO Expansion

Arduino IO Expansion

Category: Show Your Stuff

I guess SPI would tie you to an arm platform or trying to bit bang from the host PC.
SPI is not recommended for long distance runs (its only really meant to board comms), even 6 or so inches can be unreliable when approaching MHz speeds. Seen this when experimenting with a Mesa 7c81.

Serial can use differential signals if there is noise, SPI differential signals can play havoc with timing at speeds.

And in reality unless you have a real hardware serial port, the serial comms is USB (at the host PC), doesn't run in realtime......in fact there is no realtime serial driver for Linuxcnc.
 

I actually mentioned this before as you would think as much legacy is built into LinucCNC someone would have worked on an RT serial component. I know Andy replied something along the lines of "I was wondering the same thing" but didn't offer much insight.

Alot of miniPCs expose Intel UART on GPIO headers. I've gotten it to run at reasonably high baud rates but I've only actually used it at standard baud rates. You're pretty much on point about SPI though I2C does get used in alot of cabled applications, Every HDMI cable has I2C in it. It's pretty easy to convert UART to RS422 with just a transceiver IC so that's not a big deal, not sure if using UART for this has any real benefits being there is no RT component but that's one of the things I was hoping to try out as I'd think it'd be just as easy to setup with Arduino-Connector.

I pretty much dropped what I was doing with Arduino-Connector because the lag on the Python side was intolerable. I just looked at the git issues and somebody figured out that it was just due to some serial timeout settings so I'll probably start messing with it again. One problem is I wasn't thrilled about the way the matrix keyboard setup worked and I would up redesigning my key panel to use I2C IO expanders to use with something else that didn't get finished. Now I'm just hoping someone can get support for I2C IO into Arduino Connector so I can try that. I don't think it would be difficult, but I don't do much code myself.
 
  • Cant do this anymore bye all
  • Cant do this anymore bye all's Avatar
03 Jan 2025 09:01
Replied by Cant do this anymore bye all on topic Arduino IO Expansion

Arduino IO Expansion

Category: Show Your Stuff

I guess SPI would tie you to an arm platform or trying to bit bang from the host PC.
SPI is not recommended for long distance runs (its only really meant to board comms), even 6 or so inches can be unreliable when approaching MHz speeds. Seen this when experimenting with a Mesa 7c81.

Serial can use differential signals if there is noise, SPI differential signals can play havoc with timing at speeds.

And in reality unless you have a real hardware serial port, the serial comms is USB (at the host PC), doesn't run in realtime......in fact there is no realtime serial driver for Linuxcnc.
  • Cant do this anymore bye all
  • Cant do this anymore bye all's Avatar
01 Jan 2025 12:49
Replied by Cant do this anymore bye all on topic LinuxCNC on Raspberry Pi 5

LinuxCNC on Raspberry Pi 5

Category: Installing LinuxCNC

You coming at this arse about. Which makes me wonder if this is for academic purposes, a potential commercial endeavor or a tech blog.
First one decides on the type of cnc machine they want to build, then they choose the controller to suit.
The simplest entry point for one who has no plan for their actual "cnc machine" would be.

A Lenovo M73e tower, preferably with an i5, the appropriate MB to Parallel Port cable ( there's some trickery with the cable that enables the PP hardware) and a generic Parallel Port breakout board. I've recommended this combination as I know it works, I have tested it with a lathe for basic functionality. I actually found this machine on the side of road with a celeron processor, which I swapped out for an i5 (3470 I think) and an SSD from the "useful box".

What people want is something that will run their hardware (their cnc machine be it a plasma cutter, lathe, mill router, laser tube profiler, PnP machine, cnc soldering machine) at a price point they can afford. As you can guess this is quite an expansive list.
  • dbtayl
  • dbtayl
17 Nov 2024 22:34 - 17 Nov 2024 22:39

Strange motion offsets in one direction on one axis

Category: General LinuxCNC Questions

1. Entirely plausible

2. Yes. The point of those was to highlight the noise seen is very high frequency, and seemingly unlikely to cause steps

3. Spindle is a BT30 taper with a manual drawbar- no ATC/belleville washers/pull studs/etc. End mill is held in a Nikken SK10 collet holder torqued to 35~40 ft-lbs, which is the recommended value. Tools are changed with an impact driver on the drawbar.

4. I should definitely re-run the code and see if I can reproduce. Haven't wanted to spend the time/material doing so, but I've wasted enough other time on this to dwarf both costs. I'll rerun both with the same tools originally used and also with a different one. May or may not have time to do that today.

5. I put an indicator on the tool and pushed on it. I can get it to deflect ~0.0005 (5 tenths) before I don't really want to push on it any harder. Seems to apply going any direction.

6. So climb vs conventional? I've thought about this, but the pocket was roughed with an adaptive/HSM toolpath, which started in the center of the pocket- so the cutter is roughing -Y to +Y on the +X side of the pocket, and +Y to -Y on the -X side. Correct me if my logic is wrong here, but if cut direction were the problem, wouldn't you expect to see issues in (eg) the +X+Y and -X-Y quadrants instead of the -Y half?


Grounding: One ground loop snuck in (shielded cable with shield connected at both ends), though disconnecting that has no impact on noise I can see. Will fix it anyway.

Beyond that, I wouldn't rule ground issues out, but am not seeing an obvious issue. The entire cabinet is aluminum and grounded. It's not a single point due to eg the filters, PSUs, and spindle drive all grounding through their chassis. The axis motors have a completely isolated supply (transformer-based)- as far as they're concerned, the world is the isolated 65V and a couple opto-couplers. The 24V and 5V negatives are all tied to a single bus bar- which is NOT ground. A multimeter shows an open circuit between 24V negative and the enclosure. The machine body has no dedicated ground, but is grounded indirectly via the spindle motor. The axis motor bodies are electrically connected to the machine, but that's isolated from their power supply.

Spindle drive has all the recommended filtering. I deviated slightly from the recommendations by omitting fuses on the logic power, replacing the contactor with an SSR, and placing said SSR before all the filtering, though I don't see an issue with that. Pictures show datasheet drawing and the schematic of how my machine is wired.

Noise is much better when motors are disabled- got it on my to-do list to see what's the root causes there. Guess is the spindle drive, but need to verify. No ferrites on anything at the moment- and no mention of them in the DYN4 (spindle) nor ClearPath (axis) manuals. Not to say they wouldn't help, just that the manuals don't call them out as important. The PSUs are MeanWell units, so at least not no-name. SOP is to not buy dubious PSUs- they can cause too many problems and take out too much valuable hardware to be worth the risk. Not to mention noise, as you say.
  • LabOuest
  • LabOuest
17 Nov 2024 14:06 - 17 Nov 2024 14:37

Remora - ethernet NVEM / EC300 / EC500 cnc board

Category: Computers and Hardware

Yeah, I was running a youtube video in the background but still, you're right, it's quite high.
I thought that this could be a possible cause so I've already made all of the recommended changes to the bios.
Thank you for the heads up on the core isolation, I must have misunderstood Talla83's video.
I will try to better understand kernel settings, unfortunately, there's isn't a lot of information about my dell optiplex 3020m.
Pinging the EC500 gives a latency between 0.130 and 0.25ms.

I'm trying to narrow down the possible causes, do you experience about the same ethernet latency as I do ?

EDIT: Using Halshow I can get so more debug information:
  • remora.read.time is between 5 to 700 000
  • remora.update-freq.time is between 4-700
  • remora.write.time is 5 to 800 000
  • jkaminski
  • jkaminski
15 Nov 2024 20:27 - 15 Nov 2024 20:30
Replied by jkaminski on topic Position vs Velocity mode

Position vs Velocity mode

Category: EtherCAT

Hi!
@zmrdko : 
thank to you and other experienced users in this thread for educating other folks and providing invaluable linuxcnc knowledge. I have some follow up questions on one of your posts:

- Would you mind sharing which z390 motherboard manufacturer / series do you have that allowed you to achieve 2.3us latency?
- What Intel PCIe Ethernet card did you choose? I saw that in this thread: gitlab.com/etherlab.org/ethercat/-/issues/104 they recommended "cheap realtek 100mb/s" ethernet card.
- Did you go with intel integrated graphics?
- IIRC, you (or maybe other user?) mentioned that with newer kernel the performance dropped from 8kHz (at 4.19rt) to 4kHz.
- Were there any other factors that positively affected performance besides the servo thread latency to get 8kHz? (e.g. ethernet roundtrip was quick)
- Have you measured how long does it take to execute your HAL components in each control cycle?
- Is there some other computer hardware that you leaned about and would be eager to try out with EtherCAT?

I hope this is not too much off-topic. Please correct me if there is a better form to ask these questions.

Thank you for your consideration,
Regards, Jakub
  • domse
  • domse
11 Nov 2024 18:23 - 11 Nov 2024 18:24

Linuxcnc crashing randomly when pressing buttons

Category: General LinuxCNC Questions

Hello, so this same problem occurs on on two different machines. One is an old core 2 duo pc + mesa 7i96 with monitor, keyboard, mouse. The other one is a raspberry pi 4 + 7i96s with a vnc connection (no monitor, no mouse, no keyboard) running a plasma machine.

Randomly the program crashes when navigating the gmocappy gui. it happens while jogging in small increments, when switching to program mode, when searching for a gcode file. I'd say the raspberry crashes more often than the pc. When i manage to start a gcode file, even if it is hours long, it is stable.

i attached a report below, this time the machine was homed and the y axis was moved in small increments when it crashed.

Report:
Warning: Spoiler!


Thank you 
  • rebelx
  • rebelx
25 Oct 2024 11:49
LinuxCNC on Intel Clear Linux was created by rebelx

LinuxCNC on Intel Clear Linux

Category: Installing LinuxCNC

I have been playing with the "Clear Linux" distro for a while, and I am truly impressed by its blazing fast performance. Clear Linux is an open source project from Intel, and it is highly optimized for Intel platforms, although most of these optimizations also apply to AMD platforms.
From its website clearlinux.org : "Clear Linux OS is an open source, rolling release Linux distribution optimized for performance and security, from the Cloud to the Edge, designed for customization, and manageability."

Clear Linux (CL) works with software packages that are called Bundles. A Bundle is in a way similar to a Flatpak, as it includes all the dependencies and the bundle is thoroughly tested to work on any Clear Linux system. When a package is not available yet as a Bundle, it is also possible to compile software from source, but the recommended way to install a new application is by submitting a package-request, after which the request will be reviewed by the CL team and eventually assigned to a CL resource for creating and maintaining a new bundle for that application.

I have been trying to compile LinuxCNC on Clear Linux, but ran into too many dependency issues that could not easily be resolved as many libraries are not available on Clear Linux yet, and compiling them all one by one is a very time consuming job. As I think that it would be a very interesting case to have a dedicated LinuxCNC bundle created for CL that will allow a "one click" installation of LinuxCNC on Clear Linux, I submitted a package-request to the CL team earlier this week and I am very happy to see that it has already been assigned to an experienced Intel developer who is also active in several CNC communities. I hope this may result in an easy way to install LinuxCNC on Clear Linux and I am very curious to see if any of their performance optimizations may be beneficial to LinuxCNC. I think it could provide a secure and stable way to run LinuxCNC on modern hardware platforms moving forward.

My CL package-request can be found here:  github.com/clearlinux/distribution/issues/3197

Please share your thoughts on this.
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