This thread is getting interesting. I have a full time (day ) job to pay the bills and as of now this is mostly hobby so my build will probably take a good while. I will keep a record and photos and post as often as possible.
For this machine, I felt like mach3 wouldn't be up to the challenge so I had originally planned using linuxcnc and mesa cards. Someone told me about dynamotions kflop (don't remember who know) and said i should take a look at it. kflop can be controlled with it's own front end "kmotioncnc" or alternately with mach3. I am sort of
undecided at the moment , but kflop does seem like an option
I have no desire for us to get into the whole mach3 vs linuxcnc debate here. Hopefully we can just point out which controller is capable of what functions, discuss which boards that it will take to do the tasks at hand with real life reasons as to why. So many times I see "well XXX is better" and someone asks why and the reply is something like " well because I use it and I said so"
I can honestly say I like the wizards in mach3. Sometimes it's just faster and easier to fill in the blanks and cut a part than it is to cad/cam it. I haven't used linuxcnc for a while now but I think I read a few people have written some conversational addons ,, I don't know , but if anyone does please respond and tell us your experience with them.
i guess now is as good a time as any to describe my machine.
At present it's a 5 ton boat anchor.
1990 hurco bmc 30, from all I can gather this is apparently leadwell iron fitted with hurco controls.
30" x, 20" y and 20"z, travel (from memory)
6000 rpm 7.5 kw 2 speed spindle motor
24 position cat 40 toolchanger (Geneva)
Yaskawa ac servos and yaskawa analog +-10vdc drives (i'll add the model #s later)
yaskawa spindle motor and yaskawa controller.
dual 5000 count encoders on each axis. One on each yaskawa axis motor that connects directly to the corresponding drive and one on each ballscrew that went to the hurco controller (the one I have to worry about) has 8 terminals: a+,a-,b+,b-,index+,index-,+5vdc, and common .someone has mentioned that these are actually 2500 count encoders called 5000 because they are quadrature, at the moment all I can give is what the manual says , I will check for sure before getting that far into it.
a limit switch (run of the mill) nc/no/com ) on the + and - of each axis. the (have to check again) normally closed contact is directly connected to the related servo drive for + limit or- limit and the NO to the controller for + _ for each axis
Have not dug deep enough to see if there is an encoder on the spindle , all i see right off is a prox switch presumably for toolchange index.
haven't identified everything coming out of the tool changer yet ,, electric motor rotates carousel (doesn't appear to have an encoder ,,since Geneva mechanism I'm guessing just an index to let it know it's made a full turn (but how do you track which pocket?)
any number of air solenoids,, lets see,, one 2 way for the tool changer slide, one 2 way for carousel up down
0ne for tool release, one for spindle clearing, have i left any out?
any number of limit switches on tool changer,,
i know,, I know ,, count all my I/O's before deciding on equipment.. come on people ,, this is supposed to be fun...
one I/O for spindle chiller (yep got ac)
one for flood coolant
oh yeah one for the other air solenoid (air chip removal)
"The Want List"
3 things that i really desire,, rigid tapping, thread milling, and the ability to electronically gear a 4th axis spindle to whichever axis needed, including the mill spindle.
This is the one area that I think linuxcnc shines above the rest.
I have had the idea in my head for a long time to use an old cnc lathe headstock for a 4th axis with encoder feedback so it could be used for indexing or turning.
If my spindle doesn't already have an encoder,, at some point i would like to add one for full control.
I haven't even gave thought to the console and pendant yet.
I/o's ,, whew,,,alright,, I'll break out pen and paper and list 'em all..