Luxturn LTI Lathe Retrofit

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27 May 2021 21:23 - 27 May 2021 21:25 #210466 by Bassblaster
Hi guys,

I want to share my experience retrofitting a 30 year old Japanese lathe that I lovingly call "Wakako".(From Cyberpunk 2077)
This is her in full 'old' glory:

File Attachment:

I am mostly posting this to share my pain as I am trying to enable her features, but also to maybe get some advice.
I am using a Mesa 7i96 card connected via ethernet to a Dell Optiplex running Debian 10 and Linux 2.8.0 .

The old lady sure is a little troublemaker, but so far, I got the x- and z-axis moving.

The next tasks will be:
  • Get the limit switches etc. connected and make sure they are working
  • Get the mesa board to output a PWM signal for the VFD for the main spindle
  • Get the spindle encoder to work with the mesa Board
  • Try to get the revolver-style ATC running

After everything is finished, I want to make a tutorial video on Youtube so that other people have an easier time (is that even possible? :evil: )

Kind regards,
Manuel
Last edit: 27 May 2021 21:25 by Bassblaster.
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27 May 2021 21:42 #210470 by tommylight
That is a nice little lady ! :)
The following user(s) said Thank You: Bassblaster

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28 May 2021 23:27 - 28 May 2021 23:28 #210568 by Bassblaster
Today, I made some more progress.
I used PnCConf tool to get an initial config. This way, I was able to get the limit switches and the coolant pump and so on working.

My Lathe already had a spindle encoder, and I wanted to keep it in order to avoid additional work on the hardware side of things.
Fortunately, I got the stock spindle encoder to work changing the jumpers on the mesa 7i96 board according to the manual for a single ended encoder. The encoder was a little bit confusing, because it has 8 wires coming out, but 4 of them need to be grounded, so it is indeed single ended:
File Attachment:


I was able to verify the working state of the encoder using halshow, The structure of the parameters wasn't intuitive in my opinion, but we can see it working here:

File Attachment:


Unfortenately, getting the mesa card to output a pwm signal for the spindle is appearantly not as easy. I did the following steps:
  • Flashing the mesacard with the firmware for 4 stepgens and 1 pwm generator using mesaflash
  • I then changed the .hal file manually, since PnCConf seems to have a problem with the custom firmware. I only changed one line, in which I specified the number of pwm gens to be 1.
  • Running mesaflash --device 7i96 --addr 10.10.10.10 -readhmid ,I found out the pins, where the pwm generator was assigned to.
  • Then I connected an oscilloscope (to pins 1 and 3 of TB2 in my case), but was not able to get any signal.

My first guess is that I have to change more in the .hal file. Does anyone have a clue what to change? Or an example of a .hal file from an 7i96 with pwm spindle control?
Last edit: 28 May 2021 23:28 by Bassblaster.

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29 May 2021 01:58 #210580 by PCW
Replied by PCW on topic Luxturn LTI Lathe Retrofit
Can you post your current hal and ini files?

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30 May 2021 20:02 - 30 May 2021 20:03 #210728 by Bassblaster
Here are the .ini and the .hal , I think that in the .hal I might need to specify a pin for the PWM, I took a look at RotarySMP's ini and hal files for the minilathe, but couldn't get it to work for me. :unsure:

This is the .ini:
# Erstellt von PNCconf am Sun May 30 21:54:52 2021
# Using LinuxCNC version:  2.8
# Änderungen an dieser Datei werden beim nächsten
# overwritten when you run PNCconf again

[EMC]
MACHINE = Wakako
DEBUG = 0
VERSION = 1.1

[DISPLAY]
DISPLAY = gmoccapy
POSITION_OFFSET = RELATIVE
POSITION_FEEDBACK = ACTUAL
MAX_FEED_OVERRIDE = 2.000000
MAX_SPINDLE_OVERRIDE = 1.500000
MIN_SPINDLE_OVERRIDE = 0.500000
INTRO_GRAPHIC = linuxcnc.gif
INTRO_TIME = 5
PROGRAM_PREFIX = /home/wakako/linuxcnc/nc_files
INCREMENTS = 5mm 1mm .5mm .1mm .05mm .01mm .005mm
LATHE = 1
POSITION_FEEDBACK = ACTUAL
DEFAULT_LINEAR_VELOCITY = 6.000000
MAX_LINEAR_VELOCITY = 25.000000
MIN_LINEAR_VELOCITY = 0.500000
DEFAULT_ANGULAR_VELOCITY = 12.000000
MAX_ANGULAR_VELOCITY = 180.000000
MIN_ANGULAR_VELOCITY = 1.666667
EDITOR = gedit
GEOMETRY = xz

[FILTER]
PROGRAM_EXTENSION = .png,.gif,.jpg Greyscale Depth Image
PROGRAM_EXTENSION = .py Python Script
png = image-to-gcode
gif = image-to-gcode
jpg = image-to-gcode
py = python

[TASK]
TASK = milltask
CYCLE_TIME = 0.010

[RS274NGC]
PARAMETER_FILE = linuxcnc.var

[EMCMOT]
EMCMOT = motmod
COMM_TIMEOUT = 1.0
SERVO_PERIOD = 1000000

[HMOT]
CARD0=hm2_7i96.0

[HAL]
HALUI = halui
HALFILE = Wakako.hal
HALFILE = custom.hal
POSTGUI_HALFILE = postgui_call_list.hal
SHUTDOWN = shutdown.hal

[HALUI]

[KINS]
JOINTS = 2
KINEMATICS = trivkins coordinates=XZ

[TRAJ]
COORDINATES =  XZ
LINEAR_UNITS = mm
ANGULAR_UNITS = degree
DEFAULT_LINEAR_VELOCITY = 3.33
MAX_LINEAR_VELOCITY = 33.33
NO_FORCE_HOMING = 1

[EMCIO]
EMCIO = io
CYCLE_TIME = 0.100
TOOL_TABLE = tool.tbl

#******************************************
[AXIS_X]
MAX_VELOCITY = 33.3333333333
MAX_ACCELERATION = 100.0
MIN_LIMIT = -0.0
MAX_LIMIT = 140.0

[JOINT_0]
TYPE = LINEAR
HOME = 10.0
FERROR = 10.0
MIN_FERROR = 1.0
MAX_VELOCITY = 33.3333333333
MAX_ACCELERATION = 100.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 41.67
STEPGEN_MAXACCEL = 125.00
P = 1000.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP   = 10000
DIRHOLD    = 10000
STEPLEN    = 5000
STEPSPACE  = 5000
STEP_SCALE = 5120.0
MIN_LIMIT = -0.0
MAX_LIMIT = 140.0
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = -1.000000
HOME_LATCH_VEL = -0.500000
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_SEQUENCE = 1
#******************************************

#******************************************
[AXIS_Z]
MAX_VELOCITY = 33.3333333333
MAX_ACCELERATION = 100.0
MIN_LIMIT = -350.0
MAX_LIMIT = 0.0

[JOINT_1]
TYPE = LINEAR
HOME = -20.0
FERROR = 10.0
MIN_FERROR = 1.0
MAX_VELOCITY = 33.3333333333
MAX_ACCELERATION = 100.0
# The values below should be 25% larger than MAX_VELOCITY and MAX_ACCELERATION
# If using BACKLASH compensation STEPGEN_MAXACCEL should be 100% larger.
STEPGEN_MAXVEL = 41.67
STEPGEN_MAXACCEL = 125.00
P = 1000.0
I = 0.0
D = 0.0
FF0 = 0.0
FF1 = 1.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 0.0
# these are in nanoseconds
DIRSETUP   = 10000
DIRHOLD    = 10000
STEPLEN    = 5000
STEPSPACE  = 5000
STEP_SCALE = 5120.0
MIN_LIMIT = -350.0
MAX_LIMIT = 0.0
HOME_OFFSET = 0.000000
HOME_SEARCH_VEL = -1.000000
HOME_LATCH_VEL = -0.500000
HOME_FINAL_VEL = 0.000000
HOME_USE_INDEX = NO
HOME_SEQUENCE = 0
#******************************************

[SPINDLE_0]
P = 0.0
I = 0.0
D = 0.0
FF0 = 1.0
FF1 = 0.0
FF2 = 0.0
BIAS = 0.0
DEADBAND = 0.0
MAX_OUTPUT = 1500.0
ENCODER_SCALE = 1024.0

And this is the hal:
# Erstellt von PNCconf am Sun May 30 21:54:52 2021
# Using LinuxCNC version:  2.8
# Änderungen an dieser Datei werden beim nächsten
# overwritten when you run PNCconf again

loadrt [KINS]KINEMATICS
loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[KINS]JOINTS
loadrt hostmot2
loadrt hm2_eth board_ip="10.10.10.10" config=" num_encoders=1 num_pwmgens=1 num_stepgens=3 sserial_port_0=00xxxx" 
setp    [HMOT](CARD0).watchdog.timeout_ns 5000000
loadrt pid names=pid.x,pid.z,pid.s
loadrt scale names=scale.gear
loadrt mux16 names=ratio_select

addf [HMOT](CARD0).read          servo-thread
addf motion-command-handler   servo-thread
addf motion-controller        servo-thread
addf pid.x.do-pid-calcs       servo-thread
addf pid.z.do-pid-calcs       servo-thread
addf pid.s.do-pid-calcs       servo-thread
addf ratio_select             servo-thread
addf scale.gear               servo-thread
addf [HMOT](CARD0).write         servo-thread

# external output signals

# --- COOLANT-FLOOD ---
net coolant-flood  =>     [HMOT](CARD0).ssr.00.out-00

# --- SPINDLE-ENABLE ---
net spindle-enable  =>     [HMOT](CARD0).ssr.00.out-01

# --- SPINDLE-CW ---
net spindle-cw  =>     [HMOT](CARD0).ssr.00.out-02

# --- SPINDLE-CCW ---
net spindle-ccw  =>     [HMOT](CARD0).ssr.00.out-03

# --- MACHINE-IS-ENABLED ---
net machine-is-enabled  =>     [HMOT](CARD0).ssr.00.out-04

# --- DOUT-00 ---
net dout-00  =>     [HMOT](CARD0).ssr.00.out-05


# external input signals

# --- MIN-X ---
net min-x     <=  [HMOT](CARD0).gpio.000.in

# --- MAX-X ---
net max-x     <=  [HMOT](CARD0).gpio.001.in

# --- HOME-X ---
net home-x     <=  [HMOT](CARD0).gpio.002.in

# --- MIN-Z ---
net min-z     <=  [HMOT](CARD0).gpio.003.in

# --- MAX-Z ---
net max-z     <=  [HMOT](CARD0).gpio.004.in

# --- HOME-Z ---
net home-z     <=  [HMOT](CARD0).gpio.005.in


#*******************
#  AXIS X JOINT 0
#*******************

setp   pid.x.Pgain     [JOINT_0]P
setp   pid.x.Igain     [JOINT_0]I
setp   pid.x.Dgain     [JOINT_0]D
setp   pid.x.bias      [JOINT_0]BIAS
setp   pid.x.FF0       [JOINT_0]FF0
setp   pid.x.FF1       [JOINT_0]FF1
setp   pid.x.FF2       [JOINT_0]FF2
setp   pid.x.deadband  [JOINT_0]DEADBAND
setp   pid.x.maxoutput [JOINT_0]MAX_OUTPUT
setp   pid.x.error-previous-target true
# This setting is to limit bogus stepgen
# velocity corrections caused by position
# feedback sample time jitter.
setp   pid.x.maxerror 0.012700

net x-index-enable  <=> pid.x.index-enable
net x-enable        =>  pid.x.enable
net x-pos-cmd       =>  pid.x.command
net x-pos-fb        =>  pid.x.feedback
net x-output        <=  pid.x.output

# Step Gen signals/setup

setp   [HMOT](CARD0).stepgen.00.dirsetup        [JOINT_0]DIRSETUP
setp   [HMOT](CARD0).stepgen.00.dirhold         [JOINT_0]DIRHOLD
setp   [HMOT](CARD0).stepgen.00.steplen         [JOINT_0]STEPLEN
setp   [HMOT](CARD0).stepgen.00.stepspace       [JOINT_0]STEPSPACE
setp   [HMOT](CARD0).stepgen.00.position-scale  [JOINT_0]STEP_SCALE
setp   [HMOT](CARD0).stepgen.00.step_type        0
setp   [HMOT](CARD0).stepgen.00.control-type     1
setp   [HMOT](CARD0).stepgen.00.maxaccel         [JOINT_0]STEPGEN_MAXACCEL
setp   [HMOT](CARD0).stepgen.00.maxvel           [JOINT_0]STEPGEN_MAXVEL
setp   [HMOT](CARD0).stepgen.00.step.invert_output   true
setp   [HMOT](CARD0).stepgen.00.direction.invert_output   true

# ---closedloop stepper signals---

net x-pos-cmd    <= joint.0.motor-pos-cmd
net x-vel-cmd    <= joint.0.vel-cmd
net x-output     <= [HMOT](CARD0).stepgen.00.velocity-cmd
net x-pos-fb     <= [HMOT](CARD0).stepgen.00.position-fb
net x-pos-fb     => joint.0.motor-pos-fb
net x-enable     <= joint.0.amp-enable-out
net x-enable     => [HMOT](CARD0).stepgen.00.enable

# ---setup home / limit switch signals---

net home-x     =>  joint.0.home-sw-in
net min-x     =>  joint.0.neg-lim-sw-in
net max-x     =>  joint.0.pos-lim-sw-in

#*******************
#  AXIS Z JOINT 1
#*******************

setp   pid.z.Pgain     [JOINT_1]P
setp   pid.z.Igain     [JOINT_1]I
setp   pid.z.Dgain     [JOINT_1]D
setp   pid.z.bias      [JOINT_1]BIAS
setp   pid.z.FF0       [JOINT_1]FF0
setp   pid.z.FF1       [JOINT_1]FF1
setp   pid.z.FF2       [JOINT_1]FF2
setp   pid.z.deadband  [JOINT_1]DEADBAND
setp   pid.z.maxoutput [JOINT_1]MAX_OUTPUT
setp   pid.z.error-previous-target true
# This setting is to limit bogus stepgen
# velocity corrections caused by position
# feedback sample time jitter.
setp   pid.z.maxerror 0.012700

net z-index-enable  <=> pid.z.index-enable
net z-enable        =>  pid.z.enable
net z-pos-cmd       =>  pid.z.command
net z-pos-fb        =>  pid.z.feedback
net z-output        <=  pid.z.output

# Step Gen signals/setup

setp   [HMOT](CARD0).stepgen.01.dirsetup        [JOINT_1]DIRSETUP
setp   [HMOT](CARD0).stepgen.01.dirhold         [JOINT_1]DIRHOLD
setp   [HMOT](CARD0).stepgen.01.steplen         [JOINT_1]STEPLEN
setp   [HMOT](CARD0).stepgen.01.stepspace       [JOINT_1]STEPSPACE
setp   [HMOT](CARD0).stepgen.01.position-scale  [JOINT_1]STEP_SCALE
setp   [HMOT](CARD0).stepgen.01.step_type        0
setp   [HMOT](CARD0).stepgen.01.control-type     1
setp   [HMOT](CARD0).stepgen.01.maxaccel         [JOINT_1]STEPGEN_MAXACCEL
setp   [HMOT](CARD0).stepgen.01.maxvel           [JOINT_1]STEPGEN_MAXVEL

# ---closedloop stepper signals---

net z-pos-cmd    <= joint.1.motor-pos-cmd
net z-vel-cmd    <= joint.1.vel-cmd
net z-output     <= [HMOT](CARD0).stepgen.01.velocity-cmd
net z-pos-fb     <= [HMOT](CARD0).stepgen.01.position-fb
net z-pos-fb     => joint.1.motor-pos-fb
net z-enable     <= joint.1.amp-enable-out
net z-enable     => [HMOT](CARD0).stepgen.01.enable

# ---setup home / limit switch signals---

net home-z     =>  joint.1.home-sw-in
net min-z     =>  joint.1.neg-lim-sw-in
net max-z     =>  joint.1.pos-lim-sw-in

#*******************
#  SPINDLE
#*******************

setp   pid.s.Pgain     [SPINDLE_0]P
setp   pid.s.Igain     [SPINDLE_0]I
setp   pid.s.Dgain     [SPINDLE_0]D
setp   pid.s.bias      [SPINDLE_0]BIAS
setp   pid.s.FF0       [SPINDLE_0]FF0
setp   pid.s.FF1       [SPINDLE_0]FF1
setp   pid.s.FF2       [SPINDLE_0]FF2
setp   pid.s.deadband  [SPINDLE_0]DEADBAND
net ratio_select.out   pid.s.maxoutput 
setp   pid.s.error-previous-target true

net spindle-index-enable  <=> pid.s.index-enable
net spindle-enable        =>  pid.s.enable
net spindle-vel-cmd-rpm-abs     => pid.s.command
net spindle-vel-fb-rpm-abs      => pid.s.feedback
net spindle-pid-out  pid.s.output    => scale.gear.in
net gear-ratio       ratio_select.out-f => scale.gear.gain
setp ratio_select.in00 0.000667
setp ratio_select.in01 0.000167
net gear-select-a         =>  ratio_select.sel0
net spindle-output        <=  scale.gear.out

# ---Encoder feedback signals/setup---

setp    [HMOT](CARD0).encoder.00.counter-mode 0
setp    [HMOT](CARD0).encoder.00.filter 1
setp    [HMOT](CARD0).encoder.00.index-invert 0
setp    [HMOT](CARD0).encoder.00.index-mask 0
setp    [HMOT](CARD0).encoder.00.index-mask-invert 0
setp    [HMOT](CARD0).encoder.00.scale  [SPINDLE_0]ENCODER_SCALE

net spindle-revs             <=   [HMOT](CARD0).encoder.00.position
net spindle-vel-fb-rps       <=   [HMOT](CARD0).encoder.00.velocity
net spindle-index-enable     <=>  [HMOT](CARD0).encoder.00.index-enable

# ---setup spindle control signals---

net spindle-vel-cmd-rps        <=  spindle.0.speed-out-rps
net spindle-vel-cmd-rps-abs    <=  spindle.0.speed-out-rps-abs
net spindle-vel-cmd-rpm        <=  spindle.0.speed-out
net spindle-vel-cmd-rpm-abs    <=  spindle.0.speed-out-abs
net spindle-enable             <=  spindle.0.on
net spindle-cw                 <=  spindle.0.forward
net spindle-ccw                <=  spindle.0.reverse
net spindle-brake              <=  spindle.0.brake
net spindle-revs               =>  spindle.0.revs
net spindle-at-speed           =>  spindle.0.at-speed
net spindle-vel-fb-rps         =>  spindle.0.speed-in
net spindle-index-enable      <=>  spindle.0.index-enable

# ---Setup spindle at speed signals---

sets spindle-at-speed true


#******************************
# connect miscellaneous signals
#******************************

#  ---HALUI signals---

net axis-select-x  halui.axis.x.select
net jog-x-pos      halui.axis.x.plus
net jog-x-neg      halui.axis.x.minus
net jog-x-analog   halui.axis.x.analog
net x-is-homed     halui.joint.0.is-homed
net axis-select-z  halui.axis.z.select
net jog-z-pos      halui.axis.z.plus
net jog-z-neg      halui.axis.z.minus
net jog-z-analog   halui.axis.z.analog
net z-is-homed     halui.joint.1.is-homed
net jog-selected-pos      halui.axis.selected.plus
net jog-selected-neg      halui.axis.selected.minus
net spindle-manual-cw     halui.spindle.0.forward
net spindle-manual-ccw    halui.spindle.0.reverse
net spindle-manual-stop   halui.spindle.0.stop
net machine-is-on         halui.machine.is-on
net jog-speed             halui.axis.jog-speed
net MDI-mode              halui.mode.is-mdi

#  ---coolant signals---

net coolant-mist      <=  iocontrol.0.coolant-mist
net coolant-flood     <=  iocontrol.0.coolant-flood

#  ---probe signal---

net probe-in     =>  motion.probe-input

#  ---motion control signals---

net in-position               <=  motion.in-position
net machine-is-enabled        <=  motion.motion-enabled

#  ---digital in / out signals---

net dout-00     <=  motion.digital-out-00
#  ---estop signals---

net estop-out     <=  iocontrol.0.user-enable-out
net estop-out     =>  iocontrol.0.emc-enable-in

#  ---manual tool change signals---

loadusr -W hal_manualtoolchange
net tool-change-request     iocontrol.0.tool-change       =>  hal_manualtoolchange.change
net tool-change-confirmed   iocontrol.0.tool-changed      <=  hal_manualtoolchange.changed
net tool-number             iocontrol.0.tool-prep-number  =>  hal_manualtoolchange.number
net tool-prepare-loopback   iocontrol.0.tool-prepare      =>  iocontrol.0.tool-prepared
Last edit: 30 May 2021 20:03 by Bassblaster.

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30 May 2021 21:11 - 30 May 2021 21:12 #210743 by andypugh
Replied by andypugh on topic Luxturn LTI Lathe Retrofit
The missing link seems to be pid.s.output to pwm.

Somewhere in the [SPINDLE] section try adding:
net spindle-enable [HMOT](CARD0)pwmgen.00.enable
net pwm-dc pid.s.output [HMOT](CARD0)pwmgen.00.value
setp [HMOT](CARD0)pwmgen.00.scale {your max rpm}
Last edit: 30 May 2021 21:12 by andypugh.
The following user(s) said Thank You: Bassblaster

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30 May 2021 21:52 #210750 by Bassblaster
Thanks for the help, that totally worked! Now the old lady is spinning up! B) I am a total noob, so I appreciate your help a lot!

For now there is one task left, unfortunately, it is propably also the most difficult. The toolchanger.
The toolchanger is a 8-station turret toolchanger, which can freely move in one direction,but in the other direction, there are stops for each tool position, kind of like a ratchet. Currently there is no index switch on the toolchanger, so I might add one, if necessary.
I am planning to utilize one of the mesa cards stepgenerators to drive the stepper motor for the toolchanger.
I think I have to write a macro of sorts to achieve this, if I am right.

Do you have any suggestions/ examples for this case?

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30 May 2021 21:55 #210751 by andypugh
Replied by andypugh on topic Luxturn LTI Lathe Retrofit
I wrote a HAL component for this:

linuxcnc.org/docs/2.8/html/man/man9/carousel.9.html

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