Hi all,
Hoping this is the right place for a conversation about machine controller conversions. I'm a hobby user, not a production shop. I've got a Mazak VQC 20/40 mill with M2 control, it's a nice fully functional machine with good tolerances for it advanced age. It's lack of memory is a real pain point. Programming in Mazatrol CAM M2 was probably great back in the day, not so much now. I can send G-Code files to it, but hit file size limits rather quickly. It's not capable of drip feed. I think I'm ready to go for the Mesa upgrade. With AI help I've input all the info I can think of, this is where I'm at... realistic? reasonable?
Servo Motors & Drives:
X-axis: Mitsubishi HD-81-12 DC permanent magnet servo motor with analog drive accepting ±10V command (terminals: AX, BX, G1X, G2X, G)
Y-axis: Mitsubishi HD-81-12S DC PM servo with analog drive (terminals: AY, BY, G1Y, G2Y, G)
Z-axis: Mitsubishi HD-101-12 DC PM servo with analog drive (terminals: AZ, BZ, G1Z, G2Z, G)
All three drives are MELDA-8 or similar Mitsubishi analog cards that accept ±10V command signals—these are REUSABLE
Position Feedback:
X-axis: Magnescale SR-921RH linear encoder (outputs quadrature signals directly) + MS3100B 20-29P tacho generator
Y-axis: Tamagawa Seiki resolver (MS3108B 20-29P, pins: RS1, RS2, RC1, RC2, RO1, RO2) + tacho generator
Z-axis: Magnescale SR-921RH-450-R-0 linear encoder + MS3108B 20-29P tacho generator
Spindle:
Mitsubishi AC motor SE-EV-FV with FREQROL FR-SX VFD controller
Already accepts 0-10V analog speed command and direction signal—fully LinuxCNC compatible
Tool Changer:
20-tool carousel ATC with CAT40 tooling
Nachi proximity sensors for position detectionMesa Hardware StackCore Cards
7i92H - Ethernet-based motion controller, main brain
7i77 - 6-axis ±10V analog outputs + encoder inputs + 48 I/O points
7i49 - 6-channel resolver interface (for Y-axis only)
7i73 - Pendant/operator panel interface
Servo Drive Connections:
Existing 24VDC power supply (HR-11F, outputs P24 and G24) remains in service:
Mesa 7i77 I/O is 24V compatible
Existing Contactors (3S-1, 3S-2, 3S-3, 3S-4):
Control servo drive enable sequencing
Spindle power control
Lube/coolant pump control
These stay and get controlled through Mesa 7i77 I/O outputsATC IntegrationInputs to LinuxCNC:
Tool-in-position sensors (Nachi proximity switches)
Carousel rotation feedback
Gripper open/close confirmation
Drawbar clamp/unclamp sensors
Outputs from LinuxCNC:
Carousel motor control (forward/reverse)
Gripper solenoid
Drawbar solenoid
Air blast control
