Gantry oxyfuel / plasma type machine from scratch

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20 Jul 2026 14:43 #347876 by saxa
Hello all, I am rebuilding an old gantry type machine which I plan to use for cutting mostly with oxyfuel and eventually for thinner plates with the plasma source.  The machine is 10m long on Y (longitudinal axis) and about 5m wide on X (transversal axis).
I would like to use linuxcnc and I have bought many years ago the servo motors and drives from DMM Tech, more precisely the DYN4 
series. I have 2 motors for the Y axis which I plan to use in parallel (1kW each motor) and a smaller motor to move the torches on the X
axis (a 750W one). All motors have a single turn absolute encoder.

Now recently I have visited some exhibition and I saw today most of industrial things are on EtherCAT. I saw that LinuxCNC supports it 
in the latest versions, but since I have no experience with EtherCAT I would like to ask if I have to pay some special attention to certain things or there are no troubles at all with the compatibility ?

My plan is to make linuxcnc act as an master node, and send signals to the motion controller which will then through some adapters transform the signal to pulse/dir and send to the drives.

This is the general idea on how this should be working. 

Can I hear some comments from you guys , anybody have a similar setup , should I go some other way around the thing ?
Thanks for the time.
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20 Jul 2026 17:04 #347882 by tommylight
Replied by tommylight on topic Gantry oxyfuel / plasma type machine from scratch


Now recently I have visited some exhibition and I saw today most of industrial things are on EtherCAT.

Yes, it does seem so...


My plan is to make linuxcnc act as an master node, and send signals to the motion controller which will then through some adapters transform the signal to pulse/dir and send to the drives.

That would be redundant as LinuxCNC is the motion controller.
In short:
-buy a Mesa 7i96S and a THCAD
-a used Entrprise PC
-A network cable
-Wire, install LinuxCNC, start wiring drives and motors
-those drives will have to be set in position mode, hence 7i96S
-yeah, wiring, you will need very good quality shielded cables for everything as cables that long will collect a lot of interference, not very important for oxy cutting, but a mist for plasma cutting.
-....well, that is it.

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21 Jul 2026 05:04 #347905 by rodw
Welcome. Have a look in the ethercat section. There are a couple of stickies. There is a seperate Ethercat master application that runs on the Linuxcnc  PC and there is another driver that connects Linuxcnc to the Ethercat master which in turn talks to all your slaves. You should be able to use a Beckhoff analog input (0-10 volts) to read the divided torch voltage. Other than that, it will be similar to what Tommy described for Mesa hardware. The Beckhoff modules are rated for over voltage of 500 volts, same as the Mesa THCAD. I'm uncertain that other brands of analog inputs have this protection. I can't help with oxy.

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21 Jul 2026 05:50 #347906 by NWE
I recently bought an old plasma + oxyfuel machine to retrofit and resell. I awaits me first finishing some other projects. I plan to connect ethercat servos directly to a linuxcnc pc. I have not yet studied the serial interface for the big XPR plasma power unit that came with it. On a previous project I used mesa + THCAD, never heard any complaints from that one.

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21 Jul 2026 07:32 #347908 by rodw
In an Ethercat world, I think you can use a Beckhoff 0-10 volt analog interface as it has similar over voltage specs as the THCAD. People have cracked the Hypertherm Ethercat machines here. But do use industrial Ethercat cables in a HF world
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