New LinuxCNC Multi-Channel System – Looking for Testers & Feedback

Hi everyone,I’ve been working on a new multi-channel extension for LinuxCNC, mainly targeting complex turning/milling machines such as INDEX, Gildemeister, multi-spindle lathes and other machines with several independent machining units.The goal is to bring LinuxCNC much closer to the functionality normally found on industrial controls such as Siemens SINUMERIK, especially for machines with multiple turrets, spindles and synchronized machining processes.Main featuresMultiple CNC channelsThe system can run multiple independent machining channels simultaneously. The architecture is not limited to just two channels and is designed to support a very large number of channels, depending mainly on the hardware and machine configuration.Each channel can execute its own NC program independently.Example:Dynamic axis assignmentAxes are not permanently tied to one channel.An axis can be transferred from one machining channel to another during operation.For example:This makes it possible to handle machines where several machining units need temporary access to the same spindle or axis.Channel synchronizationThe system includes synchronization functions similar to those used on industrial multi-channel controls.Channels can wait for each other or synchronize at defined points inside their NC programs.Typical applications are:

• part transfer between main and sub spindle
• synchronized machining
• waiting for another turret
• synchronized spindle operations
• coordinated tool changes
• machining sequences involving several channels

Turning / milling transformationsSupport for combined turning and milling machines is also included.The system supports transformations for:

• cylindrical surface machining
• face machining
• C-axis milling
• turning/milling combinations

This allows standard Cartesian milling programs to be transformed to the corresponding rotary-axis movements.3D machine simulationThe HMI includes an integrated 3D machine simulation.It shows:

• complete machine geometry
• tools
• workpiece
• fixtures
• spindles
• turrets
• axis movements

Material removal is simulated directly during machining.This makes it possible to see the actual workpiece state during program execution.Collision detection / Crash GuardCollision detection runs together with the machine simulation.It can detect collisions between:

• tool and machine
• tool and chuck
• tool and fixture
• turret and spindle
• machine components
• workpiece and machine

Importantly, collision monitoring is not limited to automatic mode.The Crash Guard can also remain active during JOG/manual operation, which is especially useful during setup and commissioning.Tool databaseA more industrial-style tool management system has also been implemented.The tool database supports:

• tool geometry
• tool offsets
• sister tools
• tool life monitoring
• remaining tool life
• automatic replacement with sister tools
• tool status
• tool usage tracking

The idea is to provide tool management similar to what operators are used to on modern industrial CNC controls.Industrial HMIThe user interface is designed around typical industrial CNC workflows rather than a traditional desktop/Linux application.The goal is to have a control system that can realistically be used on production machines with touchscreens and machine operator panels.The current development is being tested mainly on turning/milling and multi-channel machine configurations.I’m especially interested in feedback from people who have experience with:

• INDEX machines
• Gildemeister / DMG machines
• multi-spindle machines
• dual-turret lathes
• main/sub-spindle machines
• complex LinuxCNC configurations

I’m also looking for a real machine for extended testing of the multi-channel system.It does not matter whether the machine still has the original drives. Existing analog servo drives with encoder feedback can potentially be retained, or the machine can be converted to EtherCAT servo drives.If anyone is interested in testing the system, contributing, or discussing the architecture, I’d be happy to share more details, screenshots and videos.