This is a DIY controller for the original Emco Turn 120/220 toolchanger.
Software, PCB and schematic are now available at: https://github.com/f1oat/EATC-120
Many thanks to Tom for the original Toolerator 3000 design that inspired EATC-120.
Slicing with Simplify3D
The 3D printing job
The EATC-120 module is almost finished !
This is a driver for the EmcoTurn 120/220 original 8 positions ATC.
This design is derived from the excellent Toolerator 3000 USB controlled driver.
EATC-120 is adding MODBUS capabilities for easy integration with an industrial environment.
Single 24V power supply with embedded 5V DC/DC converter.
The “brain” of the module is an Arduino Micro.
The motor is driven by an LMD18245T providing current control.
The lock status is automatically detected by measuring the peak current when the motor stalls.
Everything is reported in MODBUS registers.
Integration with Machinekit/LinuxCNC is easy thanks to “mb2hal” HAL component.
I have found a nice empty DIN rail enclosure and designed a special PCB to fit with it.
Stay tuned !
I have replaced the Probotix cape by a Furaday cape to get more I/O pins.
Here is the updated schematic diagram:
I needed this feature for my lathe control panel project. The goal is to drive the jog steps size by the rotation speed of the jog wheels.
The algorithm has been validated from 5 Hz to 100 kHz.
Maximum measurement error is 1%. See curves below.
The patch is available here: https://github.com/f1oat/machinekit
loadusr -w ../setup.sh loadrt threads name1=servo-thread period1=1000000 loadrt hal_pru_generic prucode=$(HAL_RTMOD_DIR)/xenomai/pru_generic.bin pru=0 num_encoders=1 num_pwmgens=1 pru_period=2500 halname=hpg addf hpg.update servo-thread addf hpg.capture-position servo-thread setp hpg.encoder.00.chan.00.A-pin 7 #925 ENCxI setp hpg.encoder.00.chan.00.counter-mode 2 #Up Counter (counts rising edges on A, always counts up, B ignored) setp hpg.pwmgen.00.out.00.pin 921 #PWM1 setp hpg.pwmgen.00.out.00.enable 1 setp hpg.pwmgen.00.pwm_period 1000000 setp hpg.pwmgen.00.out.00.value 0.5 start loadusr -w sleep 1 loadusr -w python encoder_test.py
#!/usr/bin/python import subprocess import time import os def readpin(p): r = subprocess.check_output('halcmd -s show pin ' + p + '|head -1',shell=True) lst = r.split() return lst def setpin(p, v): subprocess.check_output('halcmd -s setp %s %d' % (p, v), shell=True) freq = 5.0 prev_freq = 0.0 maxerror = 0 f = open('result.csv', 'w') line = 'in(Hz), out(Hz), err(%), latency(ms)' print line f.write(line + '\n') time.sleep(2) while freq < 100e3: period = int(1e9/freq/2500) * 2500 # because pru_period=2500 real_freq = 1e9/period if (real_freq <> prev_freq): prev_freq = real_freq setpin('hpg.pwmgen.00.pwm_period', period) time.sleep(0.2) measured_freq = float(readpin('hpg.encoder.00.chan.00.velocity')) latency = float(readpin('hpg.encoder.00.chan.00.latency')) * 1e-6 error = abs(real_freq / measured_freq - 1.0) maxerror = max(maxerror, error) line = "%8.1f, %8.1f, %4.2f, %3.0f" % (real_freq, measured_freq, error*100.0, latency) print line f.write(line + '\n') freq = 1.1*freq f.close() print "Max error %.1f%s" % (maxerror*100.0, '%')
Brainstorming, CAD, CAM, simulation, wood, machining, gluing, sanding, HIPS … the control panel is almost ready!
The structure of the control panel is made of 5mm plywood. The red color is coming from a 1mm sheet of HIPS. Everything machined on my CNC-6040 router with 3.17mm carbide endmill.
The touchscreen is a Beetronics 12″ model. Connected through HDMI to the BeagleBone Black board. Easy configuration: there is native support for the touchscreen USB pointing device in the Machinekit Linux image!
First step was CAD design with ViaCAD software.
Plywood panel machined with 3.17mm carbide endmill. Some pockets to have 2mm thickness for industrial buttons fixture.
MPG and lights will be managed by an Arduino UNO. Stay tuned …
My new project is the retrofit of an Emco Turn 120P CNC lathe.
For the motion controller, I have chosen Machinekit running on a Beaglebone Black board. 12″ touchscreen with Gmoccapy GUI. A Controllino PLC to manage all non-realtime I/O such as the pneumatic chuck, the tailstock, the pumps, etc …
The original 5-phases stepper motors has been kept. They are driven by two Vexa UDK5128N drivers. Need 110V AC source for them, coming from an auto-transformer.
The original spindle DC motor has been replaced by a 3 kW AC motor driven by an Hitachi NE-S1-022 VFD. This VFD is controlled over MODBUS by the Machinekit controller through the PLC. I have patched the standard MODBUS over TCP stack to have a gateway to the RS485 bus.
Here is the global schematic diagram of the electronics.
Next step is the modification of the Probotix PBX-BB cape to give access to the eQEP2 quadrature encoder for the spindle position sensor.