Thanks! I'll do a more detailed walk through soon, with special attention how the Mesa boards are wired, etc. Probably after the tool change is also converted. Might try to incorporate LinuxCNC servo tuning instructions into it as well. There are good written instructions for that on the forums, but I think a video could be helpful to many folks.

Well I don't delude mysef in thinking I'm actually getting 3 tenths positioning in the real world, but the motors commanded angle should be doing their part. In reality the ballscrews have lots of wear at this age (and up to 0.002"" unevenly across travel) and there is considerable backlash, similar to traditional leadscrew. 0.008" on Y axis, 0.024" on X if I remember correctly. Could be some tightening on the ballnuts is needed, and the Lovejoy couplers might also be to blame. I have gotten the backlash compensation values in the neighborhood, within 0.001", but it will take a lot more precise measurement and data entry to home in under that. The actual travel for the X axis can almost squeeze out about 21.7" without having moved the hard end stops. The factory setting soft limit is 20" and I keep it at 21" because the wear is uneven as it has never really been run in those extreme values and would bind and require slower speed out at the ends unless I scrape things evenly, which I may eventually do anyway. From what I can see I think I might be able to get perhaps as much as 23" if I moved the hardstops out a bit more. The Y likewise gives me 16.75" between hard stops and I run it at 16.25" soft limit right now. Z I run at 23" which is probably as high as it will physically allow. The spindle is only about an inch away from table at full depth, without a tool, and at the top it seems to be backing up to the nut. I have also toyed with the idea of adapting a bigger table onto this machine. 16.75" Y would still be usable for a lot of things if I could get 36-40" travel out of X. Maybe find a table from another larger machine and adapt it to fit. There's a lot about this machine that I like that would cause me to retrofit it rather than get a bigger machine. Namely, the weight, frame rigidity, power requirements are low, etc etc. well organized and well thought out design, a real joy to work on. Getting ready to add in an improvised 4th axis from an old mini lathe headstock as well

I revisited this, digging deeper. It turns out the ballscrews themselves have very little wear, under 0.001". The slop was coming from the thrust bearings and issues with the gibs. I was able to clean everythign up and tighten it and get under 0.001" backlash on all but Y. Y needs a new thrust bearing. You can get them for about $40/pair (each axis has two preloaded to take up lash). It needs a precision shim, you can make your own if you keep shim stock on hand. the info on ultimate travel is still somewhat accurate. I could take off the Bellevile washers to get more travel, but that area of the ways seeing less wear means everythign gets very tight out there and I'd have to really slow down the machine or scrape the ways.

@@calphis I’m literally in the same boat! I need to replace the Y thrust bearing….making a clicking noise with every revolution. If you happen to make a video of the repair…I’d be ecstatic! Thank you.

thanks!

With encoders already in, you should have a fairly easy time of it. the PNCconf wizard makes it really easy if you have servo amp boards that already have gain/current adjust pots on them. In the wizard you just start running a slow speed, check the position feedback, then adjust the trim pots until the actual measure speed and commanded jog are the same. move speed up a bit higher and repeat until you reach the top speed you plan to use. I'll make another video on this process as well as soon as I'm able. The LinuxCNC folks have done a great job on the core, this wizard, and the servo tuning system. They've even documented it very well on the forums. It's really not nearly as complex as it sounds when described verbally. For some folks like me a video might help clear things up. Thanks for stopping by. And you are welcome to drop by (and anyone else for that matter) to check the machine out if you ever make it out this way

@@calphis you make the internet a better place.

@@jensparrow27 Thanks so much! That's high praise!

@@calphis Thanks, did your machine have inch or metric ball screws?

@@MotorsportDiesel Mine had 5tpi or 0.2" pitch all around

I am in a little rural town about a hour away from Franklin/Nashville, TN. Though if you're not anywhere nearby I'm happy to make another video showing how I did the conversion, what hardware was used, and wiring it up, etc. In fact, I was planning on doing so anyhow. There is only one part I had to make -- the rotary encoder mounting adapter for the drive motor feedback. It's just a disc of aluminum with 3 critical dimensions then drill the 3 mounting holes. It could be lathe turned manually with not much problem. You could probably even 3d print if your machine is dialed in well, it's not under high mechanical stress other than the rpm and the coupling should be done with a flexible coupling anyway due to the high rpm. Fusion 360 design link: a360.co/3HE9aM9 I'll make a rough video soon with just an overview at least but long term I'll make a more detailed walk through of that machine conversion. Thanks for stopping by!

Oh, and this is the encoder I used that fits that design. It's a cheapo one, but it works fine and the accuracy level is more than acceptable for the kind of work I do. Based on the leadscrew pitch on my machine at least, my math shows I can get 0.0003" per pulse. www.amazon.com/gp/product/B07MX1SYXB/ref=ppx_yo_dt_b_search_asin_title?ie=UTF8&psc=1

@@calphis I actually spent a bunch of time in Shelbyville, South of Nashville. I'm in Dallas. I would love more videos, but once you have the ATC working I really would come visit. I can fly into the nearest municipal airport. I've subscribed to your channel so I'll reach back out as you get further along and then try to come see what it really takes to do the conversion to LinuxCNC.

@@calphis Great work you have done here :) I would love to see a bit more details as at some point my VMC will need a retrofit too for various reasons. Any chance of showing another video with details?

Thanks for stopping by! Things are busy around the shop but I will do my best to get this out to you guys as soon as possible.

Well, it's complete now. But I used 7i33TA and 5i24. Works great doesnt' need anything.

@@calphis also the ATC?

@@alexandrucosmin90 I haven't finished that part yet but have already inspected it. There is a belted motor that slides the carousel towards spindle, another that rotates it. There are two inductive sensors to indicate position and carousel index. The original main board of relays that activate the motors can be controlled with 5V I/o from a Mesa interface. So should be very simple to wire up.

If you go down the pins of the relay board ribbon connector you can isolate which one turns on each motor

@@calphis do you have also hi/low and rigid tap?