> - How stable is the hm2 fpga-code + driver right now? anyone 
> using it routinely for 'production' ?

I can't comment on 'production' stability as I am only a hobbiest, but my
lathe conversion with a 5i20 and hm2 (my first foray into emc) went
painlessly (ie none of the problems were emc/5i20 related).  I used the
lathe last week for the whole day and I had no problems.


> For the lathe I will have servos on the Z- and X-axes, not 
> sure about DC-brush vs. brushless yet, but Jon Elsons PWM 
> amps work very well on the mill so I am leaning towards them. 
> Then the spindle will hopefully be driven by a big 1.75kW 
> brushless servo. 

I picked up second hand AC servos and drivers on ebay.  I use a 1.5kW AC
servo on the spindle (geared 3:1 so max rpm is down to 1500).  I use the
encoder and index directly on the spindle to synchronise threading.  My plan
is to use the servo on the spindle as an A axis, and add a Z (Y?) axis with
another spindle to be able to machine rotary table style - this is more of a
dream.

> The lathe project also calls for a 
> revolver-type toolchanger which needs one I/O bit for a 
> pneumatic cylinder, and one servo/stepper axis to rotate the revolver.
> In addition I will need the usual jog-pendant I/O: MPG 
> (thinking about two, separate for X and Z), a few 
> selection-switches, and some buttons. Live tooling is a dream 
> for the future :) Looking at the schematic for the mill[1], I 
> think the lathe setup will be pretty similar and I should be 
> OK with 72 I/O pins.

I've only used 2 I/O pins so far - home X and touch probe.  I have a USB
pendant.  I can't see myself ever using all the I/Os.


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