On 1/4/2016 4:50 AM, andy pugh wrote:
> On 4 January 2016 at 11:28, Gregg Eshelman <[email protected]> wrote:
>> How much for a 2.5 mod, 10 mm thick with a 35 mm inside diameter?
>
> If you have a CNC mill, a spindle encoder and a CNC rotary axis you
> have all that you need to hob your own gears.
> The rest is just HAL code to feed a scaled spindle position to the rotary 
> axis.

One out of three ain't bad? ;) I have a ProLIGHT PLM2000. It has servos 
on all three axes and its controller only talks to the old DOS software. 
For some reason the company only supported the stepper motor PLM1000 
with their Windows software.

They had an optional, very expensive, HASS 4th axis but only the PLM2000 
mills originally sold with it can use it. There were well under 100 sold 
with the 4th axis option. Without the 4th axis a 3 axis controller was 
installed.

What would be useful is if I could have the firmware in the controller 
dumped. It can be communicated with using a terminal program, one is 
built into the DOS control software. Only a few commands are documented 
and those only because a power setting was incorrect on some of the mills.

If I can ever get my 1920's LeBlond* sold I'll be able to get the 
PLM2000 moved to a better location where I can setup the PC I have for 
it, and a second box set up to log the bi-directional serial 
communication. I tried a DOS logging program, but it failed to record 
anything. The software will almost work in XP but XP periodically says 
"Mine!" to the serial ports and breaks communication with the DOS 
software. I put Windows 95 or 98 on the old box to see if I can get a 
Windows serial logger to run and not interfere with the mill communication.

If the data can be sniffed out, that could make it possible to add 
support to LCNC, then things like a spindle encoder and a 4th axis could 
be added and coordinated with the mill's original control.

For the PLM1000, it's easier just to toss the big box and proprietary 
PCI or ISA card and replace them with something new, especially if the 
card is missing.

*It's an 18" swing by about 25" between centers Rapid Production, fully 
outfitted as an engine lathe with leadscrew, tapered roller bearing 
spindle, gearbox, back gear and standard tailstock instead of a turret. 
No serial number anywhere. Probably a one-off special order. Someone 
wanted this specific configuration with the clutch and brake. It's 
exactly 7 feet long at the chip tray. Would fit crosswise in the back of 
a garage. :)

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