path: root/configs/by_machine/boss/boss.hal

# HAL config file for Bridgeport BOSS.
#
# Load the core RT modules that will be needed.

# Kinematics
loadrt trivkins

# motion controller, get name and thread periods from ini file
loadrt [EMCMOT]EMCMOT servo_period_nsec=[EMCMOT]SERVO_PERIOD num_joints=[TRAJ]AXES

# PID module, for four PID loops
loadrt pid num_chan=4

# Install motenc driver.
loadrt hal_motenc

# Install PLC.
loadrt boss_plc

# Install debounce filters for operator console (cycle hold/start,
# limit override, spindle increase/decrease/status).
loadrt debounce cfg="7"

# Add functions to servo thread so they will be evaluated
# every servo period.
#
# Inputs are read at the beginning of the thread
addf debounce.0 servo-thread 1
addf motenc.0.encoder-read servo-thread 1
addf motenc.0.misc-update servo-thread 1
#addf motenc.0.adc-read servo-thread 1
addf motenc.0.digital-in-read servo-thread 1
# Do processing.
addf boss_plc.0.refresh servo-thread -1
addf motion-command-handler servo-thread -1
addf motion-controller servo-thread -1
addf pid.0.do-pid-calcs servo-thread -1
addf pid.1.do-pid-calcs servo-thread -1
addf pid.2.do-pid-calcs servo-thread -1
addf pid.3.do-pid-calcs servo-thread -1
# Outputs are updated at the end of the thread
addf motenc.0.dac-write servo-thread -1
addf motenc.0.digital-out-write servo-thread -1

# PID loops.
#
# Get maximum (and minimum) output volts from ini file.
setp pid.0.maxoutput [AXIS_0]MAX_OUTPUT
setp pid.1.maxoutput [AXIS_1]MAX_OUTPUT
setp pid.2.maxoutput [AXIS_2]MAX_OUTPUT
setp pid.3.maxoutput [AXIS_3]MAX_OUTPUT

# Set PID loop gains.
setp pid.0.Pgain [AXIS_0]P
setp pid.0.Igain [AXIS_0]I
setp pid.0.Dgain [AXIS_0]D
setp pid.0.bias [AXIS_0]BIAS
setp pid.0.FF0 [AXIS_0]FF0
setp pid.0.FF1 [AXIS_0]FF1
setp pid.0.FF2 [AXIS_0]FF2
# deadband should be just over 1 count
setp pid.0.deadband [AXIS_0]DEADBAND

setp pid.1.Pgain [AXIS_1]P
setp pid.1.Igain [AXIS_1]I
setp pid.1.Dgain [AXIS_1]D
setp pid.1.bias [AXIS_1]BIAS
setp pid.1.FF0 [AXIS_1]FF0
setp pid.1.FF1 [AXIS_1]FF1
setp pid.1.FF2 [AXIS_1]FF2
# deadband should be just over 1 count
setp pid.1.deadband [AXIS_1]DEADBAND

setp pid.2.Pgain [AXIS_2]P
setp pid.2.Igain [AXIS_2]I
setp pid.2.Dgain [AXIS_2]D
setp pid.2.bias [AXIS_2]BIAS
setp pid.2.FF0 [AXIS_2]FF0
setp pid.2.FF1 [AXIS_2]FF1
setp pid.2.FF2 [AXIS_2]FF2
# deadband should be just over 1 count
setp pid.2.deadband [AXIS_2]DEADBAND

setp pid.3.Pgain [AXIS_3]P
setp pid.3.Igain [AXIS_3]I
setp pid.3.Dgain [AXIS_3]D
setp pid.3.bias [AXIS_3]BIAS
setp pid.3.FF0 [AXIS_3]FF0
setp pid.3.FF1 [AXIS_3]FF1
setp pid.3.FF2 [AXIS_3]FF2
# deadband should be just over 1 count
setp pid.3.deadband [AXIS_3]DEADBAND

# Connect the enable signals to the PID blocks.
net xEnable axis.0.amp-enable-out => pid.0.enable
net yEnable axis.1.amp-enable-out => pid.1.enable
net zEnable axis.2.amp-enable-out => pid.2.enable
net aEnable axis.3.amp-enable-out => pid.3.enable

# Connect position commands to PID inputs.
net xPosCmd axis.0.motor-pos-cmd => pid.0.command
net yPosCmd axis.1.motor-pos-cmd => pid.1.command
net zPosCmd axis.2.motor-pos-cmd => pid.2.command
net aPosCmd axis.3.motor-pos-cmd => pid.3.command

# DACs
#
# Set DAC output scaling from ini file.
setp motenc.0.dac-01-gain [AXIS_0]OUTPUT_SCALE
setp motenc.0.dac-03-gain [AXIS_1]OUTPUT_SCALE
setp motenc.0.dac-02-gain [AXIS_2]OUTPUT_SCALE
setp motenc.0.dac-00-gain [AXIS_3]OUTPUT_SCALE

# Set DAC offset from ini file.
setp motenc.0.dac-01-offset [AXIS_0]OUTPUT_OFFSET
setp motenc.0.dac-03-offset [AXIS_1]OUTPUT_OFFSET
setp motenc.0.dac-02-offset [AXIS_2]OUTPUT_OFFSET
setp motenc.0.dac-00-offset [AXIS_3]OUTPUT_OFFSET

# Connect PID output signals to DACs.
net xOutput pid.0.output => motenc.0.dac-01-value
net yOutput pid.1.output => motenc.0.dac-03-value
net zOutput pid.2.output => motenc.0.dac-02-value
net aOutput pid.3.output => motenc.0.dac-00-value

# Encoders.
#
# Set feedback scaling from ini file.
setp motenc.0.enc-01-scale [AXIS_0]INPUT_SCALE 
setp motenc.0.enc-03-scale [AXIS_1]INPUT_SCALE 
setp motenc.0.enc-02-scale [AXIS_2]INPUT_SCALE 
setp motenc.0.enc-00-scale [AXIS_3]INPUT_SCALE 

# Connect position feedback to PID loop.
net xPosFb motenc.0.enc-01-position => pid.0.feedback
net yPosFb motenc.0.enc-03-position => pid.1.feedback
net zPosFb motenc.0.enc-02-position => pid.2.feedback
net aPosFb motenc.0.enc-00-position => pid.3.feedback

# Connect position feedback to motion module.
net xPosFb => axis.0.motor-pos-fb
net yPosFb => axis.1.motor-pos-fb
net zPosFb => axis.2.motor-pos-fb
net aPosFb => axis.3.motor-pos-fb

# Connect position feedback to PLC.
net xPosFb => boss_plc.0.x-position-in
net yPosFb => boss_plc.0.y-position-in

# Connect index pulses to motion controller.
net xIndex motenc.0.enc-01-index-enable <=> axis.0.index-enable
net yIndex motenc.0.enc-03-index-enable <=> axis.1.index-enable
net zIndex motenc.0.enc-02-index-enable <=> axis.2.index-enable
net aIndex motenc.0.enc-00-index-enable <=> axis.3.index-enable

# Limits.
#
# Connect limit/home switch inputs to PLC and motion controller.
net xLimitSw motenc.0.in-09 => boss_plc.0.x-limit-in
net xLimitSw => axis.0.home-sw-in
net yLimitSw motenc.0.in-13 => boss_plc.0.y-limit-in
net yLimitSw => axis.1.home-sw-in
net zMinlimSw motenc.0.in-26 => boss_plc.0.z-limit-neg-in
net zMaxlimSw motenc.0.in-25 => boss_plc.0.z-limit-pos-in
net zHome motenc.0.in-27 => axis.2.home-sw-in

# Connect PLC limit switch outputs to motion controller.
net xMinLim boss_plc.0.x-limit-neg-out => axis.0.neg-lim-sw-in
net xMaxLim boss_plc.0.x-limit-pos-out => axis.0.pos-lim-sw-in
net yMinLim boss_plc.0.y-limit-neg-out => axis.1.neg-lim-sw-in
net yMaxLim boss_plc.0.y-limit-pos-out => axis.1.pos-lim-sw-in
net zMinLim boss_plc.0.z-limit-neg-out => axis.2.neg-lim-sw-in
net zMaxLim boss_plc.0.z-limit-pos-out => axis.2.pos-lim-sw-in

# Amp enables/faults.
#
# Connect amp ready to PLC.
net xReady motenc.0.in-08 => boss_plc.0.x-amp-ready-in
net yReady motenc.0.in-12 => boss_plc.0.y-amp-ready-in
net zReady motenc.0.in-24 => boss_plc.0.z-amp-ready-in
net aReady motenc.0.in-28 => boss_plc.0.a-amp-ready-in

# Connect amp enables to I/O.
net xEnable => motenc.0.out-00
net yEnable => motenc.0.out-01
net zEnable => motenc.0.out-08
net aEnable => motenc.0.out-09

# Connect amp enables to PLC.
net xEnable => boss_plc.0.x-amp-enable-in
net yEnable => boss_plc.0.y-amp-enable-in
net zEnable => boss_plc.0.z-amp-enable-in
net aEnable => boss_plc.0.a-amp-enable-in

# Connect amp faults to motion controller.
net xFault boss_plc.0.x-amp-fault-out => axis.0.amp-fault-in
net yFault boss_plc.0.y-amp-fault-out => axis.1.amp-fault-in
net zFault boss_plc.0.z-amp-fault-out => axis.2.amp-fault-in
net aFault boss_plc.0.a-amp-fault-out => axis.3.amp-fault-in

# Spindle.
#
# Connect spindle speed to PLC and spindle fwd/rev/stat to I/O.
net spindleSpeed motion.spindle-speed-out => boss_plc.0.spindle-speed-in
net spindleFwd boss_plc.0.spindle-fwd-out => motenc.0.out-11
net spindleRev boss_plc.0.spindle-rev-out => motenc.0.out-12
net spindleIsOnSw motenc.0.in-29-not => debounce.0.5.in
net spindleIsOnDly debounce.0.5.out => debounce.0.6.in
net spindleIsOn debounce.0.6.out => boss_plc.0.spindle-is-on-in

# Connect spindle brake to PLC and PLC brake to I/O.
setp boss_plc.0.brake-on-delay 500
setp boss_plc.0.brake-off-delay 800
net spindleBrakeOnMot motion.spindle-brake => boss_plc.0.brake-en-in
setp motenc.0.out-02-invert 1
net spindleBrakeOn boss_plc.0.brake-en-out => motenc.0.out-02

# Tool change.
#
# Loop back tool prepare pins.
net toolPrepare iocontrol.0.tool-prepare iocontrol.0.tool-prepared

# Connect tool change pins to PLC.
net toolChange iocontrol.0.tool-change => boss_plc.0.tool-change-in
net toolChanged boss_plc.0.tool-changed-out => iocontrol.0.tool-changed

# Coolant.
#
# Connect mist/flood coolant to PLC.
net mistOnIo iocontrol.0.coolant-mist => boss_plc.0.mist-on-in
net floodOnIo iocontrol.0.coolant-flood => boss_plc.0.flood-on-in

# Connect mist/flood coolant to I/O.
net mistOn boss_plc.0.mist-on-out => motenc.0.out-14
net floodOn boss_plc.0.flood-on-out => motenc.0.out-15

# Lube.
#
# Connect lube motor run to I/O.
net lubeOn iocontrol.0.lube => motenc.0.out-13
#net lubeOn motion.spindle-on => motenc.0.out-13

# Connect lube level to I/O.
net lubeLevel motenc.0.in-30-not => iocontrol.0.lube_level

# Operator console.
#
# Set debounce time.
setp debounce.0.delay 20

# Connect e-stop I/O.
net eStopSense motenc.0.in-32 => iocontrol.0.emc-enable-in
net eStopWrite iocontrol.0.user-enable-out => motenc.0.out-16

# Connect cycle hold/start.
net cycleHoldSw motenc.0.in-33-not => debounce.0.0.in
net cycleHold debounce.0.0.out => boss_plc.0.cycle-hold-in
net cycleStartSw motenc.0.in-34 => debounce.0.1.in
net cycleStart debounce.0.1.out => boss_plc.0.cycle-start-in
net feedHold boss_plc.0.feed-hold-out => motion.feed-hold
net waitUser boss_plc.0.wait-user-out => motenc.0.out-17

# Connect speed overrides.
net spindleIncSw motenc.0.enc-04-index => debounce.0.2.in
net spindleIncDb debounce.0.2.out => boss_plc.0.spindle-inc-in
net spindleInc boss_plc.0.spindle-inc-out => motenc.0.out-03
net spindleDecSw motenc.0.enc-06-index => debounce.0.3.in
net spindleDecDb debounce.0.3.out => boss_plc.0.spindle-dec-in
net spindleDec boss_plc.0.spindle-dec-out => motenc.0.out-04

# Connect limit override.
net limitOverrideSw motenc.0.in-35-not => debounce.0.4.in
net limitOverride debounce.0.4.out => boss_plc.0.limit-override-in
net limitActive boss_plc.0.limit-active-out => motenc.0.out-18

# Connect rapid/feed overrides.
net adaptiveFeed boss_plc.0.adaptive-feed-out => motion.adaptive-feed
setp halui.feed-override.scale 0.01
net feedOverride motenc.0.enc-04-count => halui.feed-override.counts
#net rapidOverride motenc.0.enc-06-count => halui.rapid-override.counts

# Set the jog mode so motion stops as soon as the wheel stops.
setp axis.0.jog-vel-mode TRUE
setp axis.1.jog-vel-mode TRUE
setp axis.2.jog-vel-mode TRUE
setp axis.3.jog-vel-mode TRUE

# Connect jog axis select to motion controller and PLC.
net xJog motenc.0.in-40 => axis.0.jog-enable
net yJog motenc.0.in-41 => axis.1.jog-enable
net zJog motenc.0.in-42 => axis.2.jog-enable
net aJog motenc.0.in-43 => axis.3.jog-enable
net xJog => boss_plc.0.x-jog-en-in
net yJog => boss_plc.0.y-jog-en-in
net zJog => boss_plc.0.z-jog-en-in

# Connect jog wheel encoder.
net jogCounts motenc.0.enc-05-count => axis.0.jog-counts axis.1.jog-counts axis.2.jog-counts axis.3.jog-counts

# Connect jog scale selects to PLC.
setp boss_plc.0.jog-scale-0 0.000001
setp boss_plc.0.jog-scale-1 0.000010
setp boss_plc.0.jog-scale-2 0.000100
net jogScaleSel0 motenc.0.in-36 => boss_plc.0.jog-sel-in-0
net jogScaleSel1 motenc.0.in-37 => boss_plc.0.jog-sel-in-1
net jogScaleSel2 motenc.0.in-38 => boss_plc.0.jog-sel-in-2

# Connect PLC jog scale output.
net jogScale boss_plc.0.jog-scale-out => axis.0.jog-scale axis.1.jog-scale axis.2.jog-scale axis.3.jog-scale