I'm now in the process of building/designing the wire EDM and probably will use Mach3 to control it. I do though have some problems that I'm not exactly sure of how to deal with.
1. I know that I can wire an input and in Mach3 instruct that this and this input should act like a button, but how is it done at Mach3's end? I would like to include feed hold and reverse run buttons.
2. Does the Mach3 reverse run from a feed hold situation?
3. For feed hold and reverse run signals, what would you recommend? Measure the gap voltage and if it is too high, feed. If it is too low (short), reverse run and if it is between the extremes, feed hold? As I remember that Mach3 doesn't do variable feed rate based on an input or does it?
I really would like to get it process controlled and not waste wire by running the machine "slow enough so it won't short"
FYI, the machine will have about 250 x 250 mm working area, has an adjustable Z height (around 100 mm max height). The moving parts are "inside" the tank area, so nothing protrudes from the machines footprint once in place. Linear guide rails with linear bearings and C7 accuracy ballscrews with stepper motors on them. Pulse type power supply (probably around 20-50 kHz). I'll have test and see but for now the plan is to have a wire brake that can be adjusted (a stepper motor shorted with a pot) and an adjustable wire speed and pressure flushing that can be adjusted from 0-2 bar pressure probably.
The filtering system will have a magnetic filter, a regular filter and a deionizing tank in series so that I can good and reliable water in the working tank.