HiCON Integra - 4, 6, & 8 Motors Step/Direction Ethernet Motion Controller

Overview

  • Designed for use with Mach4 CNC software and Digital Drives (stepper/servo motors) using Ethernet connectivity
  • Provides excellent integration with Mach4 (proven by thousands of satisfied end-users since 2011)
  • Offers extremely smooth FPGA hardware generated pulse train
  • Packed with comprehensive set of features for CNC applications
  • Provides an all-in-one solution for controllers and breakout boards
  • Offers superb Open-Loop performance
  • Optional closed-loop feature to connect Glass scale or rotary encoders to implement a full closed loop system for extremem precision
  • The PID closed loop logic compensates for any deviation 1000 times a second while in motion

The Integra controller can be used in a variety of applications, e.g.,

  1. CNC Routers
  2. Plasma / Oxy Fuel Tables
  3. Milling / Lathe CNC Machines
  4. PC Based or Standalone Motion and I/O Controller
  5. Storage and Retrieval Systems
  6. And many other apps....

Also check out the new ARCPRO Plasma Controls for torch height control functionality with this controller.

Note: The HiCON Motion Controller line is intended for use with Windows 10 and higher. Prior Windows versions are not supported.

Product Highlights

Base Features

  • 6 Step and Direction Channels using FPGA 2MHz Pulse Engine.
  • 3 Quadrature Encoder Inputs.
  • 2 Mhz Max Encoder frequency. Encoder resolution multiplied by 4 thru Hardware.
  • 16 24V digital inputs (8 NPN, 8 PNP).
  • 8 24V digital outputs (4 NPN, 4 PNP).
  • 7 TTL low-voltage inputs.
  • Ethernet 100Mb connectivity using TCP/IP interface.
  • Hardware configurable limit and estop inputs for ultra-fast system disarm.
  • Modes of Motion: Mach4, Point-to-Point, Linear and Circular interpolation, Jogging, Electronic Gearing, Feedrate Override.
  • Industrial-strength Aluminum enclosure.

CNC Features

  • MPG Control using Electronic Gearing for quick response.
  • Probing.
  • Lathe Threading.
  • Rigid Tapping.
  • Backlash compensation.
  • Manual Mode.
  • Homing Using Home Sensor and/or Index Pulse.
  • Rotary Axis Homing with Index pulse.
  • Use One Home Sensor Input for all axis, or separate Home Sensors for each axis.
  • Use Limit switches as homing sensors.
  • Feedrate Override above 100%.
  • Instant FeedHold.
  • Slave Axis Support.
  • PID Tuning Graph.
  • Multiple Spindle control type: 0-10v, Servo/Stepper Motor Spindle (OOB Motor).
  • High Speed 3D machining support.
  • Quick connect 15-pin plug for MPG Handwheel.

Optional Features

  • Expansion up to 11 Quadrature Encoder Inputs
  • Closed Loop Stepper using PID Control for Glass Scale and Rotary Encoders
  • Optional 2 Channel Analog Inputs, Range 0 - 3.3 Volts, 12-bit Resolution
  • Optional 48 Digital I/O available via Expansion Connectors
  • SDK Libraries available for Software Developers.
  • Optional Standalone Operation by programming the unit with BASIC or C programming language for high-speed I/O processing.
  • Hardware and firmware customization available

The figure below shows a typical Milling/Lathe machine connection using HiCON Integra.

HiCON Integra Setup Diagram


Integra Closed Loop Stepper & Industrial Package

  • The Integra controller allows to connect Glass scale or Rotary Encoders to implement a full closed loop system
  • A full closed loop system ensures maximum accuracy in machining
  • The PID closed loop logic compensates for any deviation while in motion and positions the stepper motors accurately on the trajectory supplied by Mach4
  • The closed loop feature automatically apply the necessary position correction by accounting for any missing steps during transmission
  • Position correction prevents following errors from accumulating
  • The DROs on Mach4 will show the actual machine position instead of just a step counter
  • Closed loop option allows to use the mill in manual mode where user manipulates the axis manually while seeing the actual positions in the DROs
  • With 7737 board, user can use RJ45 cables between the controller and the motor drivers
  • Aditional encoders are also accessible with Differential mode
  • Drive-Interface baords for AC Servo Motors and Drives, allows the connection to servo drives a matter of pluging RJ45 cables

The figure below shows how tidy and compact the electrical panel is with Integra controller.

HiCON Integra in a Panel


HiCON Integra Discount Packages

  • 7866-CL4: HiCON Integra 7866 with 4 Motor Enabled, One 7737 Step/Dir Encoder Board, Integra Closed Loop Activation, Extended I/O Activation
  • 7866-CL6: HiCON Integra 7866 with 6 Motor Enabled, Two 7737 Step/Dir Encoder Boards, Integra Closed Loop Activation, Extended I/O Activation
  • 7868-CL8: HiCON Integra 7868 with 8 Motor Enabled, Two 7737 Step/Dir Encoder Boards, Integra Closed Loop Activation, Extended I/O Activation

For Mach4-Industrial version with discounted pricing, please see the price list below.

Mach4 CNC Software

Mach4 is an excellent PC-based software solution for CNC. When paired with a HiCON motion controller, it creates a state of the art CNC solution for machine-shops as well as industrial applications. Mach4 plus HiCON greatly simplifies retrofitting and increases operation reliability. For the latest release of the Mach4 HiCON Plugin, please refer to the download section below.


Note: As Mach4 has become the mainstream CNC software, we have stopped supporting Mach3.

Integra Documentation

Integra 78xx User Manual (Black)

Mach4 Integration Manual

VSI Device Manager Manual

HiCON Basic User Manual

VSI C-Macro User Manual

Integra Real-World I/O Examples

VSI Custom Mach4 Registers Manual

7737 Wiring

Closed loop PID configuration

Rigid Tapping User Guide

Integra Files

Integra Mach4 Plugin and Firmware

VSI Device Manager

VSI Macro Loader

Mach4 Integra Lathe Profile (Sample)

Mach4 Integra Mill Profile (Sample)

Media

HiCON Basic Setup Video

Mach4 in production run G52 offset with Sub

Optional Components for HiCON Integra System

Advanced and production applications may also benefit from these add-ons:
HiCON-EXTIO [1]: Enables 24 additional I/O points on J7 and J8 socket, and also enables Mach4 Sync Outputs (M62/M63). This feature is included with the purchase of 7535 I/O Board. It can also be purchased individually without the 7535 hardware, but please note that working directly with the J7/J8 ports without optical isolation can damage the 3.3V pins.
HiCON-ADC [1]: This software feature enables the use of the 2 analog inputs located on J6.
ArcPRO Plasma [1]: M4ARCPRO software feature allows the use of ArcPro Plasma screen. 77ISO is required to read the plasma analog voltage. For packages and more information visit ARCPRO page.
INTG-CLOOP [1]: This software feature allows Closed-Loop Stepper operation with or without PID control and enables Encoder channels 3-8 on J7/J8. Using the 7737 Board greatly simplifies wiring for Encoder Feedback and Step/Dir channels on J7 and J8 .
7737 Board : The pn7737 Differential Step/Direction and Encoder Board allows access to the Step/Direction and Encoder channels on J7 and J8 plugs, and allows a simple plug-and-play setup using standard RJ45/Ethernet cables. When used with Drive Interface Board (EPx-DIB) for Maxsine AC Servo Drives, this board provides almost plug and play installation. In order to use encoders for Axis Feedback purpose, "Closed Loop Activation" must be purchased.
7535 Board : The I/O Termination board (7535P or 7535N) provides 24 Volts optically isolated digital I/O. Each board has 16 input terminals and 8 output terminals. All I/O terminals are clearly marked for quick and easy installation. Upto two 7535 (N or P) boards can be plugged into HiCON Integra, providing additional 32 Inputs and 16 outputs (24Volts 1Amp).
YSK-ABS [1]: This software feature allows the use of Yaskawa Absolute Encoder feature. Only compatible with Yaskawa Drives with absolute Encoder models. Ask sales for more information .
HiCON-MACRO [1]: This software feature allows the user to write custom programs (in C and BASIC languages) which can be downloaded to the controller for fast execution. Advantages of Hbi-Macro Include:
  • Real-time program execution
  • Ultra-fast I/O manipulation (eg. Tool Changer)
  • Extends Mach 3/4 Functionality
  • Standalone Operation (No PC Control)

[1] - These items may be purchased any time before or after shipping as they are software features

Discount Offer

We are looking for your awesome videos showcasing your machine and our motion controller. Send us videos and get 10% to 20% discount (depends on quality) on your next purchase of any of our motion controller. If you dont plan to purchase, we will refund you as a gift for making the video.

Here are some pointers for creating a good demo video:
  • This is a good example video a previous customer made for us.
  • The video demonstrates a part being created.
  • The video specifically shows our controller wired up and operating in a clean well organized panel.
  • Lots of camera angles and good editing (high quality editing is not 100% necessary, but the video should at least look somewhat professional)
  • Ultimately the amount for the discount (upto 20%) will depend on the quality of the video. A high quality video can receive a high discount, while it may be hard to justify a discount if the video will be difficult to use for marketing.

Price List

Discount Packages

7866-Mach4 $775
HiCON Integra 7866 & Mach4-Hobby License ($20 Discount) Add to order
7866-CL4 $895
HiCON Integra Closed Loop 4-Axis Package Add to order
7866-CL6 $995
HiCON Integra 7866 Closed Loop 6-Axis Package Add to order
7868-CL8 $1450
HiCON Integra Closed Loop 8-Axis Package Add to order

Controllers

7866 $595
HiCON Integra Motion Controller 6-Axis Add to order
7854 $525
HiCON Integra Motion Controller 4-Motors Add to order
7868 $1000
HiCON Integra Motion Controller 8-Axis Add to order
7766 $995
HiCON Integra Controller (Obsolete, Unsupported) Add to order

Breakout Boards

7535P $95
16in/8Out OptoIsolated PNP Sourcing Type I/O Board Add to order
7535N $95
16in/8Out OptoIsolated NPN Sink Type I/O Board Add to order
7737 $195
Differential Step/Dir and Encoder Board Add to order

Software and Add-ons

MACH4-INDUSTRIAL $1295
Mach4-Industrial Software License Add to order
Mach4-Hobby $200
Mach4-Hobby Software License Add to order
Mach3 $175
Mach3 Software License Add to order
MOTION_API $495
Motion and I/O Control API from Windows PC Add to order
HiCON-MACRO $475
HiCON C Programming Feature Add to order
HiCON-EXTIO $200
HiCON Extended I/O Feature (Includes Mach4 Sync Outputs M67, M62) Purchase of 7535 I/O board includes this feature! Add to order
HiCON-ADC $200
HiCON Analog Input Feature Activation Add to order
INTG-CLOOP $495
HiCON Integra Closed Loop Activation Add to order
YSK-ABS $1000
Absolute Encoder Feature for Yaskawa Add to order
THREADING $50
Lathe Threading Feature Activation Add to order
RIGID_TAP $275
Rigid Tap Feature Activation Add to order

Accessories

MPG06ED $295
MPG06 Unit w/ DB15M + EStop Button + Differential Encoder Add to order
PW50V24 $40
Power Supply 24V 2.2A 50W Add to order