The HiCON Integra motion controller is designed for use with Mach4 CNC software and Digital Drives (stepper/servo motors) using Ethernet conectivity. Integra provides excellent integration with Mach4, proven by thousands of satisfied end-users since 2011. The controller generates a hardware synthesized motion pulse train using state-of-the-art FPGA technology that offers extremely smooth motion profiles compared to low cost controllers in the market.
The HiCON Integra is packed with a comprehensive set of features for your CNC applications, and provides an all-in-one solution for controllers and breakout boards that greatly simplifies system integration and maintainence.
Integra offer superb Open-Loop performance. For even higher precision, you can purchase closed-loop feature and connect Glass scale or rotary encoders (via 7737 boards) to implement a full closed loop system for maximum accuracy in machining. The PID closed loop logic compensates for any deviation 1000 times a second while in motion and positions the stepper motor accurately on the trajectory supplied by Mach4.
The Integra controller can be used in a variety of applications, e.g.,
Also check out the new ARCPRO Plasma Controls for torch height control functionality with this controller.
Part# | Single 24V Supply | # of Motors | # of IO | NPN IO | Relays | # of IO Expansion | Encoders | Encoder Expansion | Closed Loop Stepper | 30min Remote Login Support | ||
---|---|---|---|---|---|---|---|---|---|---|---|---|
7868 | ✔ | 8 | 16In | 8Out | ✔ | 3(Unique) | 32In | 16Out | 3 | 11 | ✔ | ✔ | 7866 | ✔ | 6 | 16In | 8Out | ✔ | 3(Unique) | 32In | 16Out | 3 | 11 | ✔ | ✔ |
7854 | ✔ | 4 | 16In | 8Out | ✔ | 3(Unique) | 32In | 16Out | 3 | 11 | ✔ | ✔ |
The Integra controller allows you to connect Glass scale or Rotary Encoders to implement a full closed loop system for 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. This ensures that all stepper motors are always in sync with the trajectory and that the machine is operating at maximum accuracy.
The closed loop feature also accounts for any missing steps during transmission, and will automatically apply the necessary position correction. This prevents following errors from accumulating. In addition, the DROs on Mach4 will show the actual machine position instead of just a step counter. Closed loop option also allows you to use the mill in manual mode where you manipulate the axis manually while seeing the actual positions in the DROs.
With 7737 board, you can use RJ45 cables between the controller and the motor drivers. Also aditional encoders are accessible with Differential mode. We offer Drive-Interface baords for our AC Servo Motors and Drives, allowing the the connection to servo drives a matter of pluging RJ45 cables.
Get a discount when you purchase the Closed-Loop Package:
For Mach4-Industrial version with discounted pricing, please see the price list below.
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 software releases, please refer to the download section below
As Mach4 has become the mainstream CNC software, we have stopped supporting Mach3. Also note that the older 7766 model is obsolete and it is not recomended for new installations. Please select 7866 model instead. If you do need to order older 7766 verison, please see the ordering table at the bottom of this page.
Integra 78xx User Manual (Black)
Integra Real-World I/O Examples
HiCON Basic Setup Video
Mach4 in production run G52 offset with Sub
Most CNC applications will only require the Integra base controller. However, advanced applications can benefit from these addons:
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 HiCON-Macro Include:
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 features[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.
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 .
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 Activaion' 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).
[1] - These items may be purchased any time before or after shipping as they are software feature enablers
We are looking for your awesome videos showcasing your machine and our 7866 HiCON 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:Part # | Description | Price | Add to Order |
---|---|---|---|
Discount Packages |
|||
7866-Mach4 | HiCON Integra 7866 & Mach4-Hobby License ($20 Discount) | $775 | Add to order |
Integra-LATHE | HiCON Integra 7854, THREADING, Mach4-Hobby License ($50 Discount) | $745 | Add to order |
7866-CL4 | HiCON Integra Closed Loop 4-Axis Package | $1485 | Add to order |
7866-CL6 | HiCON Integra 7866 Closed Loop 6-Axis Package | $1685 | Add to order |
7868-CL8 | HiCON Integra Closed Loop 8-Axis Package | $1985 | Add to order |
Controllers |
|||
7866 | HiCON Integra Motion Controller 6-Axis | $595 | Add to order |
7854 | HiCON Integra Motion Controller 4-Motors | $545 | Add to order |
7868 | HiCON Integra Motion Controller 8-Axis | $1000 | Add to order |
7766 | HiCON Integra Controller (Older Model) | $995 | Add to order |
Breakout Boards |
|||
7535P | 16in/8Out OptoIsolated PNP Sourcing Type I/O Board | $275 | Add to order |
7535N | 16in/8Out OptoIsolated NPN Sink Type I/O Board | $275 | Add to order |
7737 | Differential Step/Dir and Encoder Board | $295 | Add to order |
Software and Add-ons |
|||
MACH4-INDUSTRIAL | Mach4-Industrial Software License | $1295 | Add to order |
Mach4-Hobby | Mach4-Hobby Software License | $200 | Add to order |
Mach3 | Mach3 Software License | $175 | Add to order |
MOTION_API | Motion and I/O Control API from Windows PC | $495 | Add to order |
HiCON-MACRO | HiCON C Programming Feature | $475 | Add to order |
HiCON-EXTIO | HiCON Extended I/O Feature (Includes Mach4 Sync Outputs M67, M62) Purchase of 7535 I/O board includes this feature! | $275 | Add to order |
HiCON-ADC | HiCON Analog Input Feature Activation | $200 | Add to order |
INTG-CLOOP | HiCON Integra Closed Loop Activation | $495 | Add to order |
YSK-ABS | Absolute Encoder Feature for Yaskawa | $1000 | Add to order |
THREADING | Lathe Threading Feature Activation | $50 | Add to order |
RIGID_TAP | Rigid Tap Feature Activation | $275 | Add to order |
Accessories |
|||
MPG06ED | MPG06 Unit w/ DB15M + EStop Button + Differential Encoder | $295 | Add to order |
PW50V24 | Power Supply 24V 2.2A 50W | $40 | Add to order |