You should be able to control the THC with just the PLC. Yiou would need some communication between MACH and the THC so it would know when initial height has been set.
Mach has an input for ArcOK. You would just need to provide a signal on that pin so Mach knows that it's OK to start movement. If ArcOK is lost, then Mach automatically pauses the program until ArcOK is restored.
Initial height can be set with just a timer, go down until the switch contact opens, raise for some amount of time, stop motion and tell MACH that the torch is in position. Another timer can be used to raise the torch when the THC run is turned off by MACH.
I hadn't thought of just using a standard DC motor. That would work as long as the PLC can reverse the motor direction. A better solution might be to just use a simple DC motor control that way you can control speed...Unless the PLC can send a DC pulse similar to a motor speed control.
The PLC will work for a THC with just about any type of motor - you could use a reversible AC motor, or a DC motor - you would have to use relays to control either
Ah yes...I've done that before. Used a DPDT relay to reverse a DC motor. If you fed the relay through a speed control and used the PLC to switch the relay, that should work. CNC control over Z feed rate wouldn't be needed but a way to adjust the speed would be.
I would think that it would be easier to treat the THC as a separate component and not try to control the height with MACH because the height doesn't have a good number as it is relative to what is happening between the torch and the plate.
My reasoning there was that the PLC would handle all of the logic. ArcOK is just a low current voltage or a relay contact coming from the Plasma unit. The PLC can monitor that and apply 5V to Mach's ArcOK input. Mach Also has inputs for THC UP and DOWN. If I used a stepper and stepper driver connected to Mach, the PLC could just control Mach through the UP/DOWN inputs, although that may be slower than a DC motor. The other advantage to letting Mach control motion is that I would retain the ability to attach a router, drill, engraver, etc. to the same machine, all of which do require Mach control of the Z axis.
This is how the Sound Logic THC works. Not sure, but my guess is that Toms unit works the same way. It controls Mach through the THC UP/DOWN inputs. The above idea would basically just replace the sound logic or CandCNC board with a PLC. All that would be required is a PLC with analog input. Not sure if this is possible, but instead of setting a PP pin high for torch UP/DN and ArcOK, just signal Mach through the serial interface without using any inputs or outputs. If you can programatically control an input on the PLC, you should be able to signal Mach from software just as if a physical input were applied to the PLC.