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I believe I have 10, but can't verify until tomorrow or Monday. I have only tried the one value, which was an educated guess and seemed to work.

The total delay can be loops * timeout, i.e. 60 * 5 ms = 300 ms with the default values. In practice it can become longer because of how the delay is made and how the kernel schedules the task. I would imagine that as long as the delay is more than a few servo cycles, it should work. So probably it would work even with loops set to 1. But I have not tested. Nor do I think it would solve all issues that I experience.

By the way, after re-reading your post I realized this was for a medical product line. When I mentioned sheet/panel materials (plastics, laminates, composites, etc.) I meant it in a very generic sense. I’d be really interested to know what kind of materials you were actually processing (e.g. medical-grade films, technical fabrics, multilayer laminates, polymers, etc.), since the combination of a heat press laminator and an ultrasonic cutter suggests a quite specialized process.

Well if you think about it, the delta winch drum is really the same as a pinion drive in relation to motor analysis,
So no cutting forces, 2 kg axis weight (actually that's way wrong as the print head has 3 wires supporting it) but it did not make much difference.
I have no real idea here but if you want speed, grab a 48 volt 10 amp power supply (for 3 motors) a 2:1 reduction gearbox and a 60mm diameter winch drum, and you are good for 37,000 m/min!

The limiting factor here was the voltage and this needed 46 volts. if they had a drive good for 72-80 volts like rtelligent you might crack 40 m/min  revised Report attached. Some early runs did not get past 12 m/min until I started tweakimg drums and gearing.

I'll be very interested to see how you go as I thought seriously about making one to but had no experence. Beckhoff have some interesting modi;e to read the cool stuff printers need!

I was testing new remora-eth from ben-jacobson repository. With the suggestions from you was able to make it work on SPI3, with TMC5160 drivers on remora-spi.

But now I am testing remora-eth from same repo. Can you help me in this?. I have edited ldscript for octopus pro with ethernet. But I can't ping w5500.

Das ist das aktuelle Bild meiner Erprobungsmaschine. 
Mit einer MESA Electronics 7i95.
 

What number do you use for loops? Is any number "best"?

I also use version 5.5, it seems to be a firmware issue.

Okay, thank you for the feedback. I realize now I wasn't clear in my last request, but I meant jogging with the pendant while a program is running. But you did that as well.

This setupAsyncTransfer() assertion failed is also what I had before changing the loops. That error occurs when the USB dongle has already reset, most likely because it saw no activity from the computer side.

I mentioned that after some time, the pendant still stops working for me. But I don't recall right now if I have even checked if I get the same setupAsyncTransfer failed at that time. I should check...

If you continue using this modified version, let us know if it looks to have cured the other issue you had as well.

I just started on writing a new firmware for the dongle. But I'm not sure where that will lead, if anywhere.

I will measure the Mesa output signal again and compare them with the running USB-Dongle signals.
Maybe there is something wrong with these PullUp/Down resistors.

If there is any output, it could be the wrong configuration.
If not, maybe something is wrong in my .hal
Is there any chance to see the pktuart output in terminal ?
Like wireshark or candump ?

Thank you!

Congratulations on the project, the PLC + LinuxCNC integration looks really nice and the machine layout seems very well thought out and organized.

Looking at the machine layout (heat press laminator, 4-axis CNC cutter, pallet transport, and the overhead projector), I was curious about the main application: is it aimed at processing sheet/panel materials in general (plastics/polymers, MDF, composites, laminates), or is it focused on a more specific material or process?

In my case, I’m working on a different kind of machine, more focused on laser cleaning and painting, with a modular gantry-style structure (about 2 m modules, extendable up to ~16 m on X, with ~2000 mm usable Z and ~300 mm Y). So it was really interesting to see how you handled the integration and the production flow in your system.

Regarding the integration approach: I started by trying to validate the same PLC-as-master / LinuxCNC-as-motion-controller model using mb2hal / Modbus directly, just to keep things simple and close to the field. In practice, I ran into some interoperability issues with the specific setup I have (mainly around protocol framing and what the HMI/PLC side actually exposes as “Modbus TCP”).

In the end, I validated the architecture using a Python bridge as well, but instead of Modbus TCP I used OPC UA as the integration layer between the HMI/SCADA side and LinuxCNC. With Python (using an OPC UA client library) talking to a running LinuxCNC instance, I can exchange status, commands, and recipe parameters in a very similar way to what you described: the operator never interacts with LinuxCNC directly, everything is driven from the HMI/PLC side, and LinuxCNC stays focused purely on motion.

Conceptually, the control model ends up being very close to yours: PLC/HMI remains the master, LinuxCNC is the motion controller, and the Python bridge handles the handshake, heartbeat, status propagation, and command flow between the two worlds. The main difference is just the transport layer (OPC UA instead of Modbus TCP) due to the constraints of my current hardware/software stack.

By the way, for systems like yours, do you usually integrate them with a SCADA layer, or do you prefer to keep it as PLC + HMI + LinuxCNC only? And if you do integrate SCADA, have you ever used or evaluated any open-source solutions?

Thanks again for sharing the real-world experience — it’s very valuable to see these hybrid architectures working reliably in production for years.

Tested today, but not very conclusive I'm afraid.

Default master branch.
Jog while running Gcode: Doesn't allow me.
First time running gcode, press stop. While in Auto mode spin the wheel: It crashes see screen dump below.
After restart and retry this several times: It works, it switches to Man and moves in Z.

With loops=10, it always works, at least the say five times I tried so maybe not conclusive.
I can continue with this setting to see if it fails later.
 
I always get this "assert" error when it fails.

Soooo, this new frame makes the old one look like a carvera. Sorta shocking. Hurry up with that jerk limiting.....

 

Thanks, Rodw, looks great! 
I really need a bigger faster 3d printer, my Elegoo Neptune Max gantry type printer doesn't always fit my projects... I'm inspired by an FLSUN S1 that I watched printing one day. It runs delta kinematics, and it runs so fast the print head is just a blur. Pretty much sounds like a clothes washer in fast spin cycle when it's printing.

I'm playing around with dimensions a bit. In my 3d sketch, the linear rails are 2000mm long and will be attached to the steel frame (not shown). The round build plate at the bottom is 750mm diameter. The delta legs carrying the print head will likely be aluminum round tube.

It will be enclosed and heated, build plate will also be heated. The three delta motors will be up on top outside the heated enclosure, driving the carriages up and down via gear belts.

The door will be something like polycarbonate. Two thirds of the sides will be sheet metal heavy enough so it doesn't sound like a tin can, that steel shell will probably be the main frame. One third of the sides will be the clear door spanning most of the distance between two rails.

I do not yet have any mass measurements for calculating speeds with. I will be happy if I can make it go faster than my Elegoo printer. I don't expect to win any races with that FLSUN S1, that thing looked like its delta legs might be carbon fiber.

According to downforeveryoneorjustme.com/ it has been down for everyone a few times lately.

If you use shielded tips so the bare electrode does not connect the material, I would use a second THCAD for material probing.
ONe user here stated it was crazy fast and saved a lot of time...