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Thanks for sharing your experience — this is exactly the kind of real-world example we were hoping to hear about.
Your description matches very closely the architecture we are targeting: a PLC/HMI as the cell controller (sequencing, recipes, operator workflow, interlocks), and LinuxCNC used strictly as a motion controller. The Python “bridge” approach you described, using Modbus TCP on the PLC side and the LinuxCNC Python interface on the PC side, is a very pragmatic way to implement a clean command/status boundary between the two domains.
What I find especially valuable in your example is that the operator never interacts with LinuxCNC directly: the PLC/HMI owns the workflow, selects the product/recipe, and LinuxCNC is treated as a subordinate motion engine that executes the required paths and reports status back. That is exactly the separation of responsibilities we are aiming for.
It is also very useful to hear that this setup has been running in production for several years, daily, with good reliability. This addresses one of the main concerns in industrial environments: long-term robustness and maintainability, not just theoretical capability.
Your comment about Modbus TCP being “simple and universal” is also a good reminder that, in many industrial contexts, simplicity and familiarity often translate directly into better supportability and uptime.
Thanks again for sharing this — it’s a very strong reference point for PLC + LinuxCNC architectures in real machines.

royka wrote:

Thanks, yes I can suggest it, it runs pretty stable.

Have you got an image for this?

it lives!

Thanks, yes I can suggest it, it runs pretty stable.

Yes, that appears to be a working EPP configuration

What exact mesaflash command did you use?
 

He added the picture above, seems all is good as it lists PWM and encoder pins.

No picture was included

Did you have SPI working before you changed the firmware?

 

Isleape wrote:

Hi, I loaded Halrun, followed by loadrt hostmod2 and hm2_7i90.I got the following response on the foto. However im not sure if this is realy comming from my mesa card or not due to the warning and still no mesaflash responses what so ever....I started the i790hd from Secondary eeprom that i think ...never touched. I also resoldered the cable etc. Can you tell me what im seeing? I will try to see if the inputs work in the hal monitor...Thanks for any insight...

this looks awesome

and yes i agree its massively missing in linuxcnc

i have been trying for ages to get native cam running and can't

i find on semiens and fagor controls i use the contour cycle about 90 percent of the time

everything else like facing and shamfers etc i don't use as i can just do it in the contour cycle.

and of course threading is usefull

though the built in threading cycles are not too bad for that

cheers

Andrew

Hi, I loaded Halrun, followed by loadrt hostmod2 and hm2_7i90.
I got the following response on the foto. However im not sure if this is realy comming from my mesa card or not due to the warning and still no mesaflash responses what so ever....
I started the i790hd from Secondary eeprom that i think ...never touched. I also resoldered the cable etc. Can you tell me what im seeing? I will try to see if the inputs work in the hal monitor...
Thanks for any insight...

If you still get random counts, that suggests a signal integrity issue of some kind (missing grounds?)

Unfortunately our normal analog input card (the 7I87) is out of stock currently

What voltage range, resolution and conversion speed do you need?
 

...small update , crossed wire tested unfortunately it don't help , but for EK1100 is as good as straight wire

System journal gives me huge amount of information so I filtered it a bit.

1), grzesiekzxr@grzesiekzxr:~$ sudo journalctl -k --since "1 hour ago"
lut 05 20:59:00 grzesiekzxr kernel: kauditd_printk_skb: 7 callbacks suppressed
lut 05 20:59:00 grzesiekzxr kernel: audit: type=1400 audit(1770321540.504:19): apparmor="DENIED" operation="capable" profile="/usr/sb>
lut 05 21:13:25 grzesiekzxr kernel: perf: interrupt took too long (2506 > 2500), lowering kernel.perf_event_max_sample_rate to 79750
lines 1-3/3 (END)


2). grzesiekzxr@grzesiekzxr:~$ ip link show ens5f5 | head -1
2: ens5f5: <NO-CARRIER,BROADCAST,MULTICAST,UP> mtu 1500 qdisc fq_codel state DOWN mode DEFAULT group default qlen 1000

 3). grzesiekzxr@grzesiekzxr:~$ ip a
1: lo: <LOOPBACK,UP,LOWER_UP> mtu 65536 qdisc noqueue state UNKNOWN group default qlen 1000
    link/loopback 00:00:00:00:00:00 brd 00:00:00:00:00:00
    inet 127.0.0.1/8 scope host lo
       valid_lft forever preferred_lft forever
    inet6 ::1/128 scope host noprefixroute 
       valid_lft forever preferred_lft forever
       
2: ens5f5: <NO-CARRIER,BROADCAST,MULTICAST,UP> mtu 1500 qdisc fq_codel state DOWN group default qlen 1000
    link/ether 20:cf:30:d0:44:90 brd ff:ff:ff:ff:ff:ff
    altname enp4s0f5
3: wls1: <BROADCAST,MULTICAST,UP,LOWER_UP> mtu 1500 qdisc noqueue state UP group default qlen 1000
    link/ether 48:5d:60:38:a0:16 brd ff:ff:ff:ff:ff:ff
    altname wlp2s0
    inet 10.10.0.245/24 brd 10.10.0.255 scope global dynamic noprefixroute wls1
       valid_lft 15791sec preferred_lft 15791sec
    inet6 fe80::9bf3:99e1:ddb1:dff3/64 scope link noprefixroute 
       valid_lft forever preferred_lft forever
4).
 [    8.551591] ec_master: loading out-of-tree module taints kernel.
[    8.551932] ec_master: module verification failed: signature and/or required key missing - tainting kernel
[    8.585094] EtherCAT: Master driver 1.6.8 1.6.8.g2543cc5-1+27.2
[    8.588193] EtherCAT: 1 master waiting for devices.
[    8.615964] ec_generic: EtherCAT master generic Ethernet device module 1.6.8 1.6.8.g2543cc5-1+27.2
[    8.615982] EtherCAT: Accepting 20:CF:30laugh0:44:90 as main device for master 0.
[    8.615998] ec_generic: Binding socket to interface 2 (ens5f5).
[    8.628532] EtherCAT 0: Starting EtherCAT-IDLE thread.
[    8.851296] NET: Registered PF_QIPCRTR protocol family
[    9.216918] jme 0000:04:00.5 ens5f5: Link is down
[   10.623450] wls1: authenticate with fa:92:bf:2d:84:ad
[   10.623474] wls1: 80 MHz not supported, disabling VHT
[   10.637063] wls1: send auth to fa:92:bf:2d:84:ad (try 1/3)
[   10.642346] wls1: authenticated
[   10.644441] wls1: associate with fa:92:bf:2d:84:ad (try 1/3)
[   10.652255] wls1: RX AssocResp from fa:92:bf:2d:84:ad (capab=0x1431 status=0 aid=3)
[   10.652459] wls1: associated
[   10.652573] ath: EEPROM regdomain: 0x8268
[   10.652575] ath: EEPROM indicates we should expect a country code
[   10.652576] ath: doing EEPROM country->regdmn map search
[   10.652577] ath: country maps to regdmn code: 0x37
[   10.652578] ath: Country alpha2 being used: PL
[   10.652579] ath: Regpair used: 0x37
[   10.652580] ath: regdomain 0x8268 dynamically updated by country element
[   10.732760] wls1: Limiting TX power to 20 (20 - 0) dBm as advertised by fa:92:bf:2d:84:ad
[   10.756660] IPv6: ADDRCONF(NETDEV_CHANGE): wls1: link becomes ready
[   27.921396] systemd-journald[308]: File /var/log/journal/9eae89433bf9430392b319dc655b4150/user-1000.journal corrupted or uncleanly shut down, renaming and replacing.
[  312.070512] kauditd_printk_skb: 7 callbacks suppressed
[  312.070518] audit: type=1400 audit(1770321540.504:19): apparmor="DENIED" operation="capable" profile="/usr/sbin/cupsd" pid=1611 comm="cupsd" capability=12  capname="net_admin"
[ 1177.039546] perf: interrupt took too long (2506 > 2500), lowering kernel.perf_event_max_sample_rate to 79750
[ 1508.389389] perf: interrupt took too long (3140 > 3132), lowering kernel.perf_event_max_sample_rate to 63500
[ 1879.795443] perf: interrupt took too long (3927 > 3925), lowering kernel.perf_event_max_sample_rate to 50750

The most obviousand suprising me  thing is that led closed to rj45 is not lit and not flashing while connect to OrientalMotor but when beckhoff is wired firstly led is lit and when comunication start is flashing what is what I expected.
Maybe I should try on another pc ? 
Thanks a lot for Your patience. 




 

Hi PCW,

The filter is already by default set to true. Suggest any other troubleshoot method for the same. 
Or suggest me a daughter board having analog input output pin

Progress!

You forgot the two first lines from that example cia402.hal

My head is still spinning from all the trouble I went through to revive this board.

Looking back now, I can say it was relatively easy—I just had to learn a lot in a short amount of time.

Thank you for your patience and support.

I truly can’t thank you enough.