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You should just need to use HOME_OFFSET to get your gantry square and rely on your encoders to keep them that way

Look at the example in the docs for a MPG for axis selection and scaling. I think there is also a MUX4

Oops, just thought. the tension should be able to be done using home offsets

Once the fabric is tensioned, linuxcnc should be able to use the joint axes to control 4 motors in unison. Normally, it is just used for 2 on both sides of a gantry but I know its Been used on a 4 joint Z axis where all 4 corners are lifted..

I think you should use halcompile because this also lets you document your component via a man entry and the web site in the same file.
For new contributions, you should be using 2.10 (master) branch as 2.9 is frozen.
Using C would just add extra work. Not sure on user space comps though. I have never written one.

Both is fine.
The .comp format is more compact and easier to understand and maintain particularly for people not totally familiar with pure c.

Note that the component should remain compatible with older configurations.

I would think that your biggest issue is going to be the stretching of the fabric and that partly cut sections are going to get bunched up as you move the material back and forth.

I have picked up 4 new motor drivers and ac servos. I am trying to understand how I can use these with LinuxCNC..
I've been searching but can't even figure out how to start..  Has anyone used the Omron G5 hardware?

Thanks for any help.

Personally I would add the compensation to the kinematics model but if you feel more comfortable using a hal solution then why not give that a try.

There is also the external offsets feature:
www.linuxcnc.org/docs/devel/html/motion/external-offsets.html

One easy way is to use a mux8:
linuxcnc.org/docs/2.5/html/man/man9/mux8.9.html

This way you can net your three spindle signals to the three selections of the mux and you can define your modbus values to the corresponding inputs of the mux.

I am using mb2hal (modbus) and it exposes a pin `mb2hal.00.00.int` that is an input, the values can be 1, 2, or 5. I need to set the values based on other bit pin:

if spindle.0.forward = true then mb2hal.00.00.in = 1
if spindle.0.reverse = true then mb2hal.00.00.in = 2
if spindle.0.on = false then mb2hal.00.00.in = 5

How do I create this logic in the hal?

Cool idea. I also think this shoul be possible.

I am thinking of servos instead of steppers. Reason is build in encoders (ok cl steppers have it too) and the possibility to change to torque mode. So the two pulling servos in position mode doing the move and the two servos in torque mode can build up adjustable tension.

This setup than could be used as an initial meassure of the layer thickness and correct values for that.

I can imagine some kind of tape at the sides for all corrections. Like the tape on the shaper woodworking cnc handheld machine (dont know the exact name right now). This way you can use a camera like system an be on track all the time I guess.

Cool, just ping me in here when you have time and need help getting things setup!

Most probably, yes.
Stuff helpful to know:
-what is the maximum Y length in one go?
Stuff randomly wandering through my tired brain:
-would be easier to use ESP-CAM for side monitoring and adjustment
-encoders can be tracking the material on both sides as LinuxCNC can use 2 or more encoder feedback's for the same joint/axis
-see "bottle labeling machine" for the type of sensor used for aligning the labeling foil (stuck my finger between the cutting and gluing rollers on one of those 2 weeks ago, what a mess! )

Funny you mention that, as that is on my to-do list. It's been a little bit of a challenge. Once I have the mill 90% I'll try to read my notes and get some docs done. I also need to contribute code too. I also get that there has been less EtherCAT used in the past, which may change as the cost comes down. I was able to retrofit with 1.2KW AC servos for a little more cost than keeping 30-plus year old steppers, with new drivers, power supplies, and an interface card.