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have add a little plugin-overview:

github.com/multigcs/riocore/blob/main/PLUGINS.md

forum.linuxcnc.org/9-installing-linuxcnc...ng-rtai-debs-for-2-9 new RTAI debs here with instructions

If the clothoid library can only create 2d curves then the only solution I see would be to approximate all arcs with a polyline. Which is exactly what 5axis CAM output seems to do.
With this approach there would only be line-line segment corners.

onelaboratories.us/rtai_lcnc/    5.4.258 matching RTAI kernel and LCNC debs
onelaboratories.us/abc/  5.4.279 matching RTAI kernel and LCNC debs

Don't mix up debs from each of these with each other or with other RTAI packages.
RTAI debs have to built as matched sets.

NO MIX AND MATCH!!

To install from a fresh Debian 12 with NO LCNC installed yet, just use: sudo dpkg -i (package name here without brackets)  for each deb and reboot. Choose the RTAI kernel in Grub, enjoy.

To install on Debian 12 with linuxcnc-uspace already installed use : sudo apt purge linuxcnc*  and wait for apt to completely remove every trace of LCNC.
Then follow the instructions for a fresh Debian 12 install above.

   

Bringing this back as I've finally dug this out of the corner and taken yalls suggestion of taking this apart. 

Looks like the model number for the axis control boards are D41-17445C
and the power supply board is D41-17337B

I've been searching for any wiring diagrams related to these things but haven't really turned up much. One of those free pfd places let me actually preview a CMC maintenance manual which looks like it has a wiring diagram for the control box but was too blurry to read when I zoomed in. 

The driver board does have a place for a tach as well. 

The servos only have 4 wires going to them, I assume plus and minus for power and two tach wires based on that I can read on the control board.
Part of the driver board has wires going directly to the power supply, the rest goto the main control board of which I can't really figure out what they are supposed to be doing. 

Would it simplify things to simply get a driver that can handle those servers? 

Isn't this the same situation as you would have when adding a fillet between a straight line segment and a helix segment in Gcode (except of course the helix segment would be oriented to XY, XZ or YZ plane)?

How do you handle  line-3d_arc segment corners in tool paths?

But then still if a or b rotates below the workpiece in one gcode line, we are lost.

Just so I understand the requirements for the clothoids library:

The clothoids library works for connecting segments that can create a plane.

I presume that can be any plane in space (ie it does not have to be XY XZ or YZ)?
If that is correct we can use the plane that is defined by the tool orientation vector and the corresponding point (TA knot) and project the two TA line segments (ie the one that comes from the previous TA knot and the one that goes to the next TA knot) onto that plane. Then we have the projected lines on a common plane and we can use the clothoids library to create a G2 continuous fillet.
Of course we would need to do this for all TA knots and their respective planes in space.

[edit]
Ok, I think we can forget this idea as this will still not create 3D clothoid curves but only 2D.
[/edit]

I spoke too soon. I have it turning off and on!

Not sure how this connects to axis however.

So it's axis.L.jog-scale is not set - I can force them to set to a static value, but is there a way in Probe Basic to connect it to the GUI increments? If I had room and hadn't already cut the control panel, I'd connect them to a selector switch, but the panel is cut and there's no room for increments. If I need to I can add it outside the control panel (like on the side of the pendant).

I have doing some experiments today and it is possible to run ethercat sync below 1ms interuption.. I have tried 250us sync and it was fine... but I do not know how it will be outside of bench top ...my prehistoric servo drivers has limit at 250us ... I did not test them with sync motion just communication setup and I have generic ec driver only... 

It should be great to test them then anyway.. 

@Hi arciera,

That's not difficult to do, opencascade is good in vectors, planes, etc.

But then still if a or b rotates below the workpiece in one gcode line, we are lost.
The 3d clothoid works, but output is not alway's valid. So i have to review my approach.
 
Sheisse.

Well, I spent most of yesterday at this and I don't appear any further ahead. When I ran Axis on a very similar machine a number of years ago I never saw or heard about HAL. I guess I will keep at it maybe I will get a flicker of light.
Thanks for the help, Ian aka Irritant

What does it actually say? One of the messages includes "this is not ncessarily an error"

If it works in stepconf then it ought to work in LinuxCNC. The most common cause for not doing is that the linuxcnc config drives the stepper driver enable pins and stepconf never does. And many stepper drivers have high-to-disable inputs. If you defined drive enable pins, suspect this.

Have you checked if 'axis.L.jog-enable' is true and what 'axis.L.jog-scale' is set to?