Stop Fighting
Legacy Iron.
A deterministic, real-time operating system built for modern CNCs, PLCs, and automation cells. Sub-millisecond cycle times, native OPC-UA, and zero vendor lock-in.
Initializing real-time kernel module... [OK] Mounting nvme0n1p1... [OK] Starting EtherCAT master on eth1... >> Found 12 slave devices >> State: PREOP -> SAFEOP -> OP >> Cycle time configured: 500µs [OK] EtherCAT operational. Starting OPC-UA Server (Port 4840)... [OK] Loading CNC execution engine... >> Interpolator ready. >> Look-ahead buffer: 10,000 blocks. System ready. Awaiting G-Code stream. _
Deterministic Cycle Time
Guaranteed real-time execution via isolated CPU shielding. No jitter, no skipped interpolation frames.
Block Look-Ahead
Advanced trajectory planning buffer for high-speed machining without surface finish degradation.
Hardware Agnostic
Runs on standard x86/ARM IPCs. Stop paying OEM premiums for proprietary control hardware.
OPC-UA / MQTT
Built-in telemetry streaming. No expensive MTConnect adapters or third-party edge gateways required.
The OEM Extortion
Business Model.
For 40 years, machine tool builders have treated the controller as a captive revenue stream.
You buy a $500,000 5-axis mill, but if you want to extract basic spindle load data or connect a robot loader, the OEM demands a $5,000 "unlock code" for a software feature that was already installed.
Legacy controls run on antiquated RTOS kernels (or worse, Windows CE), requiring proprietary hardware boards that cost $12,000 to replace when a capacitor blows. They use closed communication protocols designed in the 1990s, forcing you to buy expensive protocol converters just to get data onto your shop floor network.
SmartMachine OS was built to shatter this model. We decouple the software intelligence from the iron.
The Cost of Closed Systems
| Line Item | Legacy OEM | SmartMachine OS |
|---|---|---|
| Hardware Replacement (Control Board) | $8,000 - $15,000 | $800 (Standard IPC) |
| Data Extraction (OPC-UA/MTConnect) | $2,500+ Option | Included natively |
| High-Speed Look-Ahead Option | $4,000+ Option | Included natively |
| Software Updates | Requires Technician Visit | OTA or USB (Free) |
Kernel Architecture
Hard real-time deterministic execution running alongside standard Linux networking via CPU shielding.
System Specs
Full Specifications →Motion Control
- Max Axes 64 (Interpolated)
- Update Rate 125µs - 1ms
- Fieldbus EtherCAT Master
- Kinematics 5-Axis RTCP, Scara, Delta
CNC Execution
- G-Code standard RS274 / ISO 6983
- Look-ahead 10,000 blocks
- File Size Limit None (Streamed)
- Macros Parametric (Custom B)
Connectivity
- Native IT Protocols MQTT, REST API
- Native OT Protocols OPC-UA Server
- HMI Interface HTML5 / WebSockets
- Remote Access Wireguard VPN (Built-in)
Calculate Retrofit ROI
Stop scrapping mechanically sound machine tools just because the legacy control board died and the OEM won't support it. Retrofitting with SmartMachine OS and off-the-shelf EtherCAT drives typically costs 20% of a new machine.
- Save $150k+ vs buying new iron
- Modernize data collection instantly
- Standardize HMIs across mixed fleets
# Default internal iptables policy
iptables -P INPUT DROP
iptables -P FORWARD DROP
iptables -P OUTPUT ACCEPT
# Allow localhost (Internal IPC comms)
iptables -A INPUT -i lo -j ACCEPT
# Allow OPC-UA (Port 4840) from specific IT subnet ONLY
iptables -A INPUT -p tcp -s 10.0.50.0/24 --dport 4840 -j ACCEPT
# Allow Wireguard VPN for remote diagnostics
iptables -A INPUT -p udp --dport 51820 -j ACCEPT
# Drop all traffic on EtherCAT NIC (eth1) originating externally
iptables -A INPUT -i eth1 -m state --state NEW -j DROP
Zero-Trust on the Shop Floor.
Connecting a Windows 7 based machine controller to your factory network is a massive liability. SmartMachine OS eliminates this vulnerability entirely through architecture.
-
No Windows Attack Surface. Built on a headless, minimal Debian base. No Explorer.exe, no RDP vulnerabilities.
-
Physical Network Segregation. The EtherCAT motion bus (eth1) is physically isolated from the factory IT network (eth0). Malicious network traffic cannot disrupt servo timing.
-
Encrypted Telemetry. OPC-UA connections require X.509 certificates. No plaintext Telnet or FTP required for file transfers.
Unrestricted Telemetry
Stop paying OEM unlock fees just to see your own spindle load. SmartMachine OS publishes 100% of its internal state tree via MQTT and OPC-UA natively.
| NodeID (OPC-UA) | Data Type | Description | Update Rate | OEM Fee Equivalent |
|---|---|---|---|---|
| ns=2;s=Spindle.Load | Float32 | Real-time active current torque (percentage) | 10 ms | ~$1,500 Option |
| ns=2;s=Axes.X.PositionAct | Double | Actual interpolated position of X axis | 1 ms | Requires Focas/API ($$) |
| ns=2;s=Execution.LineNum | UInt32 | Currently executing G-Code line number | 10 ms | Requires Focas/API ($$) |
| ns=2;s=Tools.T1.Wear | Double | Current tool wear offset value | On Change | Requires Focas/API ($$) |
| ns=2;s=Plc.Vars.Coolant | Boolean | State of M8/M9 logic relay | On Change | None (Basic IO) |
Build Your Own HMI.
You are no longer restricted to the OEM's proprietary screen builder tool that requires a week of training. The SmartMachine OS HMI is served entirely over HTTP and WebSockets.
Want a custom operator screen that embeds your ERP job queue directly next to the G-Code viewer? Have your junior web developer build it in React or Vue.js. It just talks to our WebSocket API.
Read HMI Integration Guide →Deployment Pipeline
Hardware Procurement
Purchase any standard industrial PC (e.g., Beckhoff, OnLogic, Advantech) meeting minimum specs (Dual Core, 4GB RAM, dual Intel NICs).
Flash OS Image
Flash the pre-compiled SmartMachine OS Debian image (containing the PREEMPT_RT kernel and our stack) directly to the IPC's SSD via USB.
EtherCAT Discovery
Connect the EtherCAT port to your servo drives. Run the automated network scan tool to map nodes and generate the ENI (EtherCAT Network Information) file.
Load Kinematics & PLC
Upload your machine's kinematic configuration JSON and compiled IEC 61131-3 logic via the web interface. The machine is now ready for G-Code.
Engineering-Direct Support
Legacy OEM Support
- X File a ticket with a local distributor.
- X Wait 3 days for distributor to escalate to OEM.
- X Pay $2,500 for a technician flight and hotel.
- X Technician replaces $10,000 black-box board.
SmartMachine OS Support
- ✓ Direct Slack channel with our kernel developers.
- ✓ Built-in Wireguard VPN for secure remote diagnostics.
- ✓ Pull full system logs instantly via REST API.
- ✓ Replace failed hardware locally via Amazon/DigiKey.
Hard Questions,
Direct Answers.
We don't hide behind marketing fluff. Implementing a new machine OS is a massive engineering decision. Here is how we handle the realities of the shop floor.
Ask engineering directlyWhat hardware is actually required to run it?
Any industrial PC (IPC) with a multi-core x86 or ARM processor, at least 4GB RAM, and two dedicated Intel/Realtek network interfaces (one for IT, one for EtherCAT). No proprietary PCI motion cards are required. The entire motion interpolation happens in the isolated CPU cores.
How do you guarantee hard real-time on Linux?
We use the PREEMPT_RT patchset combined with CPU isolation (isolcpus). Cores 0 and 1 are dedicated entirely to the motion engine and EtherCAT master, invisible to the standard Linux scheduler. This guarantees sub-millisecond cycle times with jitter under 15 microseconds, tested under extreme network load.
Is the G-Code interpreter compatible with FANUC/Siemens?
Our interpreter strictly follows RS274/ISO 6983. However, legacy OEMs have added decades of proprietary M-codes and macro syntax. We provide a pre-processor translation layer that automatically converts standard FANUC Macro B and Siemens parametric programs into our native execution format before runtime.
What if the network goes down? Does the machine crash?
No. The internal control loop (OS to EtherCAT drives) is physically separated from the external IT network. If your factory network goes down, you lose telemetry and the ability to stream new programs from the server, but the machine will safely complete its current execution buffer and gracefully stop. Safety I/O is handled via Fail-Safe over EtherCAT (FSoE) independently of the IT stack.
Own Your Machine Data.
Download the full technical specification sheet or request an evaluation runtime environment to test interpolation and logic locally.