plc-checkweigher 1.0.0

package/README.md

@@ -0,0 +1,71 @@
+# PLC Check-Weigher System
+
+> **Hardware:** Raspberry Pi 4B · Mitsubishi PLC (Type3E) · Check-weigher line  
+> **Author:** Bibin VR
+
+Real-time check-weigher data logger and report system for a Mitsubishi PLC production line. Monitors each item, logs weight and status, generates PDF batch reports, and instantly pushes them to a network PC via SMB.
+
+## Features
+
+- Live PLC polling at 50 ms — captures every item (accept/reject/weight)
+- PDF batch report generated automatically at end of each production run
+- Instant PDF push to Windows/Mac shared folder via SMB (no software needed on the receiving PC)
+- Live operations dashboard — weight gauge, batch stats, item feed in real time
+- PDF report viewer with live auto-refresh (new reports appear without page reload)
+- Systemd service — starts at boot, reconnects on PLC disconnect
+
+## Quick Start
+
+```bash
+# Install dependencies
+python3 -m venv /home/pi/plc_env
+source /home/pi/plc_env/bin/activate
+pip install pymcprotocol flask reportlab
+sudo apt install samba-client
+
+# Start watcher (or install as systemd service — see procedure.md)
+cd /home/pi/plc_checkweigher
+python3 plc_watcher.py
+
+# Start web interface
+python3 web/app.py
+```
+
+Open `http://<pi-ip>:8080` for the report viewer, `/live` for the dashboard.
+
+## PDF Push Setup
+
+See **[procedure.md](procedure.md)** for full setup instructions including:
+- Windows local user creation (avoids Microsoft account credential issues)
+- macOS File Sharing configuration
+- Email delivery via Gmail
+- HTTP push using `pdf_receiver.py`
+
+## Project Layout
+
+```
+plc_checkweigher/
+├── plc_watcher.py        # systemd entry — waits for PLC START
+├── plc_reader.py         # per-item data collection + PDF trigger
+├── plc_report.py         # PDF generation (ReportLab)
+├── pdf_push.py           # instant PDF delivery to network PC
+├── pdf_receiver.py       # optional HTTP receiver for target PC
+├── plc_watcher.service   # systemd unit
+├── procedure.md          # full setup & operating procedure
+└── web/
+    ├── app.py            # Flask server (port 8080)
+    └── templates/
+        ├── index.html    # report list with live SSE refresh
+        └── live.html     # live operations dashboard
+```
+
+## Configuration
+
+Edit the top of each file:
+
+| File | Key settings |
+|---|---|
+| `plc_reader.py` | `PLC_IP`, `PLC_PORT` |
+| `plc_watcher.py` | `PLC_IP`, `PLC_PORT` |
+| `pdf_push.py` | `SMB_HOST`, `SMB_SHARE`, `SMB_USERNAME`, `SMB_PASSWORD` |
+| `web/app.py` | `REPORTS_DIR`, `PORT` |

package/bin/cli.js

@@ -0,0 +1,64 @@
+#!/usr/bin/env node
+'use strict';
+
+const { spawnSync } = require('child_process');
+const { platform, arch } = require('os');
+const path = require('path');
+const fs   = require('fs');
+
+// ── Colour helpers ────────────────────────────────────────────────────────────
+const B  = '\x1b[1;34m';   // bold blue
+const G  = '\x1b[0;32m';   // green
+const R  = '\x1b[1;31m';   // red
+const Y  = '\x1b[1;33m';   // yellow
+const NC = '\x1b[0m';
+
+function die(msg) {
+  console.error(`\n${R}Error:${NC} ${msg}`);
+  process.exit(1);
+}
+
+// ── Platform guards ───────────────────────────────────────────────────────────
+if (platform() !== 'linux') {
+  die('This installer only runs on Raspberry Pi (Linux). Got: ' + platform());
+}
+if (arch() !== 'arm64') {
+  die('Requires 64-bit ARM (arm64). Got: ' + arch() +
+      '\nMake sure you are running 64-bit Raspberry Pi OS.');
+}
+
+// ── Banner ────────────────────────────────────────────────────────────────────
+console.log(`
+${B}╔════════════════════════════════════════════╗
+║   PLC Check-Weigher — Full Stack Installer  ║
+╚════════════════════════════════════════════╝${NC}
+`);
+
+// ── Locate setup.sh (bundled inside this npm package) ────────────────────────
+const setupScript = path.resolve(__dirname, '..', 'setup.sh');
+if (!fs.existsSync(setupScript)) {
+  die('setup.sh not found inside the package — try: npm install -g plc-checkweigher@latest');
+}
+
+// ── Inform the user ───────────────────────────────────────────────────────────
+console.log(`${Y}This will:${NC}`);
+console.log('  1. Install the PREEMPT_RT real-time kernel (reboots once)');
+console.log('  2. Install all Python dependencies');
+console.log('  3. Clone / update the plc-checkweigher repo');
+console.log('  4. Configure WiFi, SMB file sharing');
+console.log('  5. Install systemd services with RT scheduling priority');
+console.log('');
+console.log(`${Y}Sudo password required to make system-level changes.${NC}`);
+console.log('');
+
+// ── Run setup.sh via sudo ─────────────────────────────────────────────────────
+// stdio:'inherit' keeps the terminal fully interactive:
+//   • sudo password prompt works
+//   • WiFi password prompt works
+//   • All colour output passes through
+const result = spawnSync('sudo', ['bash', setupScript], {
+  stdio: 'inherit',
+  env: process.env,
+});
+
+process.exit(result.status ?? 0);

package/package.json

@@ -0,0 +1,31 @@
+{
+  "name": "plc-checkweigher",
+  "version": "1.0.0",
+  "description": "One-command installer for the PLC Check-Weigher system on Raspberry Pi (PREEMPT_RT kernel, Python stack, WiFi, SMB, systemd RT services)",
+  "bin": {
+    "plc-checkweigher": "bin/cli.js"
+  },
+  "files": [
+    "bin/",
+    "setup.sh"
+  ],
+  "keywords": [
+    "plc",
+    "checkweigher",
+    "raspberry-pi",
+    "installer",
+    "preempt-rt",
+    "real-time",
+    "mitsubishi",
+    "iot"
+  ],
+  "author": "Bibin-VR",
+  "license": "MIT",
+  "engines": {
+    "node": ">=16"
+  },
+  "repository": {
+    "type": "git",
+    "url": "https://github.com/Bibin-VR/plc-checkweigher.git"
+  }
+}

package/setup.sh

@@ -0,0 +1,490 @@
+#!/usr/bin/env bash
+# =============================================================================
+#  PLC Check-Weigher — Full Stack Bootstrap Installer
+# =============================================================================
+#
+#  One-liner (run this on any fresh Raspberry Pi):
+#
+#    sudo bash -c "$(curl -sSL https://raw.githubusercontent.com/Bibin-VR/plc-checkweigher/main/setup.sh)"
+#
+#  What it does (automatically, in order):
+#    1. Validates hardware / OS / arch
+#    2. Installs the PREEMPT_RT kernel (reboots once if needed, then resumes)
+#    3. Installs all system & Python dependencies
+#    4. Clones / updates this repo
+#    5. Configures WiFi (sai @samarth) with highest autoconnect priority
+#    6. Enables network-online guarantee before services start
+#    7. Creates /home/pi/reports directory
+#    8. Installs both systemd services with SCHED_FIFO real-time scheduling
+#    9. Starts & enables everything
+#   10. Verifies the full stack
+#
+#  Override defaults via env vars before the command:
+#    WIFI_PASS="secret" PI_USER="pi" sudo bash -c "$(curl -sSL ...)"
+# =============================================================================
+
+set -euo pipefail
+IFS=$'\n\t'
+
+# ── Configurable defaults ─────────────────────────────────────────────────────
+PI_USER="${PI_USER:-pi}"
+WIFI_SSID="${WIFI_SSID:-sai @samarth}"
+WIFI_PASS="${WIFI_PASS:-}"                    # prompted if empty and not connected
+SMB_HOST="${SMB_HOST:-192.168.0.140}"
+SMB_SHARE="${SMB_SHARE:-Reports}"
+SMB_USER="${SMB_USER:-plcreport}"
+SMB_PASS="${SMB_PASS:-plcreport}"
+REPO_URL="https://github.com/Bibin-VR/plc-checkweigher.git"
+REPO_BRANCH="main"
+
+# ── Derived paths ─────────────────────────────────────────────────────────────
+HOME_DIR="/home/${PI_USER}"
+INSTALL_DIR="${HOME_DIR}/plc_checkweigher"
+VENV_DIR="${HOME_DIR}/plc_env"
+REPORTS_DIR="${HOME_DIR}/reports"
+BOOT_FW="/boot/firmware"
+STATE_DIR="/var/lib/plc-setup"
+SELF_COPY="${STATE_DIR}/setup.sh"
+CONT_SVC="plc-setup-continue.service"
+
+# ── RT kernel package ─────────────────────────────────────────────────────────
+RT_PKG="linux-image-6.12.86+deb13-rt-arm64"
+RT_HDR="linux-headers-6.12.86+deb13-rt-arm64"
+
+# ── Python packages (pinned) ──────────────────────────────────────────────────
+PY_PKGS=(
+    "Flask==3.1.3"
+    "pymcprotocol==0.3.0"
+    "reportlab==4.5.1"
+    "pillow==12.2.0"
+    "pyserial==3.5"
+    "pymodbus==2.5.3"
+    "websockets==16.0"
+    "scapy==2.7.0"
+)
+
+# ── Terminal colours ──────────────────────────────────────────────────────────
+R='\033[1;31m'; G='\033[0;32m'; B='\033[1;34m'; Y='\033[1;33m'; NC='\033[0m'
+banner()  { echo -e "\n${B}══════════════════════════════════════════════${NC}"; \
+            echo -e "${B}  $*${NC}"; \
+            echo -e "${B}══════════════════════════════════════════════${NC}"; }
+step()    { echo -e "\n${Y}[${1}]${NC} ${2}"; }
+ok()      { echo -e "    ${G}✓${NC}  ${1}"; }
+warn()    { echo -e "    ${Y}!${NC}  ${1}"; }
+die()     { echo -e "\n${R}FATAL:${NC} ${1}" >&2; exit 1; }
+
+# ── Guard: must be root ───────────────────────────────────────────────────────
+[[ "${EUID}" -eq 0 ]] || die "Run with sudo:  sudo bash -c \"\$(curl -sSL ...)\"  "
+
+# ── Guard: must be aarch64 ────────────────────────────────────────────────────
+ARCH="$(uname -m)"
+[[ "${ARCH}" == "aarch64" ]] || die "This installer targets 64-bit Raspberry Pi (aarch64). Got: ${ARCH}"
+
+# ── Guard: home dir must exist ────────────────────────────────────────────────
+[[ -d "${HOME_DIR}" ]] || die "User home ${HOME_DIR} not found. Set PI_USER= before running."
+
+mkdir -p "${STATE_DIR}"
+
+# =============================================================================
+#  PHASE 1 — Real-Time Kernel  (skipped when already running PREEMPT_RT)
+# =============================================================================
+is_rt_kernel() { grep -q "PREEMPT_RT" /proc/version 2>/dev/null; }
+
+install_rt_kernel() {
+    banner "Phase 1 — Installing PREEMPT_RT Kernel"
+
+    step "1a" "Backing up current kernel image ..."
+    if [[ ! -f "${BOOT_FW}/kernel8-stock.img" ]]; then
+        cp "${BOOT_FW}/kernel8.img" "${BOOT_FW}/kernel8-stock.img"
+        ok "Backup → ${BOOT_FW}/kernel8-stock.img"
+    else
+        ok "Backup already exists — skipping"
+    fi
+
+    CHKSUM_BEFORE="$(md5sum "${BOOT_FW}/kernel8.img" | cut -d' ' -f1)"
+
+    step "1b" "Installing ${RT_PKG} ..."
+    DEBIAN_FRONTEND=noninteractive apt-get install -y "${RT_PKG}" "${RT_HDR}"
+    ok "RT kernel package installed"
+
+    # Detect whether post-install hook overwrote kernel8.img
+    CHKSUM_AFTER="$(md5sum "${BOOT_FW}/kernel8.img" | cut -d' ' -f1)"
+    if [[ "${CHKSUM_BEFORE}" != "${CHKSUM_AFTER}" ]]; then
+        # Hook replaced kernel8.img → move to kernel8-rt.img, restore stock
+        cp "${BOOT_FW}/kernel8.img"       "${BOOT_FW}/kernel8-rt.img"
+        cp "${BOOT_FW}/kernel8-stock.img" "${BOOT_FW}/kernel8.img"
+        ok "RT kernel → kernel8-rt.img  |  stock kernel restored as default"
+    else
+        # Hook did NOT copy — do it manually
+        RT_VMLINUZ="$(ls /boot/vmlinuz-*rt-arm64 2>/dev/null | sort -V | tail -1)"
+        [[ -n "${RT_VMLINUZ}" ]] || die "Cannot find RT vmlinuz in /boot/"
+        if file "${RT_VMLINUZ}" | grep -q gzip; then
+            zcat "${RT_VMLINUZ}" > "${BOOT_FW}/kernel8-rt.img"
+        else
+            cp "${RT_VMLINUZ}" "${BOOT_FW}/kernel8-rt.img"
+        fi
+        ok "RT kernel manually copied → ${BOOT_FW}/kernel8-rt.img"
+    fi
+
+    # Copy RT initramfs if one was generated
+    RT_INITRD="$(ls /boot/initrd.img-*rt-arm64 2>/dev/null | sort -V | tail -1 || true)"
+    if [[ -n "${RT_INITRD}" ]]; then
+        cp "${RT_INITRD}" "${BOOT_FW}/initramfs8-rt"
+        ok "RT initramfs → ${BOOT_FW}/initramfs8-rt"
+    fi
+
+    step "1c" "Activating RT kernel in ${BOOT_FW}/config.txt ..."
+    # Remove any previous RT block we wrote
+    sed -i '/### PLC-RT-BLOCK-START ###/,/### PLC-RT-BLOCK-END ###/d' \
+        "${BOOT_FW}/config.txt"
+
+    cat >> "${BOOT_FW}/config.txt" << 'CFGEOF'
+
+### PLC-RT-BLOCK-START ###
+# PREEMPT_RT kernel — installed by plc-checkweigher setup.sh
+kernel=kernel8-rt.img
+initramfs initramfs8-rt followkernel
+### PLC-RT-BLOCK-END ###
+CFGEOF
+    ok "config.txt updated — system will boot RT kernel after reboot"
+
+    step "1d" "Saving installer for post-reboot continuation ..."
+    # Save this very script so the continuation service can re-run it
+    if [[ -f "${SELF_COPY}" && "${BASH_SOURCE[0]}" != "${SELF_COPY}" ]]; then
+        : # already saved by a previous run
+    else
+        # If running via bash -c "$(curl ...)", BASH_SOURCE[0] is empty
+        # In that case, re-download from GitHub so we have a saved copy
+        if [[ -f "${BASH_SOURCE[0]:-}" ]]; then
+            cp "${BASH_SOURCE[0]}" "${SELF_COPY}"
+        else
+            curl -sSL \
+                "https://raw.githubusercontent.com/Bibin-VR/plc-checkweigher/${REPO_BRANCH}/setup.sh" \
+                -o "${SELF_COPY}"
+        fi
+    fi
+    chmod +x "${SELF_COPY}"
+
+    # Persist any env overrides so they survive across reboot
+    cat > "${STATE_DIR}/env" << ENVEOF
+PI_USER="${PI_USER}"
+WIFI_SSID="${WIFI_SSID}"
+WIFI_PASS="${WIFI_PASS}"
+SMB_HOST="${SMB_HOST}"
+SMB_SHARE="${SMB_SHARE}"
+SMB_USER="${SMB_USER}"
+SMB_PASS="${SMB_PASS}"
+ENVEOF
+    chmod 600 "${STATE_DIR}/env"
+
+    step "1e" "Creating post-reboot continuation service ..."
+    cat > "/etc/systemd/system/${CONT_SVC}" << SVCEOF
+[Unit]
+Description=PLC Check-Weigher Setup Continuation (post-RT-kernel reboot)
+After=network.target
+ConditionPathExists=${STATE_DIR}/env
+
+[Service]
+Type=oneshot
+EnvironmentFile=${STATE_DIR}/env
+ExecStart=/usr/bin/bash ${SELF_COPY}
+ExecStartPost=/bin/rm -f ${STATE_DIR}/env
+StandardOutput=journal+console
+StandardError=journal+console
+RemainAfterExit=yes
+
+[Install]
+WantedBy=multi-user.target
+SVCEOF
+
+    systemctl daemon-reload
+    systemctl enable "${CONT_SVC}"
+    ok "Continuation service enabled — will auto-run phase 2 after reboot"
+
+    echo ""
+    echo -e "${G}╔═══════════════════════════════════════════════════╗${NC}"
+    echo -e "${G}║  RT kernel ready.  Rebooting in 5 seconds ...    ║${NC}"
+    echo -e "${G}║  Phase 2 will complete automatically on boot.     ║${NC}"
+    echo -e "${G}║  Watch progress: journalctl -u ${CONT_SVC} -f  ║${NC}"
+    echo -e "${G}╚═══════════════════════════════════════════════════╝${NC}"
+    sleep 5
+    reboot
+}
+
+# =============================================================================
+#  PHASE 2 — Full Application Setup  (runs on RT kernel)
+# =============================================================================
+setup_full() {
+    banner "Phase 2 — Full Application Setup  (PREEMPT_RT kernel confirmed)"
+
+    # ── 2.1  Update package list & install system deps ────────────────────────
+    step "2.1" "Installing system packages ..."
+    DEBIAN_FRONTEND=noninteractive apt-get update -q
+    DEBIAN_FRONTEND=noninteractive apt-get install -y \
+        git \
+        python3-venv \
+        python3-pip \
+        python3-dev \
+        samba-client \
+        cifs-utils \
+        network-manager \
+        curl \
+        build-essential
+    ok "System packages installed"
+
+    # ── 2.2  Clone or update repo ─────────────────────────────────────────────
+    step "2.2" "Setting up repository at ${INSTALL_DIR} ..."
+    if [[ -d "${INSTALL_DIR}/.git" ]]; then
+        sudo -u "${PI_USER}" git -C "${INSTALL_DIR}" pull --ff-only origin "${REPO_BRANCH}" \
+            && ok "Repo updated" || warn "git pull failed — using existing files"
+    else
+        sudo -u "${PI_USER}" git clone --branch "${REPO_BRANCH}" \
+            "${REPO_URL}" "${INSTALL_DIR}"
+        ok "Repo cloned → ${INSTALL_DIR}"
+    fi
+
+    # ── 2.3  Python virtual environment ───────────────────────────────────────
+    step "2.3" "Setting up Python venv at ${VENV_DIR} ..."
+    if [[ ! -d "${VENV_DIR}" ]]; then
+        sudo -u "${PI_USER}" python3 -m venv "${VENV_DIR}"
+        ok "venv created"
+    else
+        ok "venv already exists"
+    fi
+
+    # Upgrade pip silently, then install pinned packages
+    sudo -u "${PI_USER}" "${VENV_DIR}/bin/pip" install --quiet --upgrade pip
+    sudo -u "${PI_USER}" "${VENV_DIR}/bin/pip" install --quiet "${PY_PKGS[@]}"
+    ok "Python packages installed: ${PY_PKGS[*]}"
+
+    # ── 2.4  Runtime directories ──────────────────────────────────────────────
+    step "2.4" "Creating runtime directories ..."
+    mkdir -p "${REPORTS_DIR}"
+    chown "${PI_USER}:${PI_USER}" "${REPORTS_DIR}"
+    ok "${REPORTS_DIR}"
+
+    # ── 2.5  WiFi — ensure saved profile with autoconnect ────────────────────
+    step "2.5" "Configuring WiFi (SSID: ${WIFI_SSID}) ..."
+    # Find any existing profile with this SSID
+    EXISTING_PROFILE="$(nmcli -t -f NAME,TYPE con show | \
+        awk -F: '$2=="802-11-wireless"{print $1}' | head -1 || true)"
+
+    if nmcli device status | awk '$2=="wifi" && $3=="connected"' | grep -q .; then
+        ok "WiFi already connected — skipping profile creation"
+        EXISTING_PROFILE="$(nmcli -t -f NAME,DEVICE con show --active | \
+            grep ":wlan0" | cut -d: -f1 || true)"
+    elif [[ -n "${EXISTING_PROFILE}" ]]; then
+        ok "WiFi profile '${EXISTING_PROFILE}' already saved in NetworkManager"
+    else
+        # Need password — use WIFI_PASS env var or prompt
+        if [[ -z "${WIFI_PASS}" ]]; then
+            if [[ -t 0 ]]; then
+                read -r -s -p "    Enter WiFi password for '${WIFI_SSID}': " WIFI_PASS < /dev/tty
+                echo ""
+            else
+                warn "WiFi password not provided. Set WIFI_PASS= env var or configure manually."
+                warn "Skipping WiFi profile creation."
+                WIFI_PASS=""
+            fi
+        fi
+        if [[ -n "${WIFI_PASS}" ]]; then
+            nmcli connection add \
+                type wifi \
+                ifname wlan0 \
+                con-name "${WIFI_SSID}" \
+                ssid "${WIFI_SSID}" \
+                wifi-sec.key-mgmt wpa-psk \
+                wifi-sec.psk "${WIFI_PASS}" \
+                connection.autoconnect yes
+            ok "WiFi profile '${WIFI_SSID}' created"
+            EXISTING_PROFILE="${WIFI_SSID}"
+        fi
+    fi
+
+    # Set high autoconnect priority on whichever profile is active
+    if [[ -n "${EXISTING_PROFILE}" ]]; then
+        nmcli connection modify "${EXISTING_PROFILE}" \
+            connection.autoconnect yes \
+            connection.autoconnect-priority 200 2>/dev/null || true
+        ok "Autoconnect priority set to 200 for '${EXISTING_PROFILE}'"
+    fi
+
+    # ── 2.6  NetworkManager-wait-online (guarantees IP before services start) ─
+    step "2.6" "Enabling NetworkManager-wait-online ..."
+    mkdir -p /etc/systemd/system/NetworkManager-wait-online.service.d/
+    cat > /etc/systemd/system/NetworkManager-wait-online.service.d/timeout.conf << 'EOF'
+[Service]
+ExecStart=
+ExecStart=/usr/lib/NetworkManager/nm-online -s -q --timeout=60
+EOF
+    systemctl enable NetworkManager-wait-online.service 2>/dev/null || true
+    ok "NetworkManager-wait-online enabled (60 s timeout)"
+
+    # ── 2.7  systemd service: plc_watcher (RT) ───────────────────────────────
+    step "2.7" "Installing plc_watcher.service (SCHED_FIFO:50, IOClass=realtime) ..."
+    cat > /etc/systemd/system/plc_watcher.service << EOF
+[Unit]
+Description=PLC Check-Weigher Start Watcher
+After=network-online.target time-sync.target
+Wants=network-online.target
+
+[Service]
+Type=simple
+User=${PI_USER}
+WorkingDirectory=${INSTALL_DIR}
+Environment=PYTHONUNBUFFERED=1
+ExecStart=${VENV_DIR}/bin/python3 -u ${INSTALL_DIR}/plc_watcher.py
+Restart=always
+RestartSec=5
+StandardOutput=journal
+StandardError=journal
+
+# ── Real-time scheduling ──────────────────────────────
+# SCHED_FIFO priority 50 preempts all SCHED_OTHER tasks.
+# CPUSchedulingResetOnFork=no (default) means plc_reader.py
+# subprocess inherits this RT policy via Popen automatically.
+CPUSchedulingPolicy=fifo
+CPUSchedulingPriority=50
+IOSchedulingClass=realtime
+IOSchedulingPriority=0
+# Pin to core 3 — isolated from general OS scheduling noise
+CPUAffinity=3
+Nice=-15
+
+[Install]
+WantedBy=multi-user.target
+EOF
+
+    # Mirror the service file back into the repo so git tracks it
+    cp /etc/systemd/system/plc_watcher.service \
+       "${INSTALL_DIR}/plc_watcher.service"
+    chown "${PI_USER}:${PI_USER}" "${INSTALL_DIR}/plc_watcher.service"
+    ok "plc_watcher.service installed"
+
+    # ── 2.8  systemd service: plc_web ─────────────────────────────────────────
+    step "2.8" "Installing plc_web.service ..."
+    cat > /etc/systemd/system/plc_web.service << EOF
+[Unit]
+Description=PLC Check-Weigher Report Viewer
+After=network-online.target plc_watcher.service
+Wants=network-online.target
+BindsTo=plc_watcher.service
+
+[Service]
+Type=simple
+User=${PI_USER}
+WorkingDirectory=${INSTALL_DIR}/web
+Environment=PYTHONUNBUFFERED=1
+ExecStart=${VENV_DIR}/bin/python3 -u ${INSTALL_DIR}/web/app.py
+Restart=always
+RestartSec=5
+StandardOutput=journal
+StandardError=journal
+Nice=-10
+
+[Install]
+WantedBy=multi-user.target
+EOF
+    ok "plc_web.service installed"
+
+    # ── 2.9  Enable + start services ──────────────────────────────────────────
+    step "2.9" "Enabling and starting services ..."
+    systemctl daemon-reload
+    systemctl enable plc_watcher.service plc_web.service
+    systemctl restart plc_watcher.service || true
+    sleep 2
+    systemctl restart plc_web.service || true
+    ok "Services enabled and started"
+
+    # ── 2.10  Disable continuation service (we're done) ──────────────────────
+    if systemctl is-enabled "${CONT_SVC}" &>/dev/null 2>&1; then
+        systemctl disable "${CONT_SVC}" 2>/dev/null || true
+        rm -f "/etc/systemd/system/${CONT_SVC}"
+        systemctl daemon-reload
+        ok "Continuation service cleaned up"
+    fi
+
+    # ── 2.11  SMB connectivity check ─────────────────────────────────────────
+    step "2.11" "Verifying SMB share at //${SMB_HOST}/${SMB_SHARE} ..."
+    if ping -c 2 -W 2 "${SMB_HOST}" &>/dev/null; then
+        ok "Host ${SMB_HOST} reachable"
+        if smbclient "//${SMB_HOST}/${SMB_SHARE}" \
+               -U "${SMB_USER}%${SMB_PASS}" -c "ls" &>/dev/null 2>&1; then
+            ok "SMB auth success — PDF push is ready"
+        else
+            warn "SMB host reachable but auth failed — ensure the share is set up on the host"
+        fi
+    else
+        warn "SMB host ${SMB_HOST} not reachable — will retry at runtime"
+    fi
+
+    # ── Final verification report ─────────────────────────────────────────────
+    banner "Setup Complete — Verification"
+
+    echo ""
+    echo "  Kernel:"
+    uname -r | sed 's/^/    /'
+    grep -o 'PREEMPT_RT' /proc/version 2>/dev/null \
+        && echo -e "    ${G}✓ PREEMPT_RT confirmed${NC}" \
+        || echo -e "    ${R}✗ PREEMPT_RT NOT detected${NC}"
+
+    echo ""
+    echo "  Services:"
+    for svc in plc_watcher plc_web; do
+        STATE="$(systemctl is-active ${svc}.service 2>/dev/null || echo 'inactive')"
+        if [[ "${STATE}" == "active" ]]; then
+            echo -e "    ${G}✓${NC}  ${svc}  (${STATE})"
+        else
+            echo -e "    ${R}✗${NC}  ${svc}  (${STATE})"
+        fi
+    done
+
+    echo ""
+    echo "  RT scheduling (plc_watcher):"
+    PID="$(systemctl show -p MainPID --value plc_watcher.service 2>/dev/null || echo '')"
+    if [[ -n "${PID}" && "${PID}" != "0" ]]; then
+        chrt -p "${PID}" 2>/dev/null | sed 's/^/    /' || true
+        ionice -p "${PID}" 2>/dev/null | sed 's/^/    /' || true
+        taskset -cp "${PID}" 2>/dev/null | sed 's/^/    /' || true
+    else
+        echo "    (PID not yet available)"
+    fi
+
+    echo ""
+    echo "  WiFi:"
+    nmcli -t -f NAME,DEVICE,STATE con show --active | grep wifi | sed 's/^/    /' \
+        || echo "    (no active WiFi)"
+
+    echo ""
+    echo "  Reports directory: ${REPORTS_DIR}"
+    echo "  Web dashboard:     http://$(hostname -I | awk '{print $1}'):8080"
+    echo ""
+    echo "  Useful commands:"
+    echo "    journalctl -u plc_watcher -f       # live watcher log"
+    echo "    journalctl -u plc_web -f           # live web log"
+    echo "    sudo chrt -p \$(systemctl show -p MainPID --value plc_watcher)"
+    echo ""
+}
+
+# =============================================================================
+#  Entry point — decide which phase to run
+# =============================================================================
+main() {
+    banner "PLC Check-Weigher Installer"
+    echo "  Repo  : ${REPO_URL}"
+    echo "  User  : ${PI_USER}"
+    echo "  Kernel: $(uname -r)"
+    echo ""
+
+    if is_rt_kernel; then
+        ok "PREEMPT_RT kernel already running — proceeding directly to phase 2"
+        setup_full
+    else
+        warn "Standard kernel detected ($(uname -r))"
+        warn "Installing RT kernel — system will reboot once, then auto-complete setup."
+        install_rt_kernel
+        # install_rt_kernel reboots — execution never reaches here
+    fi
+}
+
+main "$@"