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Inline optical QC: devices for the record inspection station

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User, 17 Oct 2026: research on the inline QC equipment, which devices
can be used for the optical check.

- New docs/equipment/inline-optical-qc.md: defect-by-defect table with
  the optical signature, device and limit (IEC 98 / DIN 45547 hole and
  eccentricity, Stamper Discs targets, Mobineko warp limits), precedents
  (no vinyl product; Dr. Schenk ISM CD scanner as template; Basler/Xiris;
  PRP AQA 2023; CTU thesis), a station design (centring turntable, 4k
  line-scan per side with dark-field, bright-field and transmitted light,
  colour label camera, two laser warp sensors or a line profiler,
  optional thermal camera) with sourced price signals, resolution and
  eccentricity math, throughput, placement at the Duplex cell and the
  Classic, smart-camera vs open GenICam/Aravis/OpenCV/anomalib on NixOS,
  specials, Thai channels, next steps.
- Estimate USD 12k-30k hardware per station, ~USD 40k-100k for the two
  launch stations; inside the existing metrology launch tier, no plan
  price change.
- Backlinks: quality-automation.md layer 1, digital-factory.md QC
  integration row, README bullet and tree.
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grabowski committed 2026-10-17 23:47:12 +07:00
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@@ -563,7 +563,7 @@ same watcher pattern as the metrology exports below. See
| Instrument | How results reach the database | Key | Open integration item |
|---|---|---|---|
| Inline optical inspection at the press unloader (Keyence or Cognex class, custom integration) | vision controller sends one result string per record over TCP to a receiver on `vinyl-edge-press`; images pushed by SFTP to the collector, synced to the core's image dataset | press ID + cycle counter, passed from the PLC to the vision trigger | the cycle counter hand-off between PLC and vision controller is an integrator deliverable and an acceptance test |
| Inline optical inspection at the press unloader (PC-based GenICam station or Keyence/Cognex class, custom integration; devices in [inline optical QC](equipment/inline-optical-qc.md)) | vision controller sends one result string per record over TCP to a receiver on `vinyl-edge-press`; images pushed by SFTP to the collector, synced to the core's image dataset | press ID + cycle counter, passed from the PLC to the vision trigger | the cycle counter hand-off between PLC and vision controller is an integrator deliverable and an acceptance test |
| Stamper metrology (Keyence VK-X, VR-6000, XRF gauge, profilometer) | vendor Windows PCs export CSV and raw 3D to an SMB share on `vinyl-st-metrology`; a watcher parses and posts | back-side Data Matrix serial, scanned at the bench before measurement | export format per instrument confirmed with Keyence Thailand |
| PVC material lab (moisture analyzer, spectrophotometer, balance, later torque rheometer, DSC, FTIR) | instruments with RS232/USB export are read at `vinyl-st-lab`; the rest are typed in with the printout photographed; CoA PDF attached | compound lot ID (printed label scanned at intake) | which benchtop models have serial export |
| Audio QC station | capture service on `vinyl-st-audioqc` records the needle-drop (PipeWire, FLAC to the core's capture dataset); analysis pipeline computes spectral-envelope match to the source master, click/pop count, noise floor, channel balance; scores posted | record key (stamper + press + cycle + side), typed or picked from the run list | first-of-kind pipeline, developed in Expand phase against launch-phase recordings |