diff --git a/docs/equipment/inline-optical-qc.md b/docs/equipment/inline-optical-qc.md index a9c1791..4a9effe 100644 --- a/docs/equipment/inline-optical-qc.md +++ b/docs/equipment/inline-optical-qc.md @@ -424,8 +424,42 @@ October 2026). measured in hours. The racks hold about one day of output: 2,800 to 3,100 records at the launch plant (the 850k target to the ~0.94M capacity in the [calculator](../fleet-calculator.html), over 300 days). +- **Stacks and cooling plates** (decided October 2026). + - **50 records a stack,** about 15 to 25 minutes of one press. Cascade + Record Pressing pulls the spindle at 50 + ([VRTX](https://vrtxmag.com/articles/how-to-press-vinyl-locally)). + Fifty 180 g records weigh 9 kg; a day of output is about 58 stacks. + - **A flat aluminium cooling plate every 10 records** to start with, as + at MY45 ([oberflaeche.de](https://oberflaeche.de/en/knowledge/topics/electro-plating/a-vinyl-renaissance/the-great-comeback-of-the-record-3)); + Mobineko lays one under every record + ([Mobineko](https://mobineko.com/vinyl-quality-standards)). The + Classic places the plates itself ("automatic cooling plate handling", + [Newbilt](https://vinyl-pressing-plants.com/blog/newbilt-classic-12-inch-vinyl-record-press)); + at the Duplex the operator lays one by hand. Full flat discs, not ring + spacers: a warm record held only round the label sags into a dish. + - **Plates cut locally.** 5052 aluminium (5083 if they are anodised), + 3 mm thick, with the diameter and centre hole of Newbilt's plate so + the Classic's magazine takes them; thickness and alloy are our + estimate until Newbilt's drawing arrives. A 1220 × 2440 mm sheet nests + 28 discs of about 305 mm, and a 3 mm sheet costs about THB 8,300 + before VAT + ([OneStockHome](https://www.onestockhome.com/th/product_categories/aluminum-sheet-thickness-3-mm), + grade 3003, October 2026): about THB 300 of metal a plate, THB 350 to + 450 with cutting and deburring (estimate). Cut on a fibre laser or a + waterjet. Chiang Mai has several laser shops (SK Laser Cut and Laser + CNX on Rattanakosin Road, among others), but many cut only acrylic and + wood, so ask for 3 mm aluminium. Edges and the centre hole are + deburred and rounded, because a burr marks the record. Every plate is + checked on a surface plate (no gap over 0.1 mm, our target). + - **How many:** one plate per 10 records over the full 24-hour queue + needs about 350 plates (13 sheets, THB 120,000 to 160,000, estimate); + an 8-hour queue about 100 to 130. Two sheets come first, for the + plate trial (next steps). + - **Clean plates:** dust on a plate ends up on the record, so the plates + are wiped on their way back to the presses and kept covered. - **At the station.** The finishing operator takes each record off the - cooled stack and puts it on the infeed. Good records leave the outfeed + cooled stack and puts it on the infeed, and lifts each cooling plate + onto the plate cart that goes back to the presses. Good records leave the outfeed into sleeving; a reject goes into the bin, and the HMI shows the reason. Finishing handles every record anyway, so the station adds no handling step. @@ -459,6 +493,24 @@ October 2026). minute). Past that, add a second station or move to stations at the presses. +**Considered, not taken: a spiral cooling tower.** Holding the whole +queue on a spiral is out of proportion. Eight hours of output lying +single is about 2,900 records, some 300 m of 1 m belt three records +across, roughly USD 75k to 120k at USD 250 to 300 per metre for Chinese +spiral coolers +([listing](https://www.sourcingai.com/smart-products/acebakebreadmachine/flexible-screw-cooling-spiral-tower-conveyor-tower-with-advanced-cooling-technology-for-bakery-BUWkKSqORktM); +our arithmetic), for a job the racks do for a few thousand. Bakery +spirals are built for 30 to 60 minutes +([I.J. White](https://www.ijwhite.com/blog/ultra-series-spiral-cooler-at-klosterman-baking/)). +Open on a belt for hours, fresh records also collect dust on both faces, +and a record lying alone has no stack weight holding it flat. A short +spiral of 30 to 60 minutes (20 to 40 m of belt, about USD 5k to 16k +ex-works, estimate) stays a later option: it would hand cooled records +to the station one by one and give each its exact pressing time, but +warp would then be read after an hour instead of on settled records. +The plate trial checks whether the early reading predicts the settled +one. + **Later option: a station at each press.** It finds a defect streak within a cycle or two, at the price of one station per cell, and it reads warm records, so release on warp still needs cooled samples. @@ -546,19 +598,26 @@ vision share is not yet confirmed. 2. **Keyence test.** Ask Keyence Thailand for a test report on the same records. 3. **Newbilt.** Ask how the Classic hands over its spindle stacks and - cooling plates (records per stack). Also ask for the cycle counter over + cooling plates (records per stack, records per plate), and for the + drawing of its plate (diameter, thickness, alloy, centre hole) so the + locally cut plates fit its magazine. Also ask for the cycle counter over OPC UA, so every stack label carries the record key (stamper, press, cycle, side; see [digital factory](../digital-factory.md)). 4. **Warp sensors.** Choose between two point lasers and a line profiler once the trials show whether a thickness map is worth the extra cost. -5. **EtherCAT bench.** Before the frame is built, run one A6-EC kit, the +5. **Plate and settling trial.** Cut two sheets of plates (56). Press one + job with a plate every 5, 10 and 25 records, and read edge run-out and + dish on the station after 1 hour and after 24 hours. That sets the + records per plate (black, colour and specials apart) and shows whether + a 1-hour reading predicts the settled one. +6. **EtherCAT bench.** Before the frame is built, run one A6-EC kit, the EK1101 with its terminals and the spindle encoder from the mini PC with qitech_lib on EtherCrab: eight tests and pass marks are in the [control plan](inline-qc-control-plan.md#7-bench-test-before-the-frame-is-built) (about THB 56,000 of parts, all reused in the station). If the EtherCrab stack falls short on the drive, repeat the test with the IgH master. -6. **Acceptance test.** Write it before ordering. It should cover the +7. **Acceptance test.** Write it before ordering. It should cover the detection rate per defect class on the trial set, the false-reject rate on good records (black and specials apart), and every result matched to its record key.