Inline QC station: concept setup on an aluminium profile frame

User, 18 Oct 2026: create a setup for the inline optical QC, an
aluminium extrusion frame with all sensors and a conveyor mounted to it.

- docs/equipment/inline-qc-station/: FreeCAD script (build_station.py)
  and model (.FCStd) of one station, 1.9 x 0.65 x 1.5 m on 27 m of
  40x40 and 3.8 m of 40x80 profile: rim-belt conveyor (two 6 mm PU round
  belts under the unrecorded rim, open centre), label gate with top and
  bottom colour cameras on the fly, inspection position with a lift and
  rotate chuck (75 mm lift, expanding mandrel, belt-driven servo), top and
  bottom 4k line-scans on opposite radii with coaxial, dark-field and
  backlights, two warp lasers, optional thermal camera, light-tight black
  tunnel with door switch, rodless-cylinder reject pusher with chute and
  bin, outfeed stop, cabinet, PLC, NixOS edge PC, HMI, stack light.
- render_station.py renders six views (open and closed iso, front, plan,
  inspection detail and elevation via clipped temporary documents).
- inline-qc-station-bom.csv: 32 lines with sources; USD 16k to 33k per
  station without the thermal camera.
- inline-optical-qc.md: new section "The station setup" (flow table,
  inspection zone, cycle ~5 to 6 s, control, BOM by group, open points);
  cost table updated (two launch stations ~USD 50k to 105k, still inside
  the metrology launch tier); Duplex/Classic flow now via the conveyor.
- README bullet and tree.
This commit is contained in:
grabowski committed 2026-10-18 13:29:55 +07:00
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@@ -184,7 +184,9 @@ The detail lives in dedicated documents:
the 100% record inspection station (line-scan cameras with dark-field
and transmitted light, label camera, laser warp sensors, centring
turntable), CD-scanner and PRP precedents, smart-camera versus open
NixOS software, specials, prices and a two-station cost estimate
NixOS software, specials, prices and a two-station cost estimate, and
a FreeCAD concept model of the station (aluminium profile frame,
rim-belt conveyor, chuck, sensors) with a sourced bill of materials
- [Quality automation](docs/quality-automation.md): stamper metrology
(Keyence-class confocal, profiler, XRF), layered pressed-record QC (100%
optical inspection, per-cycle press telemetry, sampled automated audio
@@ -345,6 +347,8 @@ docs/
│ ├── duplex-cell-layout-sketch.png Duplex cell arrangement (sketch, not to scale)
│ ├── galvanics.md Electroforming and stamper prep equipment plan
│ ├── inline-optical-qc.md Devices for the record inspection station
│ ├── inline-qc-station/ Concept model of the station (FreeCAD script,
│ │ .FCStd, renders, bill of materials)
│ └── pressing-line.md Press fleet strategy and equipment plan
├── finance/ Project cost overviews, revenue model,
│ construction RFQ, PEA electricity tariff