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.
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# Build the CNX Vinyl inline optical QC station (concept) in FreeCAD.
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#
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# Run inside the FreeCAD GUI (26.3):
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# exec(open(r"C:/dev/cnx_vinyl/docs/equipment/inline-qc-station/build_station.py", encoding="utf-8").read())
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# It creates the document "InlineQCStation", saves inline-qc-station.FCStd next
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# to this script and leaves the view open for rendering (render_station.py).
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#
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# Concept, not a fabrication drawing: profiles are drawn as plain 40 mm bars,
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# bought parts as their envelope boxes. Sizes follow ../inline-optical-qc.md.
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#
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# Axes: x = record flow (infeed at x = 0, outfeed at x = L), y = across
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# (operator front at -y), z = up from the floor. All values in mm.
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import os
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import FreeCAD as App
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import Part
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try:
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import FreeCADGui as Gui
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HAVE_GUI = App.GuiUp
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except Exception:
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HAVE_GUI = False
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HERE = os.path.dirname(os.path.abspath(__file__)) if "__file__" in dir() else r"C:/dev/cnx_vinyl/docs/equipment/inline-qc-station"
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OUT = os.path.join(HERE, "inline-qc-station.FCStd")
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V = App.Vector
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# ---------------------------------------------------------------- parameters
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L = 1900 # frame length along the flow
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YF = 300 # centre of the outer frame profiles, +/- y
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P = 40 # profile size (40 x 40 slot profile; 40 x 80 for the base)
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ZB = 900 # top of the rim belts = record underside while conveyed
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R_REC = 150.8 # 12" record radius (IEC 98: 301.6 mm diameter)
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T_REC = 2.0 # record thickness (approx.)
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R_LABEL = 50.0 # label radius
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R_HOLE = 3.62 # centre hole 7.24 mm
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R_REC_AREA = 146.3 # recorded outer radius (292.6 mm max): the rim outside it carries no grooves
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Y_BELT = 148.5 # round belts run under the unrecorded rim
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ZL = 960 # record underside when the chuck has lifted it
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LIFT = 75 # chuck stroke: pad top 885 (below the belts) -> 960
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X_IN = 200 # infeed: operator or Classic unloader puts the record here
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X_LB = 520 # label gate: both label cameras, on the fly with strobe
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X_IS = 880 # inspection: lift, clamp, one turn under the line-scans
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X_RJ = 1320 # reject pusher
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X_OUT = L - 30 - R_REC - 4 # outfeed end stop: good records wait here
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XT0, XT1 = 320, 1100 # light-tight tunnel uprights (inner faces 360 / 1100)
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TOP_LINE = (X_IS + 50, X_IS + 155) # top line-scan sees the +x radius, r 50..155
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BOT_LINE = (X_IS - 155, X_IS - 50) # bottom line-scan sees the -x radius
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WD_LINE = 330 # 4k x 7 um sensor, 160 mm field, f = 50 mm -> ~330 mm working distance
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WD_LABEL = 303 # 2840 px x 2.74 um sensor, 140 mm field, f = 16 mm
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# ---------------------------------------------------------------- colours
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ALU = (0.78, 0.80, 0.83)
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DARK = (0.18, 0.19, 0.21)
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BLACK = (0.04, 0.04, 0.05)
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CAM = (0.36, 0.52, 0.70) # camera bodies
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LENS = (0.08, 0.08, 0.09)
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LIGHT = (0.97, 0.95, 0.80) # emitting faces
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LIGHTBODY = (0.25, 0.25, 0.27)
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BELT = (0.20, 0.62, 0.34) # green PU round belt
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UHMW = (0.95, 0.95, 0.93)
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PNEU = (0.70, 0.72, 0.75)
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SERVO = (0.12, 0.12, 0.14)
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RED = (0.85, 0.10, 0.10)
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YELLOW = (0.95, 0.80, 0.10)
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GREEN = (0.15, 0.70, 0.25)
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AMBER = (0.98, 0.60, 0.10)
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PANEL = (0.06, 0.06, 0.07)
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CLEAR = (0.75, 0.85, 0.95)
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CABINET = (0.72, 0.73, 0.70)
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LASER = (1.0, 0.05, 0.05)
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for _d in list(App.listDocuments().values()):
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if _d.Name.startswith("InlineQCStation") or _d.FileName.replace("\\", "/").endswith("inline-qc-station.FCStd"):
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App.closeDocument(_d.Name)
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doc = App.newDocument("InlineQCStation")
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doc.Label = "CNX inline optical QC station (concept)"
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groups = {}
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def grp(name):
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if name not in groups:
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g = doc.addObject("App::DocumentObjectGroup", name)
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groups[name] = g
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return groups[name]
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def add(group, name, shape, color=ALU, transp=0):
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o = doc.addObject("Part::Feature", name)
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o.Shape = shape
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grp(group).addObject(o)
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if HAVE_GUI:
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vo = o.ViewObject
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vo.ShapeColor = color
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vo.Transparency = transp
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vo.LineColor = (0.25, 0.25, 0.25)
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return o
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def box(x0, y0, z0, x1, y1, z1):
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return Part.makeBox(x1 - x0, y1 - y0, z1 - z0, V(x0, y0, z0))
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def cyl(r, h, base, d=V(0, 0, 1)):
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return Part.makeCylinder(r, h, base, d)
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def prof(group, name, x0, y0, z0, x1, y1, z1):
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return add(group, name, box(x0, y0, z0, x1, y1, z1), ALU)
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def rot(shape, center, axis, deg):
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s = shape.copy()
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s.rotate(center, axis, deg)
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return s
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def ring(r_out, r_in, h, base):
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return cyl(r_out, h, base).cut(cyl(r_in, h + 2, base - V(0, 0, 1)))
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# ---------------------------------------------------------------- frame
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G = "Frame"
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for i, (x, y) in enumerate([(20, -YF), (20, YF), (XT0 + 20, -YF), (XT0 + 20, YF),
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(XT1 + 20, -YF), (XT1 + 20, YF), (L - 20, -YF), (L - 20, YF)]):
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add(G, f"Foot{i}", cyl(30, 12, V(x, y, 0)).fuse(cyl(8, 50, V(x, y, 12))), DARK)
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for s in (-1, 1):
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prof(G, f"BaseBeam{'F' if s < 0 else 'B'}", 0, s * YF - 20, 60, L, s * YF + 20, 140) # 40 x 80
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for x0, z1, nm in [(0, 870, "End0"), (XT0, 1500, "Tunnel0"), (XT1, 1500, "Tunnel1"),
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(L - P, 1080, "End1")]:
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prof(G, f"Upright{nm}{'F' if s < 0 else 'B'}", x0, s * YF - 20, 140, x0 + P, s * YF + 20, z1)
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prof(G, f"TopBeam{'F' if s < 0 else 'B'}", XT0, s * YF - 20, 1460, XT1 + P, s * YF + 20, 1500)
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prof(G, f"LowBeam{'F' if s < 0 else 'B'}", XT0 + P, s * YF - 20, 420, XT1, s * YF + 20, 460)
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prof(G, f"RejectBeam{'F' if s < 0 else 'B'}", XT1 + P, s * YF - 20, 1040, L - P, s * YF + 20, 1080)
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for x0, nm in [(0, "End0"), (XT0, "Tunnel0"), (XT1, "Tunnel1"), (L - P, "End1")]:
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prof(G, f"BaseCross{nm}", x0, -YF + 20, 100, x0 + P, YF - 20, 140)
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prof(G, f"ConvCross{nm}", x0, -YF + 20, 790, x0 + P, YF - 20, 830)
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# top bridge: label camera and top line-scan
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prof(G, "TopCrossLabel", X_LB - 20, -YF + 20, 1460, X_LB + 20, YF - 20, 1500)
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xt = sum(TOP_LINE) / 2
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prof(G, "TopCrossLineScan", xt - 20, -YF + 20, 1460, xt + 20, YF - 20, 1500)
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prof(G, "TopCrossThermal", XT0 + P, -YF + 20, 1460, XT0 + P + 40, YF - 20, 1500)
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prof(G, "TopCrossBacklight", sum(BOT_LINE) / 2 - 38, -YF + 20, 1460, sum(BOT_LINE) / 2 + 2, YF - 20, 1500)
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# lower bridge: bottom label camera, bottom line-scan, chuck lift
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xb = sum(BOT_LINE) / 2
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prof(G, "LowCrossLabel", X_LB - 20, -YF + 20, 420, X_LB + 20, YF - 20, 460)
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prof(G, "LowCrossLineScan", xb - 20, -YF + 20, 420, xb + 20, YF - 20, 460)
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prof(G, "LowCrossChuck", X_IS - 20, -YF + 20, 420, X_IS + 20, YF - 20, 460)
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prof(G, "RejectBridgeCross", X_RJ - 20, -YF + 20, 1040, X_RJ + 20, YF - 20, 1080)
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# ---------------------------------------------------------------- conveyor
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G = "Conveyor"
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for s in (-1, 1):
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side = "F" if s < 0 else "B"
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prof(G, f"Rail{side}", 0, s * 180 - 20, 830, L, s * 180 + 20, 870)
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add(G, f"BeltSlide{side}", box(30, s * Y_BELT - 5, 880, L - 30, s * Y_BELT + 5, 894), UHMW)
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add(G, f"BeltTop{side}", cyl(3, L - 40, V(20, s * Y_BELT, ZB - 3), V(1, 0, 0)), BELT)
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add(G, f"BeltReturn{side}", cyl(3, L - 40, V(20, s * Y_BELT, ZB - 49), V(1, 0, 0)), BELT)
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for x, nm in [(20, "Idler"), (L - 20, "Drive")]:
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add(G, f"Pulley{nm}{side}", cyl(23, 14, V(x, s * Y_BELT - 7, ZB - 26), V(0, 1, 0)), DARK)
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# infeed side guides with a flared mouth, PU strip on the rim height
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add(G, f"SideGuide{side}", box(110, s * 157 - 3, ZB + 2, XT0 - 10, s * 157 + 3, ZB + 14), UHMW)
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add(G, f"SideGuideFlare{side}", rot(box(40, s * 157 - 3, ZB + 2, 112, s * 157 + 3, ZB + 14),
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V(110, s * 157, ZB), V(0, 0, 1), s * 25), UHMW)
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add(G, f"GuidePost{side}", box(150, min(s * 160, s * 172), 870, 170, max(s * 160, s * 172), ZB + 14), DARK)
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add(G, "DriveShaft", cyl(6, 2 * Y_BELT + 60, V(L - 20, -Y_BELT - 30, ZB - 26), V(0, 1, 0)), DARK)
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add(G, "DriveGearmotor", cyl(35, 150, V(L - 20, 210, ZB - 26), V(0, 1, 0))
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.fuse(box(L - 60, 200, ZB - 70, L + 15, 230, ZB + 15)), SERVO)
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add(G, "EndStopBar", box(L - 30, -200, ZB + 30, L - 12, 200, ZB + 48), DARK)
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add(G, "EndStopBumper", box(L - 32, -40, ZB + 4, L - 26, 40, ZB + 30), (0.9, 0.5, 0.1))
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# presence sensors (diffuse, looking up through the open centre) and the stop beam
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G = "Sensors"
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for x, nm in [(X_IN, "Infeed"), (X_LB - 120, "LabelTrigger"), (L - 120, "Outfeed")]:
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add(G, f"Presence{nm}", box(x - 15, -120, 850, x + 15, -100, 885), (0.15, 0.35, 0.75))
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xs = X_IS + R_REC
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for s in (-1, 1):
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add(G, f"StopBeam{'Tx' if s < 0 else 'Rx'}", box(xs - 10, min(s * 200, s * 222), 870, xs + 10, max(s * 200, s * 222), ZB + 25),
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(0.15, 0.35, 0.75))
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add(G, "StopBeamRay", cyl(0.8, 400, V(xs, -200, ZB + 8), V(0, 1, 0)), LASER, 40)
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# ---------------------------------------------------------------- label gate
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G = "LabelGate"
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add(G, "LabelCamTop", box(X_LB - 15, -15, ZB + WD_LABEL + 50, X_LB + 15, 15, ZB + WD_LABEL + 92), CAM)
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add(G, "LabelLensTop", cyl(17, 50, V(X_LB, 0, ZB + WD_LABEL)), LENS)
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add(G, "LabelRingTop", ring(70, 42, 22, V(X_LB, 0, ZB + 170)), LIGHTBODY)
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add(G, "LabelRingTopFace", ring(62, 48, 1, V(X_LB, 0, ZB + 169)), LIGHT)
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add(G, "LabelCamTopPost", box(X_LB - 20, 40, ZB + WD_LABEL + 50, X_LB + 20, 80, 1460), ALU)
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add(G, "LabelCamTopPlate", box(X_LB - 20, 15, ZB + WD_LABEL + 50, X_LB + 20, 40, ZB + WD_LABEL + 92), DARK)
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zl = ZB - WD_LABEL
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add(G, "LabelCamBottom", box(X_LB - 15, -15, zl - 92, X_LB + 15, 15, zl - 50), CAM)
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add(G, "LabelLensBottom", cyl(17, 50, V(X_LB, 0, zl - 50)), LENS)
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add(G, "LabelRingBottom", ring(70, 42, 22, V(X_LB, 0, ZB - 80)), LIGHTBODY)
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add(G, "LabelRingBottomFace", ring(62, 48, 1, V(X_LB, 0, ZB - 58)), LIGHT)
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add(G, "LabelCamBottomPost", box(X_LB - 20, 40, 460, X_LB + 20, 80, zl - 50), ALU)
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add(G, "LabelCamBottomPlate", box(X_LB - 20, 15, zl - 92, X_LB + 20, 40, zl - 50), DARK)
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# ---------------------------------------------------------------- inspection: lift, clamp, one turn
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G = "Chuck"
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zp = ZL # pad top, lifted (shown lifted)
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add(G, "ChuckPad", cyl(40, 10, V(X_IS, 0, zp - 10)), (0.85, 0.45, 0.10))
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add(G, "ChuckMandrel", cyl(3.5, 9, V(X_IS, 0, zp)).fuse(Part.makeCone(3.5, 1.2, 4, V(X_IS, 0, zp + 9))), DARK)
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add(G, "SpindleHousing", cyl(25, 110, V(X_IS, 0, zp - 120)), PNEU)
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add(G, "LiftPlate", box(X_IS - 40, -40, zp - 132, X_IS + 40, 150, zp - 120), DARK)
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add(G, "SpindleServo", cyl(30, 110, V(X_IS, 110, zp - 242)), SERVO)
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add(G, "SpindleBeltCover", box(X_IS - 32, -32, zp - 120, X_IS + 32, 142, zp - 100), (0.3, 0.3, 0.32))
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add(G, "LiftCylinderRods", cyl(6, 100, V(X_IS - 30, 0, zp - 232)).fuse(cyl(6, 100, V(X_IS + 30, 0, zp - 232))), PNEU)
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add(G, "LiftCylinder", box(X_IS - 50, -25, zp - 322, X_IS + 50, 25, zp - 232), PNEU)
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add(G, "LiftPost", box(X_IS - 20, -20, 460, X_IS + 20, 20, zp - 322), ALU)
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G = "LineScanTop"
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zr = ZL + T_REC # top face of the lifted record
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add(G, "LineCamTop", box(xt - 31, -31, zr + WD_LINE + 60, xt + 31, 31, zr + WD_LINE + 105), CAM)
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add(G, "LineLensTop", cyl(25, 60, V(xt, 0, zr + WD_LINE)), LENS)
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add(G, "LineCamTopPost", box(xt - 20, 40, zr + 150, xt + 20, 80, 1460), ALU)
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add(G, "LightHangerTop", box(xt - 10, -112, zr + 130, xt + 10, 112, zr + 150), DARK)
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add(G, "CoaxHangerTop", box(xt - 10, 30, zr + 80, xt + 10, 40, zr + 130), DARK)
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add(G, "LineCamTopPlate", box(xt - 20, 31, zr + WD_LINE + 60, xt + 20, 40, zr + WD_LINE + 105), DARK)
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x0, x1 = TOP_LINE[0] - 5, TOP_LINE[1] + 5
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add(G, "CoaxLightTop", box(x0, -30, zr + 50, x1, 30, zr + 110), LIGHTBODY)
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add(G, "CoaxLightTopFace", box(x0 + 3, -26, zr + 49, x1 - 3, 26, zr + 50), LIGHT)
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for s in (-1, 1):
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b = box(x0, -15, 0, x1, 15, 30)
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b.translate(V(0, s * 100, zr + 15))
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add(G, f"DarkFieldTop{'F' if s < 0 else 'B'}", rot(b, V(0, s * 100, zr + 30), V(1, 0, 0), s * 20), LIGHTBODY)
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add(G, f"DarkFieldTopBracket{'F' if s < 0 else 'B'}", box(xt - 10, s * 100 - 5, zr + 48, xt + 10, s * 100 + 5, zr + 130), DARK)
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bx0, bx1 = BOT_LINE[0] - 5, BOT_LINE[1] + 5
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add(G, "BacklightForBottomCam", box(bx0, -20, zr + 30, bx1, 20, zr + 52), LIGHTBODY)
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add(G, "BacklightForBottomCamFace", box(bx0 + 3, -17, zr + 29, bx1 - 3, 17, zr + 30), LIGHT)
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add(G, "BacklightBracketTop", box(xb - 30, -5, zr + 52, xb - 10, 5, 1460), DARK)
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add(G, "ScanLineTop", box(TOP_LINE[0], -0.6, zr + 0.05, TOP_LINE[1], 0.6, zr + 0.5), LASER)
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add(G, "ThermalPost", box(XT0 + 90, -240, 1430, XT0 + 110, -220, 1460), DARK)
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add(G, "ThermalCam", rot(box(XT0 + 70, -260, 1380, XT0 + 130, -200, 1440), V(XT0 + 100, -230, 1410), V(1, 0, 0), -30), (0.95, 0.45, 0.10))
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G = "LineScanBottom"
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zu = ZL # underside of the lifted record
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add(G, "LineCamBottom", box(xb - 31, -31, zu - WD_LINE - 105, xb + 31, 31, zu - WD_LINE - 60), CAM)
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add(G, "LineLensBottom", cyl(25, 60, V(xb, 0, zu - WD_LINE - 60)), LENS)
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add(G, "LineCamBottomPost", box(xb - 20, 40, 460, xb + 20, 80, zu - WD_LINE - 60), ALU)
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add(G, "LineCamBottomPlate", box(xb - 20, 31, zu - WD_LINE - 105, xb + 20, 40, zu - WD_LINE - 60), DARK)
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add(G, "CoaxLightBottom", box(bx0, -30, ZB - 80, bx1, 30, ZB - 20), LIGHTBODY)
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add(G, "CoaxLightBottomFace", box(bx0 + 3, -26, ZB - 20, bx1 - 3, 26, ZB - 19), LIGHT)
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for s in (-1, 1):
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b = box(bx0, -15, 0, bx1, 15, 30)
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b.translate(V(0, s * 175, zu - 40))
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add(G, f"DarkFieldBottom{'F' if s < 0 else 'B'}", rot(b, V(0, s * 175, zu - 25), V(1, 0, 0), -s * 8), LIGHTBODY)
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add(G, f"DarkFieldBottomBracket{'F' if s < 0 else 'B'}", box(bx0 + 40, s * 192 - 5, 870, bx0 + 60, s * 192 + 5, zu - 35), DARK)
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add(G, "BacklightForTopCam", box(x0, -20, ZB - 40, x1, 20, ZB - 15), LIGHTBODY)
|
||||
add(G, "BacklightForTopCamFace", box(x0 + 3, -17, ZB - 15, x1 - 3, 17, ZB - 14), LIGHT)
|
||||
add(G, "ScanLineBottom", box(BOT_LINE[0], -0.6, zu - 0.5, BOT_LINE[1], 0.6, zu - 0.05), LASER)
|
||||
|
||||
G = "WarpLasers"
|
||||
for r in (90, 130):
|
||||
add(G, f"Laser_r{r}", box(X_IS - 23, -r - 10, ZB - 55, X_IS + 23, -r + 10, ZB - 15), (0.15, 0.35, 0.75))
|
||||
add(G, f"LaserBeam_r{r}", cyl(0.8, zu - (ZB - 15), V(X_IS, -r, ZB - 15)), LASER, 30)
|
||||
add(G, f"LaserBracket_r{r}", box(X_IS - 10, -r - 10, 830, X_IS + 10, -r + 10, ZB - 55), DARK)
|
||||
add(G, "LaserRail", box(X_IS - 20, -200, 810, X_IS + 20, -70, 830), ALU)
|
||||
|
||||
# ---------------------------------------------------------------- reject
|
||||
G = "Reject"
|
||||
add(G, "RodlessCylinder", box(X_RJ - 30, -300, 1000, X_RJ + 30, 300, 1040), PNEU)
|
||||
yc = -205 # carriage retracted at the front
|
||||
add(G, "PusherCarriage", box(X_RJ - 35, yc - 30, 960, X_RJ + 35, yc + 30, 1000), DARK)
|
||||
add(G, "PusherArm", box(X_RJ - 10, yc - 10, ZB + 26, X_RJ + 10, yc + 10, 960), DARK)
|
||||
add(G, "PusherPaddle", box(X_RJ - 100, yc + 10, ZB + 4, X_RJ + 100, yc + 22, ZB + 26), (0.9, 0.5, 0.1))
|
||||
CX0, CX1 = X_RJ - 170, X_RJ + 170
|
||||
chute = box(CX0, 0, 0, CX1, 360, 6)
|
||||
chute = rot(chute, V(0, 0, 0), V(1, 0, 0), -42)
|
||||
chute.translate(V(0, 165, ZB - 12))
|
||||
add(G, "RejectChute", chute, (0.55, 0.57, 0.60))
|
||||
for xw in (CX0 - 6, CX1):
|
||||
w = box(xw, 0, 0, xw + 6, 360, 80)
|
||||
w = rot(w, V(0, 0, 0), V(1, 0, 0), -42)
|
||||
w.translate(V(0, 165, ZB - 12))
|
||||
add(G, f"ChuteWall{xw}", w, (0.55, 0.57, 0.60))
|
||||
binb = box(CX0 - 20, 380, 0, CX1 + 20, 720, 560).cut(box(CX0 - 8, 392, 12, CX1 + 8, 708, 600))
|
||||
add(G, "RejectBin", binb, (0.85, 0.20, 0.15), 20)
|
||||
|
||||
# ---------------------------------------------------------------- enclosure (black, light-tight tunnel)
|
||||
G = "Enclosure"
|
||||
slot = box(XT0 - 10, -205, 860, XT1 + P + 10, 205, ZB + 30)
|
||||
for x, nm in [(XT0 - 3, "Infeed"), (XT1 + P, "Outfeed")]:
|
||||
up = box(x, -YF - 22, 870, x + 3, YF + 22, 1500).cut(slot)
|
||||
add(G, f"EndWallUpper{nm}", up, PANEL, 55)
|
||||
lo = box(x, -YF - 22, 140, x + 3, YF + 22, 870).cut(box(x - 1, -205, 815, x + 4, 205, 880))
|
||||
add(G, f"EndWallLower{nm}", lo, PANEL, 55)
|
||||
for s in (-1, 1):
|
||||
side = "Front" if s < 0 else "Back"
|
||||
y0 = s * (YF + 20) if s > 0 else -YF - 23
|
||||
add(G, f"Panel{side}Upper", box(XT0, y0, 870, XT1 + P, y0 + 3, 1500), PANEL, 55)
|
||||
add(G, f"Panel{side}Lower", box(XT0, y0, 140, XT1 + P, y0 + 3, 870), PANEL, 55)
|
||||
add(G, "PanelTop", box(XT0, -YF - 23, 1500, XT1 + P, YF + 23, 1503), PANEL, 55)
|
||||
add(G, "PanelBottom", box(XT0, -YF - 20, 140, XT1 + P, YF + 20, 143), PANEL, 55)
|
||||
add(G, "DoorHandle", box(700, -YF - 45, 1150, 860, -YF - 23, 1175), DARK)
|
||||
add(G, "GuardRejectFront", box(XT1 + P, -YF - 23, 870, L, -YF - 20, 1100), CLEAR, 75)
|
||||
add(G, "GuardRejectTop", box(XT1 + P, -YF - 23, 1100, L, YF + 23, 1103), CLEAR, 75)
|
||||
|
||||
# ---------------------------------------------------------------- electrical and operator
|
||||
G = "Electrical"
|
||||
add(G, "Cabinet", box(1180, -200, 160, 1640, 170, 770), CABINET)
|
||||
add(G, "CabinetHandle", box(1600, -215, 400, 1615, -200, 520), DARK)
|
||||
add(G, "StackLightPole", cyl(10, 120, V(XT1 + 20, -YF, 1503)), DARK)
|
||||
for i, c in enumerate([GREEN, AMBER, RED]):
|
||||
add(G, f"StackLight{i}", cyl(25, 55, V(XT1 + 20, -YF, 1623 + i * 57)), c)
|
||||
add(G, "HMIArm", box(XT1 + 50, -YF - 80, 1200, XT1 + 70, -YF - 20, 1220), DARK)
|
||||
add(G, "HMI", rot(box(XT1 + 70, -YF - 100, 1130, XT1 + 330, -YF - 80, 1300), V(XT1 + 200, -YF - 90, 1215), V(1, 0, 0), -15), (0.10, 0.10, 0.12))
|
||||
add(G, "EStopBox", box(XT1 + 60, -YF - 60, 930, XT1 + 140, -YF - 20, 1010), YELLOW)
|
||||
add(G, "EStop", cyl(22, 25, V(XT1 + 100, -YF - 60, 970), V(0, -1, 0)), RED)
|
||||
add(G, "ValveTerminal", box(XT0 + 80, YF + 25, 300, XT0 + 330, YF + 75, 380), PNEU)
|
||||
add(G, "FRL", box(XT0 + 360, YF + 25, 280, XT0 + 440, YF + 85, 420), (0.2, 0.4, 0.8))
|
||||
|
||||
# ---------------------------------------------------------------- records
|
||||
G = "Records"
|
||||
|
||||
|
||||
def record(name, x, y, z, label_color, body=BLACK, transp=0, tilt=None):
|
||||
disc = cyl(R_REC, T_REC, V(x, y, z)).cut(cyl(R_HOLE, T_REC + 2, V(x, y, z - 1)))
|
||||
lab = cyl(R_LABEL, 0.3, V(x, y, z + T_REC)).cut(cyl(R_HOLE, 2, V(x, y, z + T_REC - 0.5)))
|
||||
labb = cyl(R_LABEL, 0.3, V(x, y, z - 0.3)).cut(cyl(R_HOLE, 2, V(x, y, z - 1)))
|
||||
if tilt:
|
||||
c, ax, deg = tilt
|
||||
disc, lab, labb = rot(disc, c, ax, deg), rot(lab, c, ax, deg), rot(labb, c, ax, deg)
|
||||
add(G, name, disc, body, transp)
|
||||
add(G, name + "LabelA", lab, label_color)
|
||||
add(G, name + "LabelB", labb, label_color)
|
||||
|
||||
|
||||
record("RecordInfeed", X_IN, 0, ZB, (0.95, 0.85, 0.75), body=(0.80, 0.12, 0.16), transp=25) # translucent red special
|
||||
record("RecordInspection", X_IS, 0, ZL, (0.20, 0.45, 0.80))
|
||||
record("RecordOutfeed", X_OUT, 0, ZB, (0.95, 0.60, 0.15))
|
||||
import math
|
||||
sc, a = 230, math.radians(42)
|
||||
yr = 165 + math.cos(a) * sc + 6 * math.sin(a)
|
||||
zr2 = ZB - 12 - math.sin(a) * sc + 6 * math.cos(a)
|
||||
record("RecordReject", X_RJ, yr, zr2, (0.6, 0.6, 0.6), tilt=(V(X_RJ, yr, zr2), V(1, 0, 0), -42))
|
||||
|
||||
doc.recompute()
|
||||
doc.saveAs(OUT)
|
||||
n = len([o for o in doc.Objects if o.TypeId == "Part::Feature"])
|
||||
bb = None
|
||||
for o in doc.Objects:
|
||||
if o.TypeId == "Part::Feature":
|
||||
bb = o.Shape.BoundBox if bb is None else bb.united(o.Shape.BoundBox)
|
||||
print("objects", n, "bbox", round(bb.XMin), round(bb.XMax), round(bb.YMin), round(bb.YMax), round(bb.ZMin), round(bb.ZMax))
|
||||
print("saved", OUT)
|
||||
@@ -0,0 +1,34 @@
|
||||
group,item,qty,example,unit_usd_low,unit_usd_high,line_usd_low,line_usd_high,source
|
||||
Frame,"40x40 slot profile, cut to length",27 m (37 pieces),"8-slot 4040 (Misumi HFS8-4040 class, or Thai/Chinese generic)",11,21,297,567,per m; Shopee Thailand listing from THB 356; aluxprofile EUR 19 to 24 per m
|
||||
Frame,"40x80 slot profile, base beams",3.8 m (2 pieces),8-slot 4080,22,42,84,160,"per m; estimate, about twice the 4040 price"
|
||||
Frame,"Angle brackets, T-nuts, screws, end caps",1 lot (about 120 joints),,250,600,250,600,estimate
|
||||
Frame,Levelling feet M16,8,,8,25,64,200,each; estimate
|
||||
Enclosure,"Black panels, 4 mm ACM or PP, light-tight tunnel",4.3 m2,,25,60,108,258,per m2; estimate
|
||||
Enclosure,"Clear polycarbonate guard, reject zone",1.4 m2,,30,70,42,98,per m2; estimate
|
||||
Enclosure,"Door hinges, handle, safety door switch",1 lot,,120,350,120,350,estimate
|
||||
Conveyor,"PU round belt 6 mm, welded endless",2 x 3.8 m,,15,40,30,80,"each; PU round belt listings (RS, Amazon) plus welding"
|
||||
Conveyor,"Round-belt pulleys, shaft, bearings, UHMW slide strips, side guides",1 lot,,250,700,250,700,"pulleys USD 5 to 11 each (ServoCity, REV); rest estimate"
|
||||
Conveyor,"Conveyor drive: small gear motor with drive, or servo",1,,250,600,250,600,estimate
|
||||
Handling,"Guided lift cylinder, 20 mm bore, 75 mm stroke",1,SMC MGPM20-75,330,450,330,450,SMC MGPM20-30 USD 322 (Misumi US) to 390 (Motion); 75 mm stroke a little more
|
||||
Handling,Spindle servo 200 W with drive (encoder triggers the line-scans),1,Delta ASDA-B3 class,300,700,300,700,drive USD 119 to 200 (listings); motor and cable estimate
|
||||
Handling,"Spindle head: bearing housing, timing belt, label pad, pneumatic expanding mandrel",1,machined parts,600,1800,600,1800,estimate
|
||||
Handling,"Rodless cylinder 25 mm, 350 mm stroke, with paddle",1,SMC MY1B / CY3B class,400,900,400,900,estimate
|
||||
Handling,"Valve terminal, FRL, tubing, fittings",1 lot,,400,1000,400,1000,estimate
|
||||
Vision,"4k monochrome line-scan camera, GigE",2,Basler racer 2 r2L4096 / Hikrobot MV-CL042-91GM,857,1088,1714,2176,Basler web shop via price listing
|
||||
Vision,"Line-scan lens, 50 mm",2,,300,800,600,1600,estimate
|
||||
Vision,Coaxial line light,2,,295,446,590,892,made-in-china listing USD 295 to 349; Vision Datum USD 420; light186 from USD 446
|
||||
Vision,"Dark-field line light, about 150 mm",4,Vision Datum LiN+ class,250,400,1000,1600,Vision Datum LiN+ USD 380
|
||||
Vision,Diffuse line backlight,2,,200,400,400,800,estimate
|
||||
Vision,"Colour area camera, 8 MP, GigE",2,Basler ace 2 a2A2840-14gcPRO,1119,1119,2238,2238,Basler web shop via price listing
|
||||
Vision,Lens 16 mm,2,,150,400,300,800,estimate
|
||||
Vision,Ring light,2,,150,400,300,800,estimate
|
||||
Vision,Strobe and light controllers,2,,300,800,600,1600,estimate
|
||||
Sensors,"Laser distance sensor, 50 mm range",2,Micro-Epsilon optoNCDT 1420,520,1600,1040,3200,"list from EUR 470 (Micro-Epsilon); ILD1420-25 about USD 1,600 (Radwell)"
|
||||
Sensors,Photoelectric presence sensors and one through-beam,5,,50,150,250,750,each; estimate
|
||||
Sensors,"Thermal camera (option, not in the total)",0 (1 optional),Optris Xi 400,2100,3000,0,0,"from EUR 1,950 (Optris); USD 2,995 (moviTHERM)"
|
||||
Control,PLC for sequence and safety I/O,1,Mitsubishi FX5U-32MT or Delta class,500,1096,500,1096,"FX5U-32MT/ES USD 1,096 (Mitsubishi US shop); resale from about USD 470"
|
||||
Control,"Edge PC with GPU, 4 GigE PoE ports, NixOS",1,,1500,3200,1500,3200,"qscompute buying guides 2026: USD 1,490 to 3,200"
|
||||
Control,"HMI touch panel, 10 inch",1,,400,900,400,900,estimate
|
||||
Control,"Safety relay, e-stop, door interlock wiring",1 lot,,300,600,300,600,estimate
|
||||
Control,"Cabinet, power supply, breakers, terminals, wiring, stack light",1 lot,,800,2000,800,2000,estimate
|
||||
Total,"Hardware per station, thermal camera excluded",,,,,16056,32715,sum of the lines above
|
||||
|
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|
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@@ -0,0 +1,135 @@
|
||||
# Render the inline QC station views (run in the FreeCAD GUI after build_station.py).
|
||||
# exec(open(r"C:/dev/cnx_vinyl/docs/equipment/inline-qc-station/render_station.py", encoding="utf-8").read())
|
||||
# Detail views are rendered from a temporary document holding the model clipped
|
||||
# to a box (Part common), because coin clip planes did not reach the render here.
|
||||
import os
|
||||
import FreeCAD as App
|
||||
import FreeCADGui as Gui
|
||||
import Part
|
||||
|
||||
OUTDIR = r"C:/dev/cnx_vinyl/docs/equipment/inline-qc-station"
|
||||
doc = App.getDocument("InlineQCStation")
|
||||
|
||||
_vp = App.ParamGet("User parameter:BaseApp/Preferences/View")
|
||||
_navi_before = _vp.GetBool("ShowNaviCube", True)
|
||||
_vp.SetBool("ShowNaviCube", False)
|
||||
|
||||
|
||||
def prep(d):
|
||||
Gui.setActiveDocument(d.Name)
|
||||
v = Gui.getDocument(d.Name).ActiveView
|
||||
try:
|
||||
v.setCameraType("Orthographic")
|
||||
except Exception:
|
||||
pass
|
||||
for m in ("setNavigationCubeVisible", "setCornerCrossVisible"):
|
||||
if hasattr(v, m):
|
||||
getattr(v, m)(False)
|
||||
return v
|
||||
|
||||
|
||||
def members(group):
|
||||
g = doc.getObject(group)
|
||||
return list(g.Group) if g else []
|
||||
|
||||
|
||||
def show_all():
|
||||
for o in doc.Objects:
|
||||
if o.TypeId == "Part::Feature":
|
||||
o.ViewObject.Visibility = True
|
||||
|
||||
|
||||
def hide(groups=(), names=()):
|
||||
for gname in groups:
|
||||
for o in members(gname):
|
||||
o.ViewObject.Visibility = False
|
||||
for n in names:
|
||||
o = doc.getObject(n)
|
||||
if o:
|
||||
o.ViewObject.Visibility = False
|
||||
|
||||
|
||||
def shoot(v, fname, orient, w=3200, h=2400):
|
||||
getattr(v, orient)()
|
||||
v.fitAll()
|
||||
Gui.updateGui()
|
||||
path = os.path.join(OUTDIR, fname)
|
||||
v.saveImage(path, w, h, "White")
|
||||
print("saved", path)
|
||||
|
||||
|
||||
def clipped_doc(name, clipbox, skip_groups=()):
|
||||
skip = set()
|
||||
for gname in skip_groups:
|
||||
skip.update(o.Name for o in members(gname))
|
||||
d = App.newDocument(name)
|
||||
for o in doc.Objects:
|
||||
if o.TypeId != "Part::Feature" or o.Name in skip:
|
||||
continue
|
||||
s = o.Shape.common(clipbox)
|
||||
if s.isNull() or s.Volume < 1e-3:
|
||||
continue
|
||||
n = d.addObject("Part::Feature", o.Name)
|
||||
n.Shape = s
|
||||
n.ViewObject.ShapeColor = o.ViewObject.ShapeColor
|
||||
n.ViewObject.Transparency = o.ViewObject.Transparency
|
||||
n.ViewObject.LineColor = o.ViewObject.LineColor
|
||||
d.recompute()
|
||||
return d
|
||||
|
||||
|
||||
view = prep(doc)
|
||||
enclosure_tops = ["PanelTop", "PanelFrontUpper", "PanelFrontLower", "GuardRejectFront", "GuardRejectTop", "DoorHandle"]
|
||||
|
||||
# 1 open iso: front panels and lid off, the rest of the enclosure translucent
|
||||
show_all()
|
||||
hide(names=enclosure_tops)
|
||||
shoot(view, "inline-qc-station-iso.png", "viewIsometric")
|
||||
|
||||
# 2 closed iso: as it stands in the hall
|
||||
show_all()
|
||||
for o in members("Enclosure"):
|
||||
o.ViewObject.Transparency = 15 if o.Name not in ("GuardRejectFront", "GuardRejectTop") else 70
|
||||
shoot(view, "inline-qc-station-closed.png", "viewIsometric")
|
||||
for o in members("Enclosure"):
|
||||
o.ViewObject.Transparency = 55 if o.Name not in ("GuardRejectFront", "GuardRejectTop") else 75
|
||||
|
||||
# 3 front elevation without the front panels
|
||||
show_all()
|
||||
hide(names=enclosure_tops)
|
||||
shoot(view, "inline-qc-station-front.png", "viewFront")
|
||||
|
||||
# 4 plan view without the lid and the top bridge
|
||||
show_all()
|
||||
hide(names=enclosure_tops + ["TopBeamF", "TopBeamB", "TopCrossLabel", "TopCrossLineScan", "TopCrossThermal",
|
||||
"TopCrossBacklight", "RejectBridgeCross", "RodlessCylinder", "PusherCarriage",
|
||||
"LabelCamTop", "LabelCamTopPost", "LabelCamTopPlate", "LineCamTop", "LineCamTopPost",
|
||||
"LineCamTopPlate", "LightHangerTop", "CoaxHangerTop", "CoaxLightTop", "CoaxLightTopFace",
|
||||
"BacklightForBottomCam", "BacklightForBottomCamFace", "BacklightBracketTop",
|
||||
"LabelRingTop", "LabelRingTopFace", "ThermalCam", "ThermalPost",
|
||||
"DarkFieldTopF", "DarkFieldTopB", "DarkFieldTopBracketF", "DarkFieldTopBracketB",
|
||||
"StackLight0", "StackLight1", "StackLight2", "StackLightPole", "HMI", "HMIArm"])
|
||||
shoot(view, "inline-qc-station-top.png", "viewTop")
|
||||
show_all()
|
||||
hide(names=enclosure_tops)
|
||||
view.viewIsometric()
|
||||
view.fitAll()
|
||||
doc.save()
|
||||
|
||||
# 5 inspection elevation: x 600..1120, everything in front of y = -150 cut away
|
||||
d5 = clipped_doc("QCDetailFront", Part.makeBox(520, 500, 1100, App.Vector(600, -150, 400)),
|
||||
skip_groups=("Enclosure", "Electrical", "Reject"))
|
||||
v5 = prep(d5)
|
||||
shoot(v5, "inline-qc-station-detail-front.png", "viewFront", w=2400, h=2400)
|
||||
App.closeDocument(d5.Name)
|
||||
|
||||
# 6 inspection zone, 3/4 view: x 600..1120, z 400..1500
|
||||
d6 = clipped_doc("QCDetailIso", Part.makeBox(520, 700, 1100, App.Vector(600, -350, 400)),
|
||||
skip_groups=("Enclosure", "Electrical", "Reject"))
|
||||
v6 = prep(d6)
|
||||
shoot(v6, "inline-qc-station-detail.png", "viewIsometric", w=2400, h=2400)
|
||||
App.closeDocument(d6.Name)
|
||||
|
||||
Gui.setActiveDocument(doc.Name)
|
||||
_vp.SetBool("ShowNaviCube", _navi_before)
|
||||
print("done")
|
||||
Reference in new issue
Block a user