Optical QC: one station for both presses, after the cooling racks
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User, 18 Oct 2026: for now one QC station for both machines; let the
records cool in a queue before testing them.

- inline-optical-qc.md "Where it sits": launch setup. Spindle stacks
  from the Duplex system and the Classic, labelled at the press (press,
  stamper set, first and last cycle), cool in FIFO racks (24 h accepted
  practice, 8 h at the shortest, Stamper Discs; about one day of output,
  2,800 to 3,100 records); the finishing operator feeds the station from
  the cooled stacks. Gains: warp and centring measured on settled records
  (the release value), one station instead of two, no Classic unloader
  change, no warm-record sag or thermal camera. Cost: defects found hours
  later, covered by the Duplex operator, per-cycle telemetry and an early
  lane for the first records of each run and after stamper changes.
  Record key from the stack label and stack position, checked against the
  run-out stamper number. Capacity 10 to 12 a minute against 5 to 6:
  one station to about two Duplex systems and two Classics. A station at
  each press stays the later option. Cost table, open points, infeed row,
  thermal camera note and the Newbilt question follow.
- Fleet calculator: the per-press stations and the release station are
  gone; the finishing block shows the cooling racks with record stacks
  and the one optical station by the corridor glass; tooltips, corridor
  and conveyor texts; machine park back to its legend, finishing box
  "cooling, QC, packing".
- quality-automation.md layer 1, digital-factory.md QC row,
  process-flow.md stage 6, site-candidates.md block ground floor,
  crane-workshop-tours.md tour stop 6.
- Investor render: infeed label "the operator sets each cooled record
  down".

Checks: node --check; pw_bp_calc.py 0 fails; pw_iso_view_check.py OK;
info for every data-id at all presets, levels and rotations; GF nodes
2,414 at the full preset; zoomed shots in two rotations.
This commit is contained in:
grabowski committed 2026-10-18 15:18:00 +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 (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 |
| Optical inspection of every record (at launch one station after the cooling racks, fed from labelled spindle stacks; PC-based GenICam station or Keyence/Cognex class, custom integration; devices and setup 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 |