Optical QC: sensor list

User, 18 Oct 2026: list the sensors the optical QC station uses.

- inline-optical-qc.md: sensor table in the station setup (4 cameras,
  2 warp lasers, spindle encoder, 3 presence sensors and a through-beam,
  6 cylinder position switches, door switch; thermal camera option and
  laser line profiler alternative), with where each sits, what it
  measures and the price signal.
- BOM: cylinder position switches were missing (6, SMC D-M9 class,
  USD 25 to 60 each, estimate). Total now USD 16,264 to 33,184, still
  16k to 33k; THB 0.54M to 1.10M.

docs/equipment/inline-optical-qc.md

@@ -228,6 +228,28 @@ belt crosses that line:
   sense at a press-side station; cooled records show no temperature
   pattern, so the launch setup leaves it out.
 
+**Sensor list.** Everything that measures the record, and everything the
+PLC needs to run the station. Lights, drives and cylinders are in the
+[bill of materials](inline-qc-station/inline-qc-station-bom.csv).
+
+| Sensor | Qty | Example | Where | What it measures | USD each |
+|---|---|---|---|---|---|
+| 4k monochrome line-scan camera, GigE, 50 mm lens | 2: top and bottom | Basler racer 2 r2L4096, Hikrobot MV-CL042-91GM | inspection zone, on opposite radii (top 330 mm above the record) | surface: non-fill, stitching, flow lines, specks, bubbles, under dark-field, bright-field and transmitted light on alternate lines; eccentricity from the groove spiral | 857 to 1,088 (Basler web shop); lens 300 to 800 (estimate) |
+| 8 MP colour area camera, GigE, 16 mm lens, ring light | 2: top and bottom | Basler ace 2 a2A2840-14gcPRO | label gate, 520 mm from the infeed | right label on the right side, print, label centring; the top camera also reads the stamper number in the run-out | 1,119 (Basler web shop); lens and ring light 300 to 800 (estimate) |
+| Laser distance sensor | 2 | Micro-Epsilon optoNCDT 1420 | under the record, at 90 and 130 mm radius | warp: height traced round two circles during the turn | from EUR 470 list; ILD1420-25 about 1,600 at a reseller |
+| Encoder of the 200 W spindle servo | 1 | Delta ASDA-B3 class | spindle drive | angle of the turn; clocks both line-scans and the lasers | in the servo, 300 to 700 (estimate) |
+| Diffuse photoelectric sensor | 3 | any industrial make | looking up through the open centre: infeed, label trigger, outfeed | a record at the infeed starts the cycle; the trigger fires the label cameras; a full outfeed holds the next record | 50 to 150 (estimate) |
+| Through-beam photoelectric sensor | 1 pair | any industrial make | across the conveyor at the inspection position | the record's leading edge; stops the belts over the chuck | 50 to 150 (estimate) |
+| Cylinder position switch | 6 | SMC D-M9 class | lift (up, down), reject pusher (home, out), mandrel (open, clamped) | confirms each move before the next step | 25 to 60 (estimate) |
+| Safety door switch | 1 | any safety-rated make | tunnel door | stops the station when the door opens, through the safety relay with the e-stop | in the door lot, 120 to 350 (estimate) |
+| Thermal camera (option, not in the launch setup) | 0 or 1 | Optris Xi 400 | over the unload position, at a press-side station only | temperature map of a warm record, trended against warp | from EUR 1,950 |
+| Laser line profiler (alternative to the two lasers) | 0 or 1 | Keyence LJ-X8000, LMI Gocator 2500, Micro-Epsilon scanCONTROL | across the radius | full height and thickness map | 8k to 20k (estimate) |
+
+So the launch station carries four cameras, two lasers, the servo
+encoder, four photoelectric sensors, six cylinder switches and the door
+switch. The cameras and lasers go to the edge PC; the rest goes to the
+PLC.
+
 **Cycle per record (estimate).**
 
 | Step | Time |
@@ -270,9 +292,9 @@ By group, per station:
 | Conveyor | 0.5k to 1.4k | round belts, pulleys, slide strips, drive |
 | Handling | 2.0k to 4.9k | guided lift cylinder, 200 W spindle servo, spindle head with mandrel, rodless cylinder, pneumatics |
 | Vision | 7.7k to 12.5k | 2 line-scans, 2 colour cameras, lenses, 2 coaxial, 4 dark-field and 2 backlights, 2 ring lights, controllers |
-| Sensors | 1.3k to 4.0k | 2 laser distance sensors, presence and stop sensors |
+| Sensors | 1.4k to 4.3k | 2 laser distance sensors, presence and stop sensors, cylinder switches |
 | Control | 3.5k to 7.8k | PLC, edge PC with GPU, HMI, safety, cabinet and wiring |
-| **Total** | **16k to 33k (0.53M to 1.08M THB)** | thermal camera (USD 2.1k to 3.0k) not included |
+| **Total** | **16k to 33k (0.54M to 1.10M THB)** | thermal camera (USD 2.1k to 3.0k) not included |
 
 **Open points for the machine builder.**
 
@@ -400,7 +422,7 @@ simulated.
 
 | Item | Estimate |
 |---|---|
-| Hardware per station, from the [bill of materials](inline-qc-station/inline-qc-station-bom.csv) | USD 16k to 33k (0.53M to 1.08M THB) |
+| Hardware per station, from the [bill of materials](inline-qc-station/inline-qc-station-bom.csv) | USD 16k to 33k (0.54M to 1.10M THB) |
 | First station: frame build and machined parts, lighting trials, software, training data | 2 to 4 person-months, USD 15k to 40k (our own team with a local machine builder) |
 | Launch plant: one station for both presses, after cooling | the hardware above, USD 16k to 33k, plus the first-station work (about USD 31k to 73k in all, 1.0M to 2.4M THB) |
 

docs/equipment/inline-qc-station/inline-qc-station-bom.csv

@@ -25,10 +25,11 @@ 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,"Cylinder position switches (lift up/down, pusher home/out, mandrel open/clamped)",6,SMC D-M9 class,25,60,150,360,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",,,,,16114,32824,sum of the lines above
+Total,"Hardware per station, thermal camera excluded",,,,,16264,33184,sum of the lines above