diff --git a/docs/equipment/inline-optical-qc.md b/docs/equipment/inline-optical-qc.md index ab32f87..c27ef37 100644 --- a/docs/equipment/inline-optical-qc.md +++ b/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) | diff --git a/docs/equipment/inline-qc-station/inline-qc-station-bom.csv b/docs/equipment/inline-qc-station/inline-qc-station-bom.csv index e2f9def..ee08186 100644 --- a/docs/equipment/inline-qc-station/inline-qc-station-bom.csv +++ b/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