From c939ba1fbba6d1475b6d0a5e6732f46caeacb63a Mon Sep 17 00:00:00 2001 From: grabowski Date: Mon, 19 Oct 2026 10:54:31 +0700 Subject: [PATCH] Optical QC control: QiTech Control library and shop User, 19 Oct 2026: check github.com/qitechgmbh/control and shop.qitech.de/collections/ethercat. - QiTech Control (LGPL-3.0, Rust on an EtherCrab fork, NixOS, runs QiTech's own machines): plan now uses its EtherCAT library qitech_lib, pinned, as the layer under our station service; not the full Electron app. It has DC SYNC0, SDO/PDO handling, EK1100/EL2809/EL3021/EL3024 drivers and a CiA402 MINAS A6 servo driver to copy for the A6-EC. Drivers to write: EK1101, EL1809, EL3152, EL5101, A6-EC (upstream). Kernel: start from QiTech's tested settings (6.18, preempt=full, isolcpus 2,3); 6.12 PREEMPT_RT stays the fallback for IgH. - QiTech shop (new Beckhoff stock from an insolvency, ships worldwide): EK1101 EUR 85.13, EL1809 EUR 16.53, EL2809 EUR 41.03, EL9011 EUR 1.76 replace the geizhals offers, EUR 207.57 less. TwinSAFE and Beckhoff STO servo terminals noted, not taken. - EtherCAT parts EUR 1,684 to 1,897 + 2 servo kits (THB 72k to 80k); bench parts about THB 56k; spare coupler/DI/DO now stocked. - BOM total USD 16,671 to 32,681 (THB 0.55M to 1.08M). --- README.md | 5 +- docs/equipment/inline-optical-qc.md | 32 ++-- docs/equipment/inline-qc-control-plan.md | 152 +++++++++++++----- .../inline-qc-station-bom.csv | 12 +- 4 files changed, 138 insertions(+), 63 deletions(-) diff --git a/README.md b/README.md index e4e50ad..05d8700 100644 --- a/README.md +++ b/README.md @@ -189,8 +189,9 @@ The detail lives in dedicated documents: rim-belt conveyor, chuck, sensors) with a sourced bill of materials - [QC station control plan](docs/equipment/inline-qc-control-plan.md): EtherCAT with two 100 W servo kits, Beckhoff I/O and an N100 mini PC - running an open-source master on NixOS; bus layout, I/O list, - geizhals.de prices, safety circuit, bench test and build order + running QiTech's open-source EtherCAT library on NixOS; bus layout, I/O + list, geizhals.de and QiTech shop prices, safety circuit, bench test and + build order - [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 diff --git a/docs/equipment/inline-optical-qc.md b/docs/equipment/inline-optical-qc.md index 2365e9a..a9c1791 100644 --- a/docs/equipment/inline-optical-qc.md +++ b/docs/equipment/inline-optical-qc.md @@ -326,17 +326,22 @@ prices, safety circuit, bench test and build order, is in EtherCAT master and runs the station sequence, which we write ourselves; there is no PLC. - **Master software,** open source either way: - - **EtherCrab:** a pure Rust master (MIT or Apache-2.0) with - distributed clocks, CoE and basic CiA402 drive support - ([GitHub](https://github.com/ethercrab-rs/ethercrab)). It fits the Rust - stack of the factory application, and is the first choice. + - **QiTech's EtherCAT library on EtherCrab:** + [qitech_lib](https://github.com/qitechgmbh/qitech_lib) (LGPL-3.0), + the layer under [QiTech Control](https://github.com/qitechgmbh/control), + which runs QiTech's own extrusion and winding machines on NixOS. It + brings distributed clocks, SDO and PDO handling, Beckhoff drivers and + a CiA402 servo driver to copy for the A6-EC; EtherCrab + ([GitHub](https://github.com/ethercrab-rs/ethercrab), MIT or + Apache-2.0) is the pure Rust master underneath. It fits the Rust stack + of the factory application, and is the first choice. - **IgH EtherCAT Master:** the mature fallback (GPL-2.0, its library LGPL-2.1), packaged in nixpkgs ([MyNixOS](https://mynixos.com/nixpkgs/package/linuxKernel.packages.linux_6_18.ethercat)). Its native igc driver for the i226 is listed for the 6.12 kernel, so with IgH, pin the 6.12 LTS kernel ([IgH device drivers](https://docs.etherlab.org/ethercat/1.6/doxygen/devicedrivers.html)). -- **On the bus, in one line:** an EK1100 coupler with EL1809 (16 +- **On the bus, in one line:** an EK1101 coupler with EL1809 (16 inputs: photoelectric sensors, cylinder switches, door and e-stop status), EL2809 (16 outputs: valves, stack light), EL3152 (two 4 to 20 mA inputs for the warp lasers) and EL5101 (spindle encoder), then @@ -383,8 +388,8 @@ By group, per station: | Handling | 1.9k to 4.5k | guided lift cylinder, 100 W EtherCAT 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 | 1.5k to 4.6k | 2 laser distance sensors, presence and stop sensors, cylinder switches, spindle encoder | -| Control | 4.4k to 8.1k | EtherCAT controller and I/O, edge PC with GPU, HMI, safety, cabinet and wiring | -| **Total** | **17k to 33k (0.56M to 1.09M THB)** | thermal camera (USD 2.1k to 3.0k) not included | +| Control | 4.2k to 7.7k | EtherCAT controller and I/O, edge PC with GPU, HMI, safety, cabinet and wiring | +| **Total** | **17k to 33k (0.55M to 1.08M THB)** | thermal camera (USD 2.1k to 3.0k) not included | **Open points for the machine builder.** @@ -512,9 +517,9 @@ simulated. | Item | Estimate | |---|---| -| Hardware per station, from the [bill of materials](inline-qc-station/inline-qc-station-bom.csv) | USD 17k to 33k (0.56M to 1.09M THB) | +| Hardware per station, from the [bill of materials](inline-qc-station/inline-qc-station-bom.csv) | USD 17k to 33k (0.55M to 1.08M 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 17k to 33k, plus the first-station work (about USD 32k to 73k in all, 1.1M to 2.4M THB) | +| Launch plant: one station for both presses, after cooling | the hardware above, USD 17k to 33k, plus the first-station work (about USD 32k to 73k in all, 1.0M to 2.4M THB) | All three figures are estimates; the bill of materials names a source for each priced line. They fit inside the existing metrology launch-tier line, USD 170k to 460k for XRF, inline vision and the audio @@ -547,11 +552,12 @@ vision share is not yet confirmed. 4. **Warp sensors.** Choose between two point lasers and a line profiler once the trials show whether a thickness map is worth the extra cost. 5. **EtherCAT bench.** Before the frame is built, run one A6-EC kit, the - EK1100 with its terminals and the spindle encoder from the mini PC - with EtherCrab: eight tests and pass marks are in the + EK1101 with its terminals and the spindle encoder from the mini PC + with qitech_lib on EtherCrab: eight tests and pass marks are in the [control plan](inline-qc-control-plan.md#7-bench-test-before-the-frame-is-built) - (about THB 64,000 of parts, all reused in the station). If EtherCrab - falls short on the drive, repeat the test with the IgH master. + (about THB 56,000 of parts, all reused in the station). If the + EtherCrab stack falls short on the drive, repeat the test with the + IgH master. 6. **Acceptance test.** Write it before ordering. It should cover the detection rate per defect class on the trial set, the false-reject rate on good records (black and specials apart), and every result diff --git a/docs/equipment/inline-qc-control-plan.md b/docs/equipment/inline-qc-control-plan.md index c48bf73..eb7501b 100644 --- a/docs/equipment/inline-qc-control-plan.md +++ b/docs/equipment/inline-qc-control-plan.md @@ -3,8 +3,10 @@ How the [inline optical QC station](inline-optical-qc.md) is controlled, wired, priced, built and tested. Decided in October 2026: EtherCAT, no PLC, and the 100 W StepperOnline servo kit on both axes. Prices for the -EtherCAT parts were checked on [geizhals.de](https://geizhals.de/) on -19 October 2026. The station hardware itself (frame, cameras, lights, +EtherCAT parts were checked on [geizhals.de](https://geizhals.de/) and in +the [QiTech shop](https://shop.qitech.de/collections/ethercat) on +19 October 2026; the station software builds on QiTech's open-source +EtherCAT library (section 5). The station hardware itself (frame, cameras, lights, lasers) is in the station doc and its [bill of materials](inline-qc-station/inline-qc-station-bom.csv). @@ -16,7 +18,7 @@ lasers) is in the station doc and its | Spindle drive | StepperOnline A6-EC100L2A1-M17 (100 W, A6-200EC drive), cyclic synchronous position, 1:6 timing belt | torque need about 0.02 N·m at the motor against 0.32 N·m rated; the belt brings the load inertia to about 28 times the rotor (station doc) | | Conveyor drive | the same kit, cyclic synchronous velocity | one spare covers both axes | | Controller | fanless Intel N100 mini PC with Intel i226-V ports, NixOS with a real-time kernel | open source stack, declared in the plant's clan like every other machine | -| Master software | EtherCrab (Rust, MIT or Apache-2.0); IgH EtherCAT Master as the fallback | EtherCrab fits the Rust factory application; IgH is older and proven | +| Master software | QiTech's EtherCAT library (qitech_lib, LGPL-3.0) on EtherCrab; IgH EtherCAT Master as the fallback | Rust like the factory application, already running QiTech's own production machines, with distributed clocks and a servo driver to copy; IgH is older and proven | | Camera clock | separate RS-422 encoder on the spindle shaft | the A6-EC drive has no divided encoder output | | Safety | hardwired: safety relay, two contactors in the drive supply | the 100 W kit has no STO; the 400 W STO kit's manual names no safety rating (station doc) | @@ -25,7 +27,7 @@ lasers) is in the station doc and its ``` Station controller (N100, NixOS, real-time kernel) | - |-- port 1 (i226-V) == EtherCAT ==> EK1100 coupler + |-- port 1 (i226-V) == EtherCAT ==> EK1101 coupler | |-- EL1809 16 digital inputs | |-- EL2809 16 digital outputs | |-- EL3152 2 analog inputs (warp lasers, 4 to 20 mA) @@ -58,7 +60,7 @@ Spindle encoder (RS-422, 5 V from the EL5101) whether the EL5101 input already is. - **Port 2 is ordinary Ethernet** to the edge PC and the plant's OT network (VLAN as in [digital factory](../digital-factory.md)). The - EtherCAT port is a point-to-point cable to the EK1100, never a switch. + EtherCAT port is a point-to-point cable to the EK1101, never a switch. ## 3. Signals @@ -107,20 +109,21 @@ both drives can share one mapping and differ only in the mode (8 for CSP, 9 for CSV). The drive runs only in DC sync mode; its SYNC0 period range depends on the mode, so the 1 ms cycle is the first bench check. -## 4. Prices from geizhals.de +## 4. Prices from geizhals.de and the QiTech shop -Lowest listed price on 19 October 2026, in EUR including 19% German VAT; -THB at 38.115 per EUR. +Lowest price on 19 October 2026, in EUR including 19% German VAT; THB at +38.115 per EUR. Four terminals come from the QiTech shop (section 5), +the rest from the lowest geizhals.de offer. | Part | Qty | Example | EUR | THB | Source | |---|---|---|---|---|---| | Station controller | 1 | ANDAQI RS55 (6 × i226-V) / MNBOXCONET P2-N100 (2 × i226-V, fanless) | 393.99 to 455.99 | 15,017 to 17,380 | [geizhals](https://geizhals.de/mini-pc-barebone-netzwerk-pc-intel-n100-a2926989.html) | -| EtherCAT coupler | 1 | Beckhoff EK1100 | 150.75 | 5,746 | [geizhals](https://geizhals.de/144468496) | -| 16 digital inputs | 1 | Beckhoff EL1809 | 93.97 | 3,582 | [geizhals](https://geizhals.de/1371087148) | -| 16 digital outputs | 1 | Beckhoff EL2809 | 102.97 | 3,925 | [geizhals](https://geizhals.de/1371087504) | +| EtherCAT coupler | 1 | Beckhoff EK1101 (EK1100 with an ID switch) | 85.13 | 3,245 | [QiTech shop](https://shop.qitech.de/products/beckhoff-ek1101), 148 in stock | +| 16 digital inputs | 1 | Beckhoff EL1809 | 16.53 | 630 | [QiTech shop](https://shop.qitech.de/products/beckhoff-el1809), 157 in stock | +| 16 digital outputs | 1 | Beckhoff EL2809 | 41.03 | 1,564 | [QiTech shop](https://shop.qitech.de/products/beckhoff-el2809), 104 in stock | | 2 analog inputs, 4 to 20 mA | 1 | Beckhoff EL3152 | 208.90 | 7,962 | [geizhals](https://geizhals.de/185886294) | | Encoder interface, RS-422 | 1 | Beckhoff EL5101 | 291.04 | 11,093 | [geizhals](https://geizhals.de/2974477757) | -| End cap | 1 | Beckhoff EL9011 | 4.33 | 165 | [geizhals](https://geizhals.de/455904583) | +| End cap | 1 | Beckhoff EL9011 | 1.76 | 67 | [QiTech shop](https://shop.qitech.de/products/beckhoff-el9011), 131 in stock | | Spindle encoder | 1 | E6B2-CWZ1X 2000 P/R (marketplace) / GHH60 2500 P/R line driver | 45.52 to 187.83 | 1,735 to 7,159 | [geizhals](https://geizhals.de/6925000400) | | Safety relay | 1 | Pilz PNOZ s3 750103 | 148.38 | 5,656 | [geizhals](https://geizhals.de/pilz-pnoz-s3-24vdc-2-n-o-750103-a3204143.html) | | Contactor, 24 V DC coil | 2 | Siemens 3RT2015 | 27.95 each | 2,131 | [geizhals](https://geizhals.de/siemens-leistungsschuetz-3rt2015-1bb41-a3269085.html) | @@ -128,7 +131,7 @@ THB at 38.115 per EUR. | HMI touch monitor 10.1 inch | 1 | iiyama ProLite TF1015MC-B3 | 311.90 | 11,888 | [geizhals](https://geizhals.de/iiyama-prolite-tf1015mc-b3-a3228748.html) | | 24 V supply, 120 W | 1 | Mean Well SDR-120-24 | 38.87 to 47.35 | 1,482 to 1,805 | [geizhals](https://geizhals.de/980542712) | | Servo kit 100 W, EtherCAT | 2 | StepperOnline A6-EC100L2A1-M17 | USD 123.29 each | 8,137 | not on geizhals; [StepperOnline](https://www.omc-stepperonline.com/a6-series-100w-ethercat-ac-servo-motor-kit-3000rpm-0-32nm-17-bit-absolute-encoder-ip67-a6-ec100l2a1-m17), China warehouse | -| **Total** | | | **1,891.60 to 2,104.39 + USD 246.58** | **80,235 to 88,346** | | +| **Total** | | | **1,684.03 to 1,896.82 + USD 246.58** | **72,324 to 80,434** | | Notes on the prices: @@ -137,8 +140,14 @@ Notes on the prices: (7%) and duty are added. The listed gross price is therefore used as the landed low end; the bill of materials adds 30% for shipping and a Thai distributor as the high end (estimate). -- **EK1100:** geizhals has no current offer; EUR 150.75 is the last - price, with EUR 255.43 at the top of the range. +- **QiTech shop:** Beckhoff terminals new in the original box, bought + out of an insolvency, at a fraction of the usual price: EL1809 + EUR 16.53 against EUR 93.97 on geizhals, EL2809 EUR 41.03 against + EUR 102.97, EK1101 EUR 85.13 against EUR 150.75 for an EK1100 (no + current geizhals offer). Together EUR 207.57 (THB 7,912) less. The shop + ships worldwide by DHL from Darmstadt in 7 to 14 working days; the + postage to Thailand only shows at checkout (not checked). It has no + EL3152 or EL5101, so those two stay with geizhals. - **Mini PCs** on geizhals are marketplace brands (ANDAQI, MNBOXCONET, AIOPCWA). Before ordering, check that the ports are i226-V (not the older i225) and that the BIOS lets C-states be switched off. @@ -152,31 +161,87 @@ Notes on the prices: - **Not on geizhals:** the servo kits (StepperOnline direct), the optoNCDT lasers and the Basler cameras (both in the station bill of materials). -Bill of materials effect: the control group comes to USD 4.4k to 8.1k +Bill of materials effect: the control group comes to USD 4.2k to 7.7k (edge PC with GPU and the cabinet lot included) and the station to -**USD 16.9k to 33.1k (THB 0.56M to 1.09M)**, up from 16.1k to 32.9k, -mostly the EL5101 and the retail price of the mini PC. +**USD 16.7k to 32.7k (THB 0.55M to 1.08M)**. ## 5. Software on the station controller +**QiTech Control, checked 19 October 2026.** QiTech, a machine builder in +Darmstadt (filament extrusion and winding), publishes the control +software of its own machines: +[QiTech Control](https://github.com/qitechgmbh/control), LGPL-3.0, 359 +stars, 2,855 commits since January 2025, last push 16 October 2026, +running more than ten of their production machines (their README). It is +a Rust server on EtherCrab (their fork `ethercrab-dc`) with axum and +Socket.IO, an Electron and React front end, and a NixOS image with a +tuned kernel. The EtherCAT layer is a separate library, +[qitech_lib](https://github.com/qitechgmbh/qitech_lib), also LGPL-3.0. + +What fits: + +- The same choices as this plan: Rust, EtherCrab, NixOS, Beckhoff + terminals, no PLC. +- Distributed clocks are built in (SYNC0 at 1 ms with a 500 µs shift by + default), with SDO access, PDO mapping and the EtherCAT state changes. +- Drivers exist for the EK1100 and the EL2809 of our list, and for 4 to + 20 mA inputs (EL3021, EL3024). +- A CiA402 servo driver for the Panasonic MINAS A6 over CoE (169 lines) + is the template for the A6-EC: the same profile and the same PDO and + SDO steps. +- Their NixOS settings run in production: `isolcpus=2,3` (core 2 for the + EtherCAT thread, core 3 for the control loop), `nohz_full`, + `rcu_nocbs`, `pcie_aspm=off`, `preempt=full` on kernel 6.18, and a + realtime group with rtprio and memlock. + +What is missing: + +- Drivers for the EK1101, the EL1809 (the 16-channel twin of the + supported EL1008), the EL3152, the EL5101 and the A6-EC drive. A + Beckhoff driver is a short file (their EL2809: 138 lines). We write + them and send them upstream. +- The library's README warns that its API "may change drastically" + before a stable release, so we pin one commit. +- The full QiTech Control app (Electron front end, a GNOME desktop on the + machine PC, their machine catalogue) is built around their machines. + +**Decision:** qitech_lib, pinned, is the EtherCAT layer; the station +service on top of it is ours; the full app is not used. The HMI stays a +web page from the station service, which keeps the controller image +small and the station inside the factory application's stack. Adding the +station as a machine in a fork of their app stays open if their front +end proves worth it. LGPL-3.0 leaves our own code under our own licence; +changes to the library are shared under the LGPL, which we want anyway +for the drivers. The obligations only apply if we hand the software to +someone else. + +**Also in their shop, not taken:** TwinSAFE terminals (EL1918 +EUR 140.89, EL2904 EUR 105.85, EL6910 EUR 106.12) need Beckhoff's +TwinCAT tools to set up the safety logic and a master that passes the +safety frames between terminals, which qitech_lib does not offer; the +PNOZ relay is simpler. Beckhoff servo terminals with STO (EL7211-9014 +EUR 215.99 with an AM8122 motor at EUR 285.33) cost about EUR 500 an +axis and need a 48 V supply; the 100 W kit stays. + **Operating system (NixOS module in the plant's clan):** -- Kernel 6.12 LTS with PREEMPT_RT, which is in the mainline kernel since - 6.12. The same kernel suits the IgH fallback, whose native i226 (igc) +- Start from QiTech's tested kernel settings above. If the bench jitter + test fails, move to 6.12 LTS with PREEMPT_RT (in the mainline kernel + since 6.12), which the IgH fallback needs anyway: its native i226 (igc) driver is listed for 6.12 ([IgH device drivers](https://docs.etherlab.org/ethercat/1.6/doxygen/devicedrivers.html)). -- One core isolated for the bus loop (`isolcpus`, `nohz_full`, - `rcu_nocbs`), the EtherCAT port's interrupts pinned to it, deep +- The EtherCAT port's interrupts pinned to the EtherCAT core, deep C-states and Energy Efficient Ethernet off on that port. -- The station service runs under systemd with real-time priority and - restarts on failure; logs go to the plant's log store. +- The station service runs under systemd with real-time priority, + locked memory and raw-socket rights, and restarts on failure; logs go + to the plant's log store. **Station service (Rust, one program, written by us):** -1. **Bus loop:** EtherCrab every 1 ms with distributed clocks; brings - all slaves to OP, maps the drive PDOs, runs the CiA402 state machine - of both drives, and re-adds a drive that left the bus after an - e-stop. +1. **Bus loop:** the qitech_lib EtherCAT thread every 1 ms with + distributed clocks; brings all slaves to OP, maps the drive PDOs, + runs the CiA402 state machine of both drives, and re-adds a drive + that left the bus after an e-stop. 2. **Sequence:** one state machine per record: wait at the infeed, convey, stop on the latched leading edge, lift, clamp, one turn, unclamp, lower, convey out, push if rejected. Every step has a @@ -221,17 +286,17 @@ sits between the spindle and the line timing. ## 7. Bench test, before the frame is built -**Parts:** one servo kit, the mini PC, the EK1100 with the four I/O +**Parts:** one servo kit, the mini PC, the EK1101 with the four I/O terminals and the end cap, the spindle encoder, the PNOZ s3, two -contactors, the e-stop and the 24 V supply: EUR 1,579.70 on geizhals -plus USD 123.29, about **THB 64,000 (USD 1,950)**. Every part goes into +contactors, the e-stop and the 24 V supply: EUR 1,372.13 (geizhals.de +and the QiTech shop) plus USD 123.29, about **THB 56,000 (USD 1,710)**. Every part goes into the station afterwards. One laser and one line-scan camera, ordered early from the station list, make the test complete. A reject record on a test mandrel is the load. | # | Test | Pass (our targets) | |---|---|---| -| 1 | EtherCrab brings coupler, terminals and drive to OP with distributed clocks at 1 ms | all slaves in OP, no lost frames over 24 h | +| 1 | qitech_lib (EtherCrab) brings coupler, terminals and drive to OP with distributed clocks at 1 ms | all slaves in OP, no lost frames over 24 h | | 2 | Cycle timing under load: images streaming on port 2, HMI open, CPU stress on the other cores | worst-case jitter under 50 µs over 24 h | | 3 | Spindle in CSP: one turn a second, 0.15 s run-up | stop repeatable within ±0.1° at the spindle | | 4 | EL5101 count against the servo position | exactly 6 motor turns per spindle turn over 1,000 turns, index latched every turn | @@ -240,8 +305,9 @@ a test mandrel is the load. | 7 | Conveyor (same drive in CSV): through-beam on touch probe 1 | position latched on every pass | | 8 | E-stop and door | contactors open, drive leaves the bus, I/O stays in OP; drive back in OP within 10 s of the reset | -If EtherCrab fails tests 1, 2, 3 or 8 and a week of work does not fix -it, repeat them with the IgH master on the same kernel. The station +If the EtherCrab stack fails tests 1, 2, 3 or 8 and a week of work does +not fix it, repeat them with the IgH master on the 6.12 real-time +kernel. The station service keeps the bus loop behind one interface, so only that part changes. @@ -250,7 +316,7 @@ changes. | Weeks | Step | Who | |---|---|---| | 1 to 3 | order the bench parts; servo kits from StepperOnline's China warehouse, Beckhoff and the rest from Germany or a Thai distributor | us | -| 3 to 6 | bench test (section 7) | us | +| 3 to 6 | drivers for EK1101, EL1809, EL3152, EL5101 and the A6-EC in qitech_lib, sent upstream; bench test (section 7) | us | | 5 to 9 | cabinet schematic (QElectroTech, open source) and cabinet build; station service and HMI | us, with a panel builder in Chiang Mai if needed | | 7 to 11 | frame, conveyor, spindle head and pneumatics | machine builder | | 10 to 12 | cabinet on the frame, wiring, drive tuning on the real spindle, first records | us and the machine builder | @@ -262,19 +328,21 @@ records need checking (estimate). ## 9. Spares One servo kit (covers both axes), one spindle encoder and one contactor: -about USD 210 at the prices above. The Beckhoff terminals are not -stocked at launch; a failed one is a few days by courier from Europe -(estimate). +about USD 210 at the prices above. At the QiTech shop's prices a spare +coupler, EL1809 and EL2809 add only EUR 142.69 (USD 165), so they are +stocked too. The EL3152 and EL5101 are not; a failed one is a few days by +courier from Europe (estimate). ## 10. Open points -1. **EtherCrab with the A6-EC drive** is untested; its CiA402 support is - basic. The bench answers it, with IgH as the fallback. +1. **The A6-EC drive on qitech_lib** is untested; the driver is ours to + write from their MINAS A6 one. The bench answers it, with IgH as the + fallback. Pin the qitech_lib commit; its API is not stable yet. 2. **SYNC0 range of the A6-EC** at 1 ms in CSP and CSV: not in the material read so far; the bench checks it. 3. **EL5101 termination** and the RS-422 chain with three receivers. -4. **Local prices:** ask a Thai Beckhoff source for a quote before - ordering from Germany. +4. **Shipping:** the QiTech shop's postage to Thailand (shown at + checkout) and a Thai Beckhoff quote for the EL3152 and EL5101. 5. **Risk assessment** by the machine builder: confirms PL d and stop category 0, or asks for the delayed relay. 6. Still open from the station doc: 7"/10" quick change, anti-static at 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 a6d5c3a..6e426cf 100644 --- a/docs/equipment/inline-qc-station/inline-qc-station-bom.csv +++ b/docs/equipment/inline-qc-station/inline-qc-station-bom.csv @@ -28,15 +28,15 @@ Sensors,Photoelectric presence sensors and one through-beam (the through-beam al 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,"Spindle incremental encoder, RS-422 line driver, 5 V, 2,000 to 2,500 pulses a turn: A/B clock both line-scans, A/B/Z to the EL5101",1,Omron E6B2-CWZ1X 2000 P/R class,53,282,53,282,"E6B2-CWZ1X 2000 P/R listing EUR 45.52 to GHH60 2500 P/R line driver EUR 187.83 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT; marketplace sellers, test on the bench); high end +30% for shipping, Thai duty and VAT or a Thai distributor (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,"EtherCAT station controller: fanless mini PC, Intel N100, 2 or more Intel i226-V ports, NixOS with PREEMPT_RT, open-source EtherCAT master (EtherCrab, IgH fallback)",1,ANDAQI RS55 / MNBOXCONET P2-N100 / AIOPCWA AI201-TF,455,685,455,685,"EUR 393.99 to 455.99 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/mini-pc-barebone-netzwerk-pc-intel-n100-a2926989.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" -Control,EtherCAT coupler,1,Beckhoff EK1100,174,295,174,295,"EUR 150.75 to 255.43, no current offer (geizhals.de/144468496, 19 Oct 2026)" -Control,"16 digital inputs, 24 V: photoelectric sensors, cylinder switches, safety status",1,Beckhoff EL1809,109,141,109,141,"EUR 93.97 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/1371087148); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" -Control,"16 digital outputs, 24 V, 0.5 A: valves, stack light, light enable",1,Beckhoff EL2809,119,155,119,155,"EUR 102.97 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/1371087504); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" +Control,"EtherCAT station controller: fanless mini PC, Intel N100, 2 or more Intel i226-V ports, NixOS real-time tuned, station service on QiTech's open-source EtherCAT library (EtherCrab based; IgH fallback)",1,ANDAQI RS55 / MNBOXCONET P2-N100 / AIOPCWA AI201-TF,455,685,455,685,"EUR 393.99 to 455.99 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/mini-pc-barebone-netzwerk-pc-intel-n100-a2926989.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" +Control,EtherCAT coupler (the EK1101 adds an ID switch),1,Beckhoff EK1101,98,128,98,128,"EUR 85.13, 148 in stock (QiTech community shop (shop.qitech.de, new in original box from an insolvency, 19 Oct 2026, incl. 19% German VAT: shop.qitech.de/products/beckhoff-ek1101); high end +30% for shipping from Darmstadt and Thai duty and VAT (estimate)" +Control,"16 digital inputs, 24 V: photoelectric sensors, cylinder switches, safety status",1,Beckhoff EL1809,19,25,19,25,"EUR 16.53, 157 in stock (QiTech community shop (shop.qitech.de, new in original box from an insolvency, 19 Oct 2026, incl. 19% German VAT: shop.qitech.de/products/beckhoff-el1809); high end +30% for shipping from Darmstadt and Thai duty and VAT (estimate)" +Control,"16 digital outputs, 24 V, 0.5 A: valves, stack light, light enable",1,Beckhoff EL2809,47,62,47,62,"EUR 41.03, 104 in stock (QiTech community shop (shop.qitech.de, new in original box from an insolvency, 19 Oct 2026, incl. 19% German VAT: shop.qitech.de/products/beckhoff-el2809); high end +30% for shipping from Darmstadt and Thai duty and VAT (estimate)" Control,"2 analog inputs, 4 to 20 mA: the two warp lasers",1,Beckhoff EL3152,241,314,241,314,"EUR 208.90 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/185886294); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" Control,"Incremental encoder interface, RS-422, 5 V encoder supply: spindle encoder count and index latch",1,Beckhoff EL5101,336,437,336,437,"EUR 291.04 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/2974477757); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" -Control,End cap,1,Beckhoff EL9011,5,7,5,7,"EUR 4.33 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/455904583); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" +Control,End cap,1,Beckhoff EL9011,2,3,2,3,"EUR 1.76, 131 in stock (QiTech community shop (shop.qitech.de, new in original box from an insolvency, 19 Oct 2026, incl. 19% German VAT: shop.qitech.de/products/beckhoff-el9011); high end +30% for shipping from Darmstadt and Thai duty and VAT (estimate)" 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: 10.1 inch PCAP touch monitor, 7H glass, showing the station's browser page",1,iiyama ProLite TF1015MC-B3,360,468,360,468,"EUR 311.90 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/iiyama-prolite-tf1015mc-b3-a3228748.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" Control,"Safety: relay for e-stop and door switch, 2 contactors in series in the drive supply (the 100 W kit has no STO), e-stop button, reset button",1 lot,"Pilz PNOZ s3 750103, Siemens 3RT2015 24 V DC coil, Schneider Harmony e-stop",300,389,300,389,"PNOZ s3 EUR 148.38, 3RT2015-1BB41 EUR 27.95 each, e-stop EUR 45.08 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT); reset button EUR 10 (estimate); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)" Control,"Cabinet, 24 V 120 W supply, breakers, terminals, wiring, shielded EtherCAT patch cables, stack light",1 lot,Mean Well SDR-120-24 supply,800,2000,800,2000,"estimate; Mean Well SDR-120-24 from EUR 38.87 and shielded Cat5e patch cables from EUR 0.62 (geizhals.de, 19 Oct 2026)" -Total,"Hardware per station, thermal camera excluded",,,,,16912,33061,sum of the lines above +Total,"Hardware per station, thermal camera excluded",,,,,16671,32681,sum of the lines above