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).
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grabowski committed 2026-10-19 10:54:31 +07:00
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@@ -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