diff --git a/docs/equipment/inline-optical-qc.md b/docs/equipment/inline-optical-qc.md index c27ef37..956d62c 100644 --- a/docs/equipment/inline-optical-qc.md +++ b/docs/equipment/inline-optical-qc.md @@ -224,6 +224,37 @@ belt crosses that line: - **Lift drive:** the lift is a guided pneumatic cylinder, and the spindle is belt-driven from a servo set to the side. That keeps the bottom camera's view cone clear, which the elevation shows. + +**Spindle servo.** A 100 W AC servo kit is enough: +StepperOnline A6-RS100L2A1-M17, a 40 mm motor (0.32 N·m rated, +1.12 N·m peak, 17-bit magnetic encoder, 0.03 kg·cm² rotor) with the +A6-200RS drive for pulse, RS-485 or analog control. It costs USD 108.78 +from the China warehouse +([StepperOnline](https://www.omc-stepperonline.com/a6-series-100w-rs485-ac-servo-motor-kit-3000rpm-0-32nm-17-bit-absolute-encoder-ip67-a6-rs100l2a1-m17), +October 2026). + +- **Camera clock:** the A6-RS drive puts the motor encoder out as divided + A/B/Z pulses, up to 4 Mpps + ([A6-RS manual](https://www.omc-stepperonline.com/download/A6-RS_series_servo_drive_manual.pdf)). + They go straight to the encoder inputs of both line-scans (Basler racer + 2 encoder control, + [Basler](https://docs.baslerweb.com/encoder-control)), and the PLC + drives it by pulse and direction. +- **Belt ratio 1:6** (for example 15 to 90 teeth). The record alone is + about 20.5 kg·cm² (180 g at 150.8 mm radius); with the spindle head the + load is about 25 to 35 kg·cm² (estimate). That is about 1,000 times the + rotor direct; through 1:6 the ratio comes down to about 28, inside the + drive's tuning range. The motor then runs at 360 rpm for one turn a + second. +- **Torque is no limit.** Reaching one turn a second in 0.15 s takes + about 0.13 N·m at the spindle and 0.02 N·m at the motor (our + arithmetic), well under the rating. +- **Not the EtherCAT twin.** The A6-EC100L2A1-M17 (USD 123.29) has the + same motor, but its drive has no divided encoder output: CN1 carries + five inputs, two of them touch probes, and three outputs (A6-EC + manual). It also needs an EtherCAT master, which the planned PLC is + not. It only fits if the whole station moves to EtherCAT, with a + separate spindle encoder for the cameras. - **Thermal camera (option):** hangs at the tunnel entry. It only makes sense at a press-side station; cooled records show no temperature pattern, so the launch setup leaves it out. @@ -237,7 +268,7 @@ PLC needs to run the station. Lights, drives and cylinders are in the | 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) | +| Encoder of the 100 W spindle servo (17-bit) | 1 | StepperOnline A6-RS100L2A1-M17 kit | motor, 1:6 belt to the spindle; divided A/B/Z output from the drive | angle of the turn; clocks both line-scans and the lasers | in the kit, 108.78 | | 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) | @@ -290,11 +321,11 @@ By group, per station: | Frame | 0.8k to 1.6k | 32 m of 40 × 40, 3.8 m of 40 × 80, angle brackets, feet | | Enclosure and guards | 0.3k to 0.7k | black panels, polycarbonate, door switch | | 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 | +| Handling | 1.8k to 4.4k | guided lift cylinder, 100 W spindle servo kit, 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 | 1.4k 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 (0.54M to 1.10M THB)** | thermal camera (USD 2.1k to 3.0k) not included | +| **Total** | **16k to 33k (0.53M to 1.08M THB)** | thermal camera (USD 2.1k to 3.0k) not included | **Open points for the machine builder.** @@ -422,7 +453,7 @@ simulated. | Item | Estimate | |---|---| -| Hardware per station, from the [bill of materials](inline-qc-station/inline-qc-station-bom.csv) | USD 16k to 33k (0.54M to 1.10M THB) | +| 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) | | 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 ee08186..f367fbf 100644 --- a/docs/equipment/inline-qc-station/inline-qc-station-bom.csv +++ b/docs/equipment/inline-qc-station/inline-qc-station-bom.csv @@ -10,7 +10,7 @@ Conveyor,"PU round belt 6 mm, welded endless",2 x 3.8 m,,15,40,30,80,"each; PU r Conveyor,"Round-belt pulleys, shaft, bearings, UHMW slide strips, side guides",1 lot,,250,700,250,700,"pulleys USD 5 to 11 each (ServoCity, REV); rest estimate" Conveyor,"Conveyor drive: small gear motor with drive, or servo",1,,250,600,250,600,estimate Handling,"Guided lift cylinder, 20 mm bore, 75 mm stroke",1,SMC MGPM20-75,330,450,330,450,SMC MGPM20-30 USD 322 (Misumi US) to 390 (Motion); 75 mm stroke a little more -Handling,Spindle servo 200 W with drive (encoder triggers the line-scans),1,Delta ASDA-B3 class,300,700,300,700,drive USD 119 to 200 (listings); motor and cable estimate +Handling,Spindle servo kit 100 W with drive; the drive's divided encoder output (A/B/Z) triggers the line-scans; 1:6 timing belt to the spindle,1,StepperOnline A6-RS100L2A1-M17 (A6-200RS pulse/RS485 drive),109,250,109,250,"USD 108.78 kit, China warehouse (StepperOnline, Oct 2026); high end allows for shipping and duty (estimate)" Handling,"Spindle head: bearing housing, timing belt, label pad, pneumatic expanding mandrel",1,machined parts,600,1800,600,1800,estimate Handling,"Rodless cylinder 25 mm, 350 mm stroke, with paddle",1,SMC MY1B / CY3B class,400,900,400,900,estimate Handling,"Valve terminal, FRL, tubing, fittings",1 lot,,400,1000,400,1000,estimate @@ -32,4 +32,4 @@ Control,"Edge PC with GPU, 4 GigE PoE ports, NixOS",1,,1500,3200,1500,3200,"qsco 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",,,,,16264,33184,sum of the lines above +Total,"Hardware per station, thermal camera excluded",,,,,16073,32734,sum of the lines above