Optical QC: spindle servo, 100 W StepperOnline A6-RS kit
User, 18 Oct 2026, asked about the StepperOnline A6-EC100L2A1-M17 (100 W EtherCAT kit). - The motor fits: torque about 0.02 N m needed at the motor through a 1:6 belt (0.32 rated); the belt brings the load inertia (about 25 to 35 kg cm2, estimate; record 20.5) to about 28x the 0.03 kg cm2 rotor. - Take the pulse/RS-485 twin A6-RS100L2A1-M17 (USD 108.78): its drive outputs the encoder as divided A/B/Z pulses for the line-scans and takes pulse/direction from the planned PLC. The EtherCAT drive has no divided output (A6-EC manual, CN1: 5 DI, 3 DO) and needs an EtherCAT master. - inline-optical-qc.md: spindle servo paragraph, sensor table, BOM group; BOM line 109 to 250 (was 300 to 700). Total USD 16,073 to 32,734, THB 0.53M to 1.08M.
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@@ -224,6 +224,37 @@ belt crosses that line:
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- **Lift drive:** the lift is a guided pneumatic cylinder, and the
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spindle is belt-driven from a servo set to the side. That keeps the
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bottom camera's view cone clear, which the elevation shows.
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**Spindle servo.** A 100 W AC servo kit is enough:
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StepperOnline A6-RS100L2A1-M17, a 40 mm motor (0.32 N·m rated,
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1.12 N·m peak, 17-bit magnetic encoder, 0.03 kg·cm² rotor) with the
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A6-200RS drive for pulse, RS-485 or analog control. It costs USD 108.78
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from the China warehouse
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([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),
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October 2026).
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- **Camera clock:** the A6-RS drive puts the motor encoder out as divided
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A/B/Z pulses, up to 4 Mpps
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([A6-RS manual](https://www.omc-stepperonline.com/download/A6-RS_series_servo_drive_manual.pdf)).
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They go straight to the encoder inputs of both line-scans (Basler racer
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2 encoder control,
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[Basler](https://docs.baslerweb.com/encoder-control)), and the PLC
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drives it by pulse and direction.
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- **Belt ratio 1:6** (for example 15 to 90 teeth). The record alone is
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about 20.5 kg·cm² (180 g at 150.8 mm radius); with the spindle head the
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load is about 25 to 35 kg·cm² (estimate). That is about 1,000 times the
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rotor direct; through 1:6 the ratio comes down to about 28, inside the
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drive's tuning range. The motor then runs at 360 rpm for one turn a
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second.
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- **Torque is no limit.** Reaching one turn a second in 0.15 s takes
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about 0.13 N·m at the spindle and 0.02 N·m at the motor (our
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arithmetic), well under the rating.
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- **Not the EtherCAT twin.** The A6-EC100L2A1-M17 (USD 123.29) has the
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same motor, but its drive has no divided encoder output: CN1 carries
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five inputs, two of them touch probes, and three outputs (A6-EC
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manual). It also needs an EtherCAT master, which the planned PLC is
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not. It only fits if the whole station moves to EtherCAT, with a
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separate spindle encoder for the cameras.
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- **Thermal camera (option):** hangs at the tunnel entry. It only makes
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sense at a press-side station; cooled records show no temperature
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pattern, so the launch setup leaves it out.
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@@ -237,7 +268,7 @@ PLC needs to run the station. Lights, drives and cylinders are in the
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| 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) |
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| 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) |
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| 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 |
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| 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) |
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| 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 |
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| 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) |
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| 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) |
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| 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) |
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@@ -290,11 +321,11 @@ By group, per station:
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| Frame | 0.8k to 1.6k | 32 m of 40 × 40, 3.8 m of 40 × 80, angle brackets, feet |
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| Enclosure and guards | 0.3k to 0.7k | black panels, polycarbonate, door switch |
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| Conveyor | 0.5k to 1.4k | round belts, pulleys, slide strips, drive |
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| Handling | 2.0k to 4.9k | guided lift cylinder, 200 W spindle servo, spindle head with mandrel, rodless cylinder, pneumatics |
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| Handling | 1.8k to 4.4k | guided lift cylinder, 100 W spindle servo kit, spindle head with mandrel, rodless cylinder, pneumatics |
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| 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 |
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| Sensors | 1.4k to 4.3k | 2 laser distance sensors, presence and stop sensors, cylinder switches |
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| Control | 3.5k to 7.8k | PLC, edge PC with GPU, HMI, safety, cabinet and wiring |
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| **Total** | **16k to 33k (0.54M to 1.10M THB)** | thermal camera (USD 2.1k to 3.0k) not included |
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| **Total** | **16k to 33k (0.53M to 1.08M THB)** | thermal camera (USD 2.1k to 3.0k) not included |
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**Open points for the machine builder.**
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@@ -422,7 +453,7 @@ simulated.
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| Item | Estimate |
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|---|---|
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| 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) |
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| 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) |
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| 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) |
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| 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) |
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@@ -10,7 +10,7 @@ Conveyor,"PU round belt 6 mm, welded endless",2 x 3.8 m,,15,40,30,80,"each; PU r
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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"
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Conveyor,"Conveyor drive: small gear motor with drive, or servo",1,,250,600,250,600,estimate
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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
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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
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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)"
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Handling,"Spindle head: bearing housing, timing belt, label pad, pneumatic expanding mandrel",1,machined parts,600,1800,600,1800,estimate
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Handling,"Rodless cylinder 25 mm, 350 mm stroke, with paddle",1,SMC MY1B / CY3B class,400,900,400,900,estimate
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Handling,"Valve terminal, FRL, tubing, fittings",1 lot,,400,1000,400,1000,estimate
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@@ -32,4 +32,4 @@ Control,"Edge PC with GPU, 4 GigE PoE ports, NixOS",1,,1500,3200,1500,3200,"qsco
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Control,"HMI touch panel, 10 inch",1,,400,900,400,900,estimate
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Control,"Safety relay, e-stop, door interlock wiring",1 lot,,300,600,300,600,estimate
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Control,"Cabinet, power supply, breakers, terminals, wiring, stack light",1 lot,,800,2000,800,2000,estimate
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Total,"Hardware per station, thermal camera excluded",,,,,16264,33184,sum of the lines above
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Total,"Hardware per station, thermal camera excluded",,,,,16073,32734,sum of the lines above
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