diff --git a/README.md b/README.md index e7ea3a9..3b56cfd 100644 --- a/README.md +++ b/README.md @@ -209,16 +209,18 @@ The detail lives in dedicated documents: for the same orders (steps, copies pressed so far, lab and inspection results, approving a test pressing) - [Steam and cooling](docs/steam-cooling.html): the utility plant for the - five-press fleet as a clickable process diagram: water treatment, feed - tank and heat recovery, a bank of two 500 kg/h boilers, the steam header - and condensate return, and process cooling with three 250 kW chillers, + launch plant (one Duplex system and one Classic; rooms built for four + modules, the five-press growth case one click away) as a clickable + process diagram: water treatment, feed tank and heat recovery, a bank of + two 500 kg/h boilers, the steam header and condensate return, and + process cooling with two 250 kW chillers (a third with the second Duplex), a plate heat exchanger, warm and cold tanks and a branch to every press, - extruder and the hydraulic oil cooler; operating cases from the launch - press to one module down, the design basis, an equipment schedule and + extruder and the hydraulic oil cooler; operating cases from the launch plant + and its commissioning to one module down, the design basis, an equipment schedule and the open questions for the boiler and chiller RFQs - [Plant operation page](docs/plant-operation.html): a single static page - animating the mature plant as a simulated SCADA overview at real cycle - times: the Newbilt Duplex and two Classic presses, the Pheenix Alpha + animating the launch plant as a simulated SCADA overview at real cycle + times: the Newbilt Duplex system and the Classic, the Pheenix Alpha electroforming line and Sibert stamper prep, from PVC intake and the material lab through pressing, inspection, packaging and fulfillment, with the three artist gates, the mother archive, utilities and energy; @@ -352,7 +354,7 @@ docs/ ├── roadmap.md Next steps in dependency order ├── scale.md Rough project sizing on one page ├── site-candidates.md Land options and the checks before choosing -├── steam-cooling.html Steam and cooling plant diagram, five-press fleet +├── steam-cooling.html Steam and cooling plant diagram, launch plant ├── sustainability.md Energy, water, materials commitments ├── traceability.md Process logging and per-order traceability └── worker-safety.md Training, clean rooms, PPE diff --git a/docs/plant-operation.html b/docs/plant-operation.html index 72bf168..0edf2e5 100644 --- a/docs/plant-operation.html +++ b/docs/plant-operation.html @@ -93,6 +93,9 @@ footer{flex:0 0 clamp(150px,26vh,210px);display:grid;grid-template-columns:1.1fr #hint{display:block} header h1{white-space:normal} .ctl{flex-wrap:wrap} + .legend{grid-template-columns:minmax(0,1fr)} + .legend div{overflow-wrap:anywhere} + .legend .note{grid-column:auto} } /* SVG */ @@ -213,7 +216,7 @@ html[data-theme=light] .screw{stroke:#7d8aa0}
-

CNX Vinyl · Poy Records · Plant overview · mature fleet

+

CNX Vinyl · Poy Records · Plant overview · launch plant

@@ -230,7 +233,7 @@ html[data-theme=light] .screw{stroke:#7d8aa0}
D1 08:00:00sim clock
--shift
-
0/4presses
+
0/3presses
--cycles/h
0good today
0rejects
@@ -269,7 +272,7 @@ html[data-theme=light] .screw{stroke:#7d8aa0}

Click any station

-

The mature plant: the Newbilt Duplex (two HRP 12 presses on one VEX 50 extruder, with an EX 35 for colour effects), two Newbilt Classic automatic presses, the Pheenix Alpha electroforming line and Sibert stamper prep. At 1× everything runs at its real duration: press cycles of 28 s (Classic) and about 30 s (Duplex), 45 to 75 minutes of plating per part, artist approvals in days. Speed up to watch whole days (3600× runs a day in 24 s). Click a station for what happens there, its checks, and where its figures come from; durations without a published source are marked as estimates. Simulated from this repository (equipment/galvanics.md, equipment/pressing-line.md, production-timeline.md, scale.md); nothing here is live.

+

The launch plant decided in October 2026: one Newbilt Duplex system (two HRP 12 presses on one VEX 50 extruder, with an EX 35 for colour effects), one Newbilt Classic automatic press, the Pheenix Alpha electroforming line with one PDPU and Sibert stamper prep, on two boiler and two chiller modules. A second Duplex system is a growth option and is not shown. At 1× everything runs at its real duration: press cycles of 28 s (Classic) and about 30 s (Duplex), 45 to 75 minutes of plating per part, artist approvals in days. Speed up to watch whole days (3600× runs a day in 24 s). Click a station for what happens there, its checks, and where its figures come from; durations without a published source are marked as estimates. Simulated from this repository (finance/total-investment.md, equipment/galvanics.md, equipment/pressing-line.md, production-timeline.md, scale.md); nothing here is live.

Event log

Legend

@@ -349,6 +352,9 @@ const visHop=()=>!S.quiet&&S.speed<=600; /* ================================================================ titles and upstream stages */ const UP=[['intake',1,2],['gate1',2,10],['master',2,4],['gate2',2,10],['cut',1,2]]; // days, min to max +// a new title every 0.75 to 1.15 days: ~380 a year, between the revenue model's 300 and 400 titles for the launch plant +// (the four-press rate scaled by press capacity; presses run ~64 to 73 % of shift time over 90 simulated days) +const ARRIVE=[0.75,1.15]; const UPI={};UP.forEach((u,i)=>UPI[u[0]]=i); const QTY=[300,500,1000,1000,2000,3000,3000,5000,5000,10000]; // mean ~3,100 const TITLES=[];let titleN=40; @@ -364,7 +370,7 @@ function mkTitle(o){o=o||{};titleN++;const r=Math.random(); const cntStage=st=>TITLES.reduce((n,T)=>n+(T.stage===st?1:0),0); function nextUp(st){let m=Infinity;for(const T of TITLES)if(T.stage===st&&T.tEnd=S.nextArrival){const T=mkTitle();T.tEnd=S.t+rnd(1,2)*DAY;S.nextArrival=S.t+rnd(0.55,0.85)*DAY; + if(S.t>=S.nextArrival){const T=mkTitle();T.tEnd=S.t+rnd(1,2)*DAY;S.nextArrival=S.t+rnd(ARRIVE[0],ARRIVE[1])*DAY; log(T.id+' received: '+T.qty+' × 12" '+T.wt+' g '+T.kind+', checksums verified','info');} for(const T of TITLES){ const i=UPI[T.stage]; @@ -426,18 +432,19 @@ const NOM={};for(const g in GROW){const G=GROW[g];let m=0,t=0;const tgt=massFor( const PLATEQ=[]; const PRIO={F:0,R:1,M:2,S:3}; // lacquers first (they age), then remakes function plateEnq(j,from){j.prio=j.grow==='S'&&j.remake?PRIO.R:PRIO[j.grow];j.from=from;j.tq=S.t;PLATEQ.push(j);PLATEQ.sort((a,b)=>a.prio-b.prio||a.tq-b.tq);} -const CELLS=[0,1,2,3].map(i=>({i,u:i>>1,c:i&1,job:null,ph:'idle',tIn:0,I:0,V:0,mass:0,target:1,tPlate:0})); +// launch plant: one PDPU with two cells (total-investment.md; one covers full-capacity demand, galvanics.md) +const CELLS=[0,1].map(i=>({i,u:i>>1,c:i&1,job:null,ph:'idle',tIn:0,I:0,V:0,mass:0,target:1,tPlate:0})); function cellTick(c,ds){ if(c.ph==='idle'){ if(shiftOn()&&PLATEQ.length){const j=PLATEQ.shift();c.job=j;c.ph='load';c.tIn=0;c.mass=0;c.target=massFor(GROW[j.grow].th); if(j.grow==='S'){j.T.made[j.side]++;j.st={T:j.T,side:j.side,gen:'S',n:j.T.made[j.side]};} if(j.from)hop(j.from,'pdpu'+(c.u+1),j.mand); - log('PDPU '+(c.u+1)+' cell '+(c.c+1)+': '+(j.grow==='F'?'father on lacquer ':j.grow==='M'?'mother on father ':'stamper on mother ')+j.T.sid+j.side+(j.remake?' (from the archive)':''),'info');} + log('PDPU cell '+(c.c+1)+': '+(j.grow==='F'?'father on lacquer ':j.grow==='M'?'mother on father ':'stamper on mother ')+j.T.sid+j.side+(j.remake?' (from the archive)':''),'info');} return;} c.tIn+=ds; if(c.ph==='load'){if(c.tIn>=5*MIN){c.ph='plate';c.tIn=0;}return;} if(c.ph==='plate'){const g=GROW[c.job.grow];c.I=Math.min(g.Imax,20+(g.Imax-20)*c.tIn/g.ramp);c.V=8.5+c.I*0.016;c.mass+=c.I*ds/HOUR*GPAH; - if(c.mass>=c.target){c.ph='done';c.tPlate=c.tIn;c.tIn=0;c.I=0;c.V=0;log(jl(c.job)+': plated to '+f2(g.th)+' mm in '+dur(c.tPlate)+', PDPU '+(c.u+1)+' cell '+(c.c+1),'ok');} + if(c.mass>=c.target){c.ph='done';c.tPlate=c.tIn;c.tIn=0;c.I=0;c.V=0;log(jl(c.job)+': plated to '+f2(g.th)+' mm in '+dur(c.tPlate)+', PDPU cell '+(c.c+1),'ok');} return;} if(c.ph==='done'){if(shiftOn()){c.ph='unload';c.tIn=0;}return;} if(c.ph==='unload'&&c.tIn>=10*MIN){const j=c.job;c.job=null;c.ph='idle';c.tIn=0;enq('pmpb',j,'pdpu'+(c.u+1));} @@ -470,8 +477,7 @@ const CSEQ=[['LOAD',3],['CLOSE',2],['STEAM',7],['COOL',11],['OPEN',2],['EJECT',3 const PRESS=[ {id:'pDA',name:'Duplex A',type:'duplex',seq:DSEQ}, {id:'pDB',name:'Duplex B',type:'duplex',seq:DSEQ}, - {id:'pC1',name:'Classic C1',type:'classic',seq:CSEQ}, - {id:'pC2',name:'Classic C2',type:'classic',seq:CSEQ}]; + {id:'pC1',name:'Classic',type:'classic',seq:CSEQ}]; PRESS.forEach(P=>Object.assign(P,{state:'OFF',tIn:0,set:null,mode:null,run:0,life:0,tpLeft:0,open:1,force:0,moldT:58,peakT:0,lastCycle:0,cycleStart:0,prevStart:0,waiting:false,changeDur:0,lastT:null,cyc:0,after:null,restart:false,cake:false,cakeKg:0})); const RUNSTATES=['LOAD','CLOSE','STEAM','COOL','OPEN','EJECT']; // Unplanned stops, about one per 4 running hours, 15 to 45 min each (estimate): with stamper changes and @@ -559,18 +565,17 @@ function outcome(T,tp){ /* ================================================================ layout */ const MACH=[ // metal path - {id:'audio',x:20,y:56,w:110,h:120,t:'Audio intake',s:'checksums · tech QA',tags:[()=>'titles '+cntStage('intake'),()=>'next '+nextUp('intake'),()=>'~1.4 new/day']}, + {id:'audio',x:20,y:56,w:110,h:120,t:'Audio intake',s:'checksums · tech QA',tags:[()=>'titles '+cntStage('intake'),()=>'next '+nextUp('intake'),()=>'~1 new/day']}, {id:'master',x:190,y:56,w:110,h:120,t:'Mastering',s:'vinyl master',tags:[()=>'titles '+cntStage('master'),()=>'next '+nextUp('master'),()=>'2 to 4 days']}, {id:'cut',x:360,y:56,w:110,h:120,t:'Lathe cutting',s:'lacquer · scribe',tags:[()=>'titles '+cntStage('cut'),()=>'next '+nextUp('cut'),()=>'plate < 72 h']}, {id:'pasu',x:488,y:46,w:112,h:150,t:'PASU silver',s:'clean · spray Ag',st:'pasu',bar:true,tags:[()=>stTxt('pasu'),()=>stLeft('pasu'),()=>'queue '+ST.pasu.q.length,()=>'15 min (est.)']}, {id:'pppu',x:610,y:46,w:146,h:150,t:'PPPU pre-plate',s:'4 positions · 20 A',custom:'pppu',tags:[()=>'queue '+ST.pppu.q.length+' · 35 °C',()=>'20 min each']}, - {id:'pdpu1',x:766,y:46,w:158,h:150,t:'PDPU 1 plating',s:'2 cells · up to 200 A',custom:'pdpu',u:0,det:'pdpu',tags:[()=>pdpuT1(0),()=>pdpuT2(0)]}, - {id:'pdpu2',x:934,y:46,w:158,h:150,t:'PDPU 2 plating',s:'2 cells · up to 200 A',custom:'pdpu',u:1,det:'pdpu',tags:[()=>pdpuT1(1),()=>pdpuT2(1)]}, - {id:'pmpb',x:1102,y:46,w:120,h:150,t:'PMPB bench',s:'separate · passivate',st:'pmpb',bar:true,tags:[()=>stTxt('pmpb'),()=>stLeft('pmpb'),()=>'queue '+ST.pmpb.q.length,()=>'DI tank '+f0(S.diro.tank*100)+' %']}, - {id:'qc',x:1232,y:46,w:108,h:150,t:'Part QC',s:'XRF · listening',st:'qc',bar:true,tags:[()=>stTxt('qc'),()=>stLeft('qc'),()=>'queue '+ST.qc.q.length,()=>S.lastXRF]}, - {id:'vsf',x:1368,y:46,w:132,h:150,t:'VSF finisher',s:'Sibert · back-finish',st:'vsf',bar:true,tags:[()=>stTxt('vsf'),()=>stLeft('vsf'),()=>'queue '+ST.vsf.q.length,()=>'8 min (est.)']}, - {id:'vsp',x:1510,y:46,w:132,h:150,t:'VSP punch',s:'Sibert · ×100 optics',st:'vsp',bar:true,tags:[()=>stTxt('vsp'),()=>stLeft('vsp'),()=>'queue '+ST.vsp.q.length,()=>'conc. '+(S.lastConc?f0(S.lastConc)+' µm':'-')]}, - {id:'vsc',x:1652,y:46,w:132,h:150,t:'VSC coiner',s:'Sibert · centre + edge',st:'vsc',bar:true,tags:[()=>stTxt('vsc'),()=>stLeft('vsc'),()=>'queue '+ST.vsc.q.length,()=>'today '+S.day.stampers+' done']}, + {id:'pdpu1',x:766,y:46,w:158,h:150,t:'PDPU plating',s:'2 cells · up to 200 A',custom:'pdpu',u:0,det:'pdpu',tags:[()=>pdpuT1(0),()=>pdpuT2(0)]}, + {id:'pmpb',x:934,y:46,w:120,h:150,t:'PMPB bench',s:'separate · passivate',st:'pmpb',bar:true,tags:[()=>stTxt('pmpb'),()=>stLeft('pmpb'),()=>'queue '+ST.pmpb.q.length,()=>'DI tank '+f0(S.diro.tank*100)+' %']}, + {id:'qc',x:1064,y:46,w:108,h:150,t:'Part QC',s:'XRF · listening',st:'qc',bar:true,tags:[()=>stTxt('qc'),()=>stLeft('qc'),()=>'queue '+ST.qc.q.length,()=>S.lastXRF]}, + {id:'vsf',x:1200,y:46,w:188,h:150,t:'VSF finisher',s:'Sibert · back-finish',st:'vsf',bar:true,tags:[()=>stTxt('vsf'),()=>stLeft('vsf'),()=>'queue '+ST.vsf.q.length,()=>'8 min (est.)']}, + {id:'vsp',x:1398,y:46,w:188,h:150,t:'VSP punch',s:'Sibert · ×100 optics',st:'vsp',bar:true,tags:[()=>stTxt('vsp'),()=>stLeft('vsp'),()=>'queue '+ST.vsp.q.length,()=>'conc. '+(S.lastConc?f0(S.lastConc)+' µm':'-')]}, + {id:'vsc',x:1596,y:46,w:188,h:150,t:'VSC coiner',s:'Sibert · centre + edge',st:'vsc',bar:true,tags:[()=>stTxt('vsc'),()=>stLeft('vsc'),()=>'queue '+ST.vsc.q.length,()=>'today '+S.day.stampers+' done']}, {id:'archive',x:1812,y:46,w:130,h:150,t:'Archive',s:'fathers · mothers',tags:[()=>'fathers '+S.archive.F,()=>'mothers '+S.archive.M,()=>'pulled '+S.pulled,()=>'3-step plating']}, {id:'rack',x:1952,y:46,w:130,h:150,t:'Stamper rack',s:'press-ready sets',tags:[()=>'ready '+rackReady(),()=>'at gate 3 '+rackWait(),()=>'for TP '+rackTP(),()=>'next '+rackNext()]}, // pressing hall @@ -583,12 +588,10 @@ const MACH=[ {id:'vex',x:484,y:316,w:140,h:128,custom:'vex'}, {id:'ex35',x:484,y:452,w:140,h:58,t:'EX 35 colour',s:'auxiliary extruder',tags:[()=>S.ex35?'strands ON':'strands idle']}, {id:'pDB',x:634,y:316,w:124,h:196,custom:'press',t:'HRP 12 · B',s:'Duplex · semi-auto',det:'duplex'}, - {id:'pC1',x:784,y:316,w:150,h:196,custom:'press',t:'Classic C1',s:'automatic · 3-column',det:'classic',c3:true}, - {id:'pC2',x:946,y:316,w:150,h:196,custom:'press',t:'Classic C2',s:'automatic · 3-column',det:'classic',c3:true}, + {id:'pC1',x:864,y:316,w:150,h:196,custom:'press',t:'Classic',s:'automatic · 3-column',det:'classic',c3:true}, {id:'tA',x:350,y:522,w:84,h:44,t:'Trimmer A',det:'trim',tags:[()=>trimTag('pDA')]}, {id:'tB',x:634,y:522,w:84,h:44,t:'Trimmer B',det:'trim',tags:[()=>trimTag('pDB')]}, - {id:'tC1',x:784,y:522,w:110,h:44,t:'Trimmer C1',det:'trim',tags:[()=>trimTag('pC1')]}, - {id:'tC2',x:946,y:522,w:110,h:44,t:'Trimmer C2',det:'trim',tags:[()=>trimTag('pC2')]}, + {id:'tC1',x:864,y:522,w:110,h:44,t:'Trimmer C',det:'trim',tags:[()=>trimTag('pC1')]}, {id:'audioqc',x:1120,y:338,w:130,h:70,t:'Audio compare',s:'all TPs + 1 in 50',tags:[()=>'n '+S.samples+' · '+S.audioLast]}, {id:'punch',x:1264,y:338,w:130,h:70,t:'Label punch',s:'106 mm · rejects',tags:[()=>'punched '+S.punched]}, {id:'gran',x:1408,y:320,w:164,h:104,t:'Granulator 400',s:'edge trim + rejects',tags:[()=>'bin '+f1(S.gran.bin)+' kg',()=>S.gran.run?'BATCH '+f1(S.gran.run)+' kg':'waits for 12 kg',()=>'ground '+f0(S.gran.total)+' kg',()=>'200 to 250 kg/h']}, @@ -598,8 +601,8 @@ const MACH=[ {id:'pack',x:1408,y:452,w:150,h:96,t:'Packaging',s:'matrix vs barcode',tags:[()=>'assembled '+S.assembled,()=>'mismatch '+S.mismatch,()=>'barcode 100 %']}, {id:'ship',x:1572,y:452,w:200,h:96,t:'Fulfillment',s:'bulk pallet · dropship',tags:[()=>'pallet '+S.pallet+' / 300',()=>'dropship '+S.parcels+' parcels',()=>'TPs to artists '+S.tpToArtist]}, // utilities - {id:'boiler',x:20,y:676,w:160,h:132,t:'Steam boiler',s:'10 bar · 180 °C',tags:[()=>'P '+f2(S.boiler.p)+' bar',()=>'flow '+f0(S.boiler.F*HOUR)+' kg/h',()=>'cap 800 kg/h est.',()=>'press 150-180 kg/h',()=>'fuel: open']}, - {id:'chiller',x:192,y:676,w:176,h:132,t:'Process cooling',s:'chiller · cooling tower',tags:[()=>'supply '+f1(S.chiller.sup)+' °C',()=>'return '+f1(S.chiller.ret)+' °C',()=>'flow '+f0(S.chiller.flow)+' l/min',()=>'load '+f0(S.chiller.load)+' kW',()=>'cap 500 kW est.']}, + {id:'boiler',x:20,y:676,w:160,h:132,t:'Steam boilers',s:'B-1 + B-2 · 10 bar · 180 °C',tags:[()=>'P '+f2(S.boiler.p)+' bar',()=>'flow '+f0(S.boiler.F*HOUR)+' kg/h',()=>'cap 2 × 500 kg/h',()=>'press 150-180 kg/h',()=>'fuel: open']}, + {id:'chiller',x:192,y:676,w:176,h:132,t:'Process cooling',s:'CH-1 + CH-2 · air-cooled',tags:[()=>'supply '+f1(S.chiller.sup)+' °C',()=>'return '+f1(S.chiller.ret)+' °C',()=>'flow '+f0(S.chiller.flow)+' l/min',()=>'load '+f0(S.chiller.load)+' kW',()=>'cap 2 × 250 kW']}, {id:'comp',x:380,y:676,w:120,h:132,t:'Compressed air',s:'6 to 10 bar, dry',tags:[()=>'P '+f1(S.comp.p)+' bar',()=>'dew '+f1(jit(2.5,.4))+' °C',()=>'presses',()=>'Sibert, PASU']}, {id:'hyd',x:512,y:676,w:124,h:132,t:'Hydraulics',s:'Duplex aggregate',tags:[()=>'P '+f0(S.hyd.p)+' bar',()=>'oil '+f1(S.hyd.oil)+' °C',()=>'HLP 46 · 200 l',()=>'presses A + B']}, {id:'diro',x:648,y:676,w:136,h:132,t:'RO / DI water',s:'galvanics rinse',tags:[()=>'tank '+f0(S.diro.tank*100)+' %',()=>'cond '+f1(S.diro.cond)+' µS/cm',()=>'to PMPB, PASU',()=>'0.2 m³/h est.']}, @@ -635,10 +638,10 @@ function lane(x,y,txt){el('text',{x,y,class:'lane'},L.mach,txt);} lane(20,24,'Metal path · audio file to stamper'); lane(20,300,'Pressing hall · Newbilt · material and record path'); lane(20,668,'Utilities and plant systems'); -el('rect',{x:478,y:30,width:870,height:176,rx:6,class:'room'},L.pipes); +el('rect',{x:478,y:30,width:702,height:176,rx:6,class:'room'},L.pipes); el('text',{x:488,y:24,class:'roomlbl'},L.mach,'Galvanics clean room · Pheenix Alpha'); -el('rect',{x:1358,y:30,width:436,height:176,rx:6,class:'room'},L.pipes); -el('text',{x:1368,y:24,class:'roomlbl'},L.mach,'Stamper prep · Sibert'); +el('rect',{x:1190,y:30,width:604,height:176,rx:6,class:'room'},L.pipes); +el('text',{x:1200,y:24,class:'roomlbl'},L.mach,'Stamper prep · Sibert'); function boxBase(m){const g=el('g',{class:'machine',id:'m_'+m.id}); el('rect',{x:m.x,y:m.y,width:m.w,height:m.h,rx:4,class:'mbox'},g); @@ -697,7 +700,7 @@ function drawPdpu(m){m.tagY=m.y+126;const g=drawBox(m); m.cells=[0,1].map(i=>{const cx=m.x+7+i*74,cy=m.y+38,cw=70,ch=76;const cg=el('g',{class:'cell'},g); el('rect',{x:cx,y:cy,width:cw,height:ch,rx:2,class:'cellr'},cg); el('rect',{x:cx+3,y:cy+20,width:cw-6,height:ch-23,class:'liquid'},cg); - for(let b=0;b<3;b++)FX.bubbles.push({x:cx+10+b*18,y:cy+ch-5,d:rnd(0,2.2),cell:(m.id==='pdpu2'?2:0)+i}); + for(let b=0;b<3;b++)FX.bubbles.push({x:cx+10+b*18,y:cy+ch-5,d:rnd(0,2.2),cell:i}); el('rect',{x:cx+cw-11,y:cy+22,width:6,height:50,class:'thk'},cg); const tv=el('rect',{x:cx+cw-11,y:cy+72,width:6,height:0,class:'thkv'},cg); const t=[0,1,2,3].map(k=>el('text',{x:cx+4,y:cy+12+k*15,class:'ctxt'},cg,'')); @@ -730,28 +733,28 @@ function flow(d,cls){const c=cls.split(' ');FX.flows.push({k:'flow',c:c[0],thin: function route(id,d,cls){PATHS[id]=poly(d);flow(d,cls);} function pipe(d,cls,thin){FX.flows.push({k:'pipe',c:cls,p2:new Path2D(d)});flow(d,cls+(thin?' thin':''));} // pipe rack y 616 to 650, drops into each press from below -pipe('M100,676 V616 H1074','steam');['456','740','912','1074'].forEach(x=>pipe(`M${x},616 V512`,'steam')); -pipe('M1080,621 H112 V676','cond',true); -pipe('M262,676 V626 H1086','cw');['466','750','924','1086'].forEach(x=>pipe(`M${x},626 V512`,'cw')); -pipe('M1092,631 H282 V676','cwr',true); +pipe('M100,676 V616 H992','steam');['456','740','992'].forEach(x=>pipe(`M${x},616 V512`,'steam')); +pipe('M998,621 H112 V676','cond',true); +pipe('M262,676 V626 H1004','cw');['466','750','1004'].forEach(x=>pipe(`M${x},626 V512`,'cw')); +pipe('M1010,631 H282 V676','cwr',true); pipe('M574,676 V636 H444 V512','hyd');pipe('M574,636 H728 V512','hyd'); // galvanics services: up the right-hand side to headers over the clean room -pipe('M300,676 V644 H2088 V34 H845 V46','chw',true);pipe('M1013,34 V46','chw',true); -pipe('M716,676 V650 H2094 V40 H544 V46','di',true);pipe('M1162,40 V46','di',true); +pipe('M300,676 V644 H2088 V34 H845 V46','chw',true); +pipe('M716,676 V650 H2094 V40 H544 V46','di',true);pipe('M994,40 V46','di',true); // record conveyor and edge-trim collection FX.flows.push({k:'conv',p2:new Path2D('M370,590 H1772')},{k:'convd',p2:new Path2D('M370,590 H1772')}); flow('M392,574 H1104','scrap thin'); // material route('s_v','M47,436 V444 H272 V428','mat thin');route('s_r','M107,436 V444 H272 V428','reg thin');route('s_c','M167,436 V444 H272 V428','col thin'); -route('f_vex','M272,316 V308 H554 V366','mat thin');route('f_c1','M272,316 V308 H859 V316','mat thin');route('f_c2','M272,316 V308 H1021 V316','mat thin'); +route('f_vex','M272,316 V308 H554 V366','mat thin');route('f_c1','M272,316 V308 H939 V316','mat thin'); route('f_ex35','M272,316 V308 H629 V481 H624','col thin');route('ex2vex','M554,452 V444','col thin'); route('l_pDA','M194,482 H350','lbl thin');route('l_pDB','M194,500 H340 V517 H646 V512','lbl thin'); -route('l_pC1','M194,500 H340 V517 H796 V512','lbl thin');route('l_pC2','M194,500 H340 V517 H958 V512','lbl thin'); +route('l_pC1','M194,500 H340 V517 H876 V512','lbl thin'); route('trimcart','M1104,574 V444 H1440 V424','scrap thin'); route('reject','M1200,590 V570 H1257 V432 H1329 V408','scrap thin');route('sample','M1170,590 V570 H1112 V373 H1120','route thin'); route('p2g','M1394,371 H1408','scrap thin');route('regrind','M1490,320 V284 H107 V316','reg thin'); route('carton','M1685,408 V430 H1483 V452','route thin'); -['pDA:412','pDB:696','pC1:859','pC2:1021'].forEach(s=>{const [id,x]=s.split(':');route('st_'+id,`M2017,196 V278 H${x} V316`,'metal thin');}); +['pDA:412','pDB:696','pC1:939'].forEach(s=>{const [id,x]=s.split(':');route('st_'+id,`M2017,196 V278 H${x} V316`,'metal thin');}); [[180,612,'steam 10 bar'],[1250,640,'galvanics services: cooling water 12 to 20 °C · DI water'],[1500,274,'stamper sets to presses'],[130,280,'regrind to silo'], [1120,438,'edge trim, in batches'],[1262,428,'rejects'],[1116,332,'samples'],[200,478,'labels']].forEach(a=>el('text',{x:a[0],y:a[1],class:'small'},L.top,a[2])); @@ -766,7 +769,7 @@ function ctr(id){const m=M[id];return m?{x:m.x+m.w/2,y:m.y+m.h/2}:null;} function hop(from,to,it){if(!visHop()||!from)return;const a=ctr(from),b=ctr(to);if(!a||!b)return; const kind=it.grow?it.grow:it.gen==='L'?(it.silvered?'Ls':'L'):it.gen;const n=shape(kind);hops.push({n,a,b,t:0,d:1.1});place(n,a);} function routeHop(pid,kind){mover(pid,shape(kind),320,m=>m.node.remove());} -const RECS=[];const CONV0=370,CONVEND=1772,CONVY=590;const DROPX={pDA:392,pDB:676,pC1:839,pC2:1001}; +const RECS=[];const CONV0=370,CONVEND=1772,CONVY=590;const DROPX={pDA:392,pDB:676,pC1:919}; const STATIONS=[{id:'optical',at:1185,dwell:2.2},{id:'finish',at:1329,dwell:2.5},{id:'pack',at:1483,dwell:3},{id:'ship',at:1672,dwell:0.5}]; function mkRec(P,tp){const T=P.set.T;const g=spr('rec',{r:9,lr:3.2,vinyl:T.vinyl,label:T.label});if(tp)g.classList.add('tp'); const r={node:g,T,tp,ph:'trim',dwell:6,x:DROPX[P.id],y:544,pos:0,visited:{},n:P.cyc,pname:P.name};RECS.push(r);place(g,r);return r;} @@ -818,11 +821,11 @@ function matTick(){ /* ================================================================ utilities */ function utilTick(ds){ let draw=0;PRESS.forEach(P=>{if(P.state==='STEAM'&&!P.waiting)draw+=STEAM_KG/seqDur(P,'STEAM');}); - // header holds ~10 kg of steam per bar; boiler shown at 800 kg/h (estimate, see detail) - const B=S.boiler,fault=S.t0&&!fault&&B.p>9.6){B.faultUntil=-1;log('Boiler: feedwater pump back, '+f2(B.p)+' bar, presses resume','ok');} - let heat=0,flow=20;PRESS.forEach(P=>{if(running(P)){heat+=72;flow+=53;}}); + let heat=0,flow=20;PRESS.forEach(P=>{if(running(P)){heat+=72;flow+=53;}}); // average per running press; CH-1 + CH-2 = 500 kW below heat+=CELLS.filter(c=>c.ph==='plate').length*1.5; const C=S.chiller;C.load=lag(C.load,heat,1/600,ds);C.flow=lag(C.flow,flow,0.05,ds);C.sup=lag(C.sup,22+Math.max(0,C.load-500)/40,1/300,ds);C.ret=C.sup+C.load/(C.flow/60*4.186); S.comp.p=lag(S.comp.p,PRESS.some(P=>P.state==='LOAD'||P.state==='EJECT')?7.2:7.7,0.9,ds); @@ -858,7 +861,7 @@ function animate(dt){ for(let i=hops.length-1;i>=0;i--){const h=hops[i];h.t+=dt;const k=Math.min(1,h.t/h.d);place(h.n,{x:h.a.x+(h.b.x-h.a.x)*k,y:h.a.y+(h.b.y-h.a.y)*k-Math.sin(k*Math.PI)*18});if(k>=1){h.n.remove();hops.splice(i,1);}} RECS.forEach(r=>{if(!r.gone)place(r.node,r.ph==='conv'?{x:CONV0+r.pos,y:CONVY}:{x:r.x,y:r.y});}); if(S.running&&!S.quiet&&S.speed<=600){feedAcc+=dt; - if(feedAcc>0.7&&PRESS.some(running)){feedAcc=0;const k=pick(['s_v','s_v','s_r','s_c','f_vex','f_c1','f_c2']); + if(feedAcc>0.7&&PRESS.some(running)){feedAcc=0;const k=pick(['s_v','s_v','s_r','s_c','f_vex','f_vex','f_c1']); const col=k==='s_r'?'#8ea36f':k==='s_c'?'#c86bff':'#b9c2d0';mover(k,dot(col),110,m=>m.node.remove()); if(S.ex35&&Math.random()<0.5)mover('f_ex35',dot('#c86bff'),110,m=>{m.node.remove();mover('ex2vex',dot('#c86bff'),20,mm=>mm.node.remove());});} cartonAcc+=dt;if(cartonAcc>7){cartonAcc=0;mover('carton',spr('rect',{w:12,h:8,fill:'#8a6d3b',stroke:'#c9a24a'}),50,m=>m.node.remove());}} @@ -878,13 +881,13 @@ function renderTags(){ setT(m.tagEls[1],T?T.id+' · '+P.set.k:(P.state==='OFF'?'':'waiting for a set')); setT(m.tagEls[2],!T?'':P.mode==='tp'?'test press '+(TP_N-P.tpLeft)+'/'+TP_N:P.mode==='fa'?'first article':'run '+T.cycles+'/'+T.target); lampSet(P.id,P.state==='NOPVC'||P.state==='STOP'?'alarm':amber?'warn':running(P)?'run':'idle');}); - ['tA','tB','tC1','tC2'].forEach((id,i)=>lampSet(id,running(PRESS[i])?'run':'idle')); + ['tA','tB','tC1'].forEach((id,i)=>lampSet(id,running(PRESS[i])?'run':'idle')); const dRun=PRESS.slice(0,2).some(running); M.vex.zoneT.forEach((t,i)=>setT(t,f0(dRun?jit([132,146,156][i],1):[92,96,98][i])+'°')); M.vex.zoneEls.forEach((z,i)=>{setS(z,'fill',dRun?'var(--z'+(i+1)+')':'var(--z0)');});lampSet('vex',dRun?'run':'idle');lampSet('ex35',S.ex35?'run':'idle'); M.pppu.pos.forEach((p,i)=>{const w=ST.pppu.slots[i];setA(p.r,'class','pos'+(w?' on':''));setT(p.a,w?w.it.T.sid+w.it.side+' 20 A':'free');setT(p.b,w?dur(w.end-S.t):'');}); lampSet('pppu',ST.pppu.slots.some(Boolean)?'run':ST.pppu.q.length?'warn':'idle'); - [0,1].forEach(u=>{const m=M['pdpu'+(u+1)];let any=false,done=false; + [0].forEach(u=>{const m=M['pdpu'+(u+1)];let any=false,done=false; m.cells.forEach((cv,i)=>{const c=CELLS[u*2+i];const j=c.job;setA(cv.g,'class','cell'+(c.ph==='plate'?' on':c.ph==='done'?' done':'')); if(c.ph!=='idle')any=true;if(c.ph==='done')done=true; const hh=50*(j?Math.min(1,c.mass/c.target):0);setA(cv.tv,'y',(cv.cy+72-hh).toFixed(1));setA(cv.tv,'height',hh.toFixed(1)); @@ -903,7 +906,7 @@ function renderTags(){ ['comp','diro','zld','energy','trace','hvac','exh'].forEach(id=>lampSet(id,'run'));lampSet('hyd',dRun?'run':'idle'); setT(GATES.g1.c,cntStage('gate1')+' waiting');setT(GATES.g2.c,cntStage('gate2')+' waiting');setT(GATES.g3.c,TITLES.filter(T=>T.tp==='sent').length+' waiting'); setT($('kClock'),clockStr());setT($('kShift'),shiftOn()?(hourOf()<14?'1 (06-14)':'2 (14-22)'):'night'); - setT($('kPress'),PRESS.filter(running).length+'/4'); + setT($('kPress'),PRESS.filter(running).length+'/'+PRESS.length); setT($('kRate'),S.cyc.length);setT($('kGood'),S.day.good);setT($('kRej'),S.day.rej);setT($('kYield'),yieldStr()); setT($('kGalv'),galvCount());setT($('kRack'),rackReady()); setT($('kSteam'),f2(S.boiler.p)+' bar');setS($('kSteam'),'color',S.boiler.p<9.5?'#ff3b3b':''); @@ -918,12 +921,12 @@ function log(msg,lvl){S.events++;if(S.quiet)return; /* ================================================================ details */ const DETAILS={ - audio:{t:'1 · Audio intake',w:'Files arrive from the label or artist; checksums and format are verified and a technical QA pass checks levels, clipping and side length against the format. Nothing is cut until the artist confirms the master plan (gate 1, 2 to 10 days on the customer side).',c:['Checksums and format','Technical QA: levels, clipping, side length','Artist gate 1: master plan approved'],f:['1 to 2 days (production timeline)','A new title every 0.55 to 0.85 days here, ~520 a year (revenue model at full capacity: 300 to 600)','Runs of 300 to 10,000, ~3,100 records per title on average (revenue model: 2,500 to 3,300)']}, + audio:{t:'1 · Audio intake',w:'Files arrive from the label or artist; checksums and format are verified and a technical QA pass checks levels, clipping and side length against the format. Nothing is cut until the artist confirms the master plan (gate 1, 2 to 10 days on the customer side).',c:['Checksums and format','Technical QA: levels, clipping, side length','Artist gate 1: master plan approved'],f:['1 to 2 days (production timeline)','A new title every 0.75 to 1.15 days here, ~380 a year, between the revenue model\'s 300 (central) and 400 (favourable) titles for the launch plant; in 90-day test runs the presses run ~64 to 73 % of shift time, about scale.md\'s 60 to 70 % effectiveness (estimate)','Runs of 300 to 10,000, ~3,100 records per title on average (revenue model: 2,500 to 3,300)']}, master:{t:'2 · Vinyl mastering',w:'The audio is mastered for the physical limits of the groove. The artist approves the vinyl master (gate 2, 2 to 10 days) before anything is cut.',c:['Engineer QA of the vinyl master','Artist gate 2: master approved'],f:['2 to 4 days in-house (production timeline)','Mastering room ~40 to 60 m²','Mastering and lathe cutting are the planned Payap student-programme subjects (payap-partnership.md)']}, cut:{t:'3 · Lathe cutting',w:'The master is cut into a nitrocellulose lacquer per side: grooves 40 to 80 µm wide, ~28 µm deep. The dead-wax matrix code and an angular fiducial are scribed cold (never with a laser: the lacquer is flammable), and the scribe carries through every metal generation onto every record. Both lacquers go to silvering together and must be plated within roughly 24 to 72 hours.',c:['Groove microscope','Test cut','Dead-wax scribe and fiducial'],f:['1 to 2 days','Sillitoe SDMS or Agnew lathe (vendor landscape)']}, pasu:{t:'4a · PASU automatic silvering (Pheenix Alpha)',w:'The lacquer is cleaned on the bench station, sensitised, then turned at 45 rpm under four nozzles that spray the silver in an automatic sequence, making the groove conductive for the nickel. Silver is the first metal to touch the groove.',c:['Silvering chemistry logged per batch','Lacquer inspected before silvering'],f:['~15 min per lacquer (estimate; no published figure)','W 2188 × D 715 × H 1835 mm, single-phase 10 A, air 6 bar, exhaust Ø125 mm at 150 m³/h (2024 flyer)']}, pppu:{t:'4b · PPPU pre-plating (Pheenix Alpha)',w:'A thin first nickel layer over the silver at low current, before production plating. Up to four masters at once, each position with its own control and cathode movement, PID temperature control.',c:['Bath temperature PID-controlled','Current and time logged per position'],f:['15 to 30 min at 10 to 20 A in published practice; 20 min at 20 A and 35 °C here (galvanics.md)','Up to 15 VDC and 30 A per position, 385 L tank, 4.5 kW heater (2024 flyer)']}, - pdpu:{t:'4c · PDPU dual plating unit (Pheenix Alpha)',w:'Production electroforming: father on the pre-plated lacquer, mother on the father, stampers on the mother. Each cell has its own rotating cathode and digitally controlled rectifier; the current ramps up and the part grows to its thickness. The simulation deposits nickel by Faraday\'s law (1.095 g per ampere-hour at ~97 % efficiency, ~9.6 dm² for a Ø350 mm part), so the times follow from the current: father 0.25 mm in ~1 h 15 min on a slow ramp to 185 A, mother 0.25 mm in ~1 h and stamper 0.20 mm in ~50 min at 200 A. Loading takes 5 min, rinsing and unloading 10 min per part. A part that finishes after the shift waits in the cell until morning.',c:['Current, voltage and ampere-hours per cell (PLC with network access)','Bath temperature, filters, nickel top-up and anode basket alerts','Extraction interlock: no extraction, no plating'],f:['Up to 15 VDC and 200 A per cell, 40 L per cell, 385 L tank, parts up to Ø355 mm, cooling water 12 to 20 °C at 10 L/min (2024 flyer)','Published practice: father ~1 h 15 min, mother 1 to 1¼ h, stamper ~45 min (galvanics.md)','One PDPU covers full-capacity demand (20 to 32 parts a day); the second buys redundancy rather than capacity','Bath at 55 °C on screen is an estimate']}, + pdpu:{t:'4c · PDPU dual plating unit (Pheenix Alpha)',w:'Production electroforming: father on the pre-plated lacquer, mother on the father, stampers on the mother. Each cell has its own rotating cathode and digitally controlled rectifier; the current ramps up and the part grows to its thickness. The simulation deposits nickel by Faraday\'s law (1.095 g per ampere-hour at ~97 % efficiency, ~9.6 dm² for a Ø350 mm part), so the times follow from the current: father 0.25 mm in ~1 h 15 min on a slow ramp to 185 A, mother 0.25 mm in ~1 h and stamper 0.20 mm in ~50 min at 200 A. Loading takes 5 min, rinsing and unloading 10 min per part. A part that finishes after the shift waits in the cell until morning.',c:['Current, voltage and ampere-hours per cell (PLC with network access)','Bath temperature, filters, nickel top-up and anode basket alerts','Extraction interlock: no extraction, no plating'],f:['Up to 15 VDC and 200 A per cell, 40 L per cell, 385 L tank, parts up to Ø355 mm, cooling water 12 to 20 °C at 10 L/min (2024 flyer)','Published practice: father ~1 h 15 min, mother 1 to 1¼ h, stamper ~45 min (galvanics.md)','The launch plant has one PDPU (total-investment.md); it covers full-capacity demand of 20 to 32 parts a day, a second would buy redundancy rather than capacity (galvanics.md)','Bath at 55 °C on screen is an estimate']}, pmpb:{t:'4d · PMPB preparation bench (Pheenix Alpha)',w:'Between generations the new part is separated, cleaned, passivated anodically so the next generation will part from it, and spun dry. The lacquer is consumed when the father comes off; in 3-step plating the father, and later the mother, go to the archive.',c:['Passivation logged per part','Rinse water to treatment, never the drain'],f:['~10 to 15 min per part (estimate)','Spin table up to 120 rpm, DI water G3/4", single-phase 10 A (2024 flyer)']}, qc:{t:'4e · Part QC: XRF and mother listening',w:'Every father, mother and stamper gets an XRF thickness reading against its serial; every mother is played before stampers are grown from it, since the mother is the playable positive.',c:['XRF nickel thickness per part, 0.2 to 0.3 mm','Mother listening check'],f:['~3 min per XRF reading, ~25 min for a mother with listening (estimates)']}, vsf:{t:'5a · VSF back-finish (Sibert)',w:'The stamper back is wet-sanded through a sequence of abrasive grades and cleaned, so it seats evenly on the mould and no back-side defect presses through. First of the three Sibert steps: finish, punch, coin (the order Gotta Groove runs its Sibert machines in).',c:['Back visual check','Closed water loop with filtration; the nickel-bearing water goes to treatment'],f:['~5 to 10 min (estimate; Sibert publishes none), 8 min here','P120 to P2500 in nine grades, 4-station disc head, 150 to 1500 rpm, 1200 VA, 250 kg (2022 spec)']}, @@ -937,7 +940,7 @@ const DETAILS={ lab:{t:'M · Material lab gate',w:'Every incoming lot is quarantined and tested before release; production keeps running on released stock meanwhile. New lots and new suppliers are released only after a release pressing passes optical and audio QC.',c:['Moisture (halogen analyser), heat stability, density, colour','Release pressing'],f:['~2 h from start of tests to release here (estimate)','Instruments and costs: quality-automation.md']}, oven:{t:'L · Label dry oven',w:'Centre labels are pressed into the record, not glued on. Moisture in the paper causes bubbles, so labels are pre-dried before they reach a press, and the label lot is logged per press cycle.',c:['Print inspection per label lot','Label identity and centring checked by the optical inspection'],f:['France Etuves XU 112 class oven (Newbilt quote)']}, duplex:{t:'6 · Duplex: HRP 12 presses A and B (Newbilt)',w:'Two semi-automatic presses on one VEX 50 extruder and one hydraulic unit. Each cycle the operator places the bottom label, the cake and the top label; the press closes, steam at 10 bar heats the mould and ~150 t flows the vinyl into the grooves, cooling water sets it, it opens and ejects. Newbilt recommends the Duplex for splatter, so colour and splatter titles come here first; splatter runs the EX 35.',c:['Per cycle: temperatures, pressures, cycle time, cake weight, label lot','10 test pressings for every new title, then gate 3','Record key: stamper + press + cycle timestamp + side'],f:['~30 s average cycle (Newbilt website); here LOAD 4 to 6.5 (by hand), CLOSE 2, STEAM 8, COOL 10, OPEN 2, EJECT 3 s (split is an estimate)','scale.md assumes only 60 to 80 records/h per semi-automatic press with operator handling (estimate); Newbilt\'s 30 s is 120/h','HRP 12: four columns, Ø330 mm cylinder, ~150 t (2024 quote)','Steam 150 to 180 kg/h, cooling up to 100 l/min and 125 kW per press (site requirements)','Stamper change ~20 min, new title ~40 min (estimates)','Unplanned stops about one per 4 running hours, 15 to 45 min each (estimate, sized so overall effectiveness lands near scale.md\'s 60 to 70 %)']}, - classic:{t:'6 · Classic automatic presses C1 and C2 (Newbilt)',w:'Fully automatic, on a 3-column frame derived from the Toolex Alpha: built-in extruder, automatic cake and label loading, cooling-plate handling and spindle stacking. Cooling can end by time or by delivered water volume, and the target volume rises as the cooling water warms, so the cycle stretches when the chiller supply runs above design (modelled at 5 % per °C over 22 °C). Black and solid colour titles; Newbilt sends splatter to the Duplex.',c:['Steam temperature, cooling water temperature and flow monitored','Cycle and trend recording; SCADA interface over OPC UA'],f:['28 s even at 180 g, claimed ≥95 % yield and ≥95 % uptime (2024 flyer); here LOAD 3, CLOSE 2, STEAM 7, COOL 11, OPEN 2, EJECT 3 s','12" at 110 to 180 g, 7" in development, inserts shared with the Duplex (2026 flyer)','Built-in extruder: three zones, 7.5 kW motor (2024 flyer)','Unplanned stops as for the Duplex (estimate)']}, + classic:{t:'6 · Classic automatic press (Newbilt)',w:'Fully automatic, on a 3-column frame derived from the Toolex Alpha: built-in extruder, automatic cake and label loading, cooling-plate handling and spindle stacking. Cooling can end by time or by delivered water volume, and the target volume rises as the cooling water warms, so the cycle stretches when the chiller supply runs above design (modelled at 5 % per °C over 22 °C). Black and solid colour titles; Newbilt sends splatter to the Duplex.',c:['Steam temperature, cooling water temperature and flow monitored','Cycle and trend recording; SCADA interface over OPC UA'],f:['28 s even at 180 g, claimed ≥95 % yield and ≥95 % uptime (2024 flyer); here LOAD 3, CLOSE 2, STEAM 7, COOL 11, OPEN 2, EJECT 3 s','12" at 110 to 180 g, 7" in development, inserts shared with the Duplex (2026 flyer)','Built-in extruder: three zones, 7.5 kW motor (2024 flyer)','Unplanned stops as for the Duplex (estimate)']}, vex:{t:'6a · VEX 50 extruder (Newbilt)',w:'Feeds both Duplex presses: granulate from the hopper melts through three heated zones and leaves as a cake 20 to 40 g heavier than the record, the surplus becoming edge trim. The two presses draw cakes alternately.',c:['Zone temperatures and screw speed logged','Cake weight per cycle','Regrind ratio verified here'],f:['50 mm screw, three zones, 7.5 kW motor, 45° mounting (2024 quote)','15 kVA connected, 8 kW average (site requirements)']}, ex35:{t:'6b · EX 35 auxiliary extruder (Newbilt)',w:'Runs beside the VEX 50 and adds a second or third colour as PVC strands for splatter, marble and other effects. Active here whenever a Duplex press runs a splatter title.',c:['Colour lot logged per cycle'],f:['35 mm screw, three zones, two fans, frequency-controlled screw speed (2026 flyer)','Not in the 2024 quote']}, trim:{t:'7a · Edge trimmers (Newbilt)',w:'A heated blade trims each record to its final diameter straight after the press. The trim drops into bins that go to the granulator in batches.',c:['Trim quality on every record'],f:['~6 s per record (estimate; no published figure)','Heated blade, 7"/10"/12" plates, standalone or in the Duplex emergency-stop circuit (2026 flyer)']}, @@ -949,13 +952,13 @@ const DETAILS={ finish:{t:'7b · Finishing',w:'Inner sleeve and, once assembled, the shrink wrapper. The labels are already on: they were pressed in.',c:['Inner sleeve scuff check per lot','Shrink wrap sampled'],f:['2 to 3 days per order (production timeline)']}, pack:{t:'8 · Packaging and assembly',w:'The runout matrix code is scanned against the jacket barcode, so the wrong record in the right jacket is caught every time.',c:['Matrix code vs jacket barcode on every unit','Barcode verification'],f:['Packaging and finished goods ~300 to 500 m²']}, ship:{t:'9 · Fulfillment',w:'Bulk pallets, or per-parcel dropship for the label; carrier tracking joins the traceability record. Test pressings leave here for the artists.',c:['Consignment vs bill of materials','Tracking per shipment or per end customer'],f:['Quoted lead time 7 to 9 weeks mature, 2 to 3 weeks for a repress']}, - boiler:{t:'Steam boiler',w:'Saturated steam at 10 bar / 180 °C heats the moulds; each press draws ~1.3 kg per cycle. Four presses need 600 to 720 kg/h at Newbilt\'s 150 to 180 kg/h per press, so the boiler is shown at 800 kg/h. That is an estimate for this four-press page; the five-press plan (scale.md, steam-cooling.html) is a bank of two 500 kg/h modules. Below 9.5 bar the presses hold in STEAM (Steam dip button).',c:['Pressure held between 9.5 and 10.5 bar at the press','Feedwater treatment, condensate return'],f:['Fuel decision open: biomass, LPG or electric','Detached boiler hall with a 14 m flue','Five-press plan: 750 to 900 kg/h on a 2 × 500 kg/h boiler bank (steam-cooling.html)']}, - chiller:{t:'Process cooling',w:'Cooling water sets the vinyl after the steam phase. The four presses here can need up to 125 kW each, so the chiller is shown at 500 kW (estimate for this four-press page; the five-press plan is a 3 × 250 kW chiller bank, steam-cooling.html). If the supply water runs warm, the Classics stretch their cooling and their cycle. The galvanics plating units take a small branch at 12 to 20 °C.',c:['Supply 20 to 25 °C, closed loop','Up to 100 l/min per press, ~53 l/min average (site requirements)'],f:['~80 to 125 kW electrical per 250 kW of cooling','PDPU coil: 10 L/min at 12 to 20 °C (2024 flyer)']}, + boiler:{t:'Steam boilers B-1 and B-2',w:'Saturated steam at 10 bar / 180 °C heats the moulds; each press draws ~1.3 kg per cycle. The launch plant\'s three presses need 450 to 540 kg/h at Newbilt\'s 150 to 180 kg/h per press, on two 500 kg/h boiler modules running lead and lag in a boiler hall built for four (scale.md, steam-cooling.html). Below 9.5 bar the presses hold in STEAM (Steam dip button).',c:['Pressure held between 9.5 and 10.5 bar at the press','Feedwater treatment, condensate return'],f:['Launch plant 450 to 540 kg/h against 1,000 kg/h installed (scale.md)','Fuel decision open: biomass, LPG or electric','Detached boiler hall with a 14 m flue','Second Duplex (growth option, five presses): 750 to 900 kg/h on the same two modules (steam-cooling.html)']}, + chiller:{t:'Process cooling CH-1 and CH-2',w:'Cooling water sets the vinyl after the steam phase. The launch plant\'s three presses peak at ~390 kW on a hot afternoon (391.5 kW: up to 125 kW per press, 3 kW per extruder, 2.5 kW per press for hydraulics; scale.md), on two 250 kW air-cooled chiller modules, CH-1 and CH-2, 500 kW in a compound built for four (steam-cooling.html). If the supply water runs warm, the Classic stretches its cooling and its cycle. The galvanics plating unit takes a small branch at 12 to 20 °C.',c:['Supply 20 to 25 °C, closed loop','Up to 100 l/min per press, ~53 l/min average (site requirements)'],f:['~80 to 125 kW electrical per 250 kW of cooling: ~125 to 196 kW at the launch plant\'s peak (scale.md, estimate)','Second Duplex (growth option, five presses): ~650 kW on 3 × 250 kW, CH-3 in its reserved position (scale.md)','PDPU coil: 10 L/min at 12 to 20 °C (2024 flyer)']}, comp:{t:'Compressed air',w:'Dry, filtered air for the press and extruder actuators, the Sibert machines and the silvering unit.',c:['Dew point max 3 °C, impurities max 5 µm'],f:['14 m³/h for a Duplex system (site requirements)','Sibert: 6 to 8 bar, 3.1 to 4.5 L/s per machine in use; PASU 6 bar']}, - hyd:{t:'Hydraulic aggregate (Duplex)',w:'One aggregate supplies ~150 t to both Duplex presses at 180 bar from a gas-loaded accumulator. A larger central supply shared by several systems is possible (Duplex flyer); how the Classics are supplied is a re-quote question.',c:['Oil temperature and pressure logged'],f:['200 l HLP 46, 15 kVA, 12 kW average, 600 kg (site requirements)']}, + hyd:{t:'Hydraulic aggregate (Duplex)',w:'One aggregate supplies ~150 t to both Duplex presses at 180 bar from a gas-loaded accumulator. A larger central supply shared by several systems is possible (Duplex flyer); whether the Classic runs from it is a re-quote question.',c:['Oil temperature and pressure logged'],f:['200 l HLP 46, 15 kVA, 12 kW average, 600 kg (site requirements)']}, diro:{t:'RO / DI water',w:'Plating rinses need deionised water: the PMPB bench has a DI connection and the silvering chemistry is made up with it.',c:['Conductivity logged'],f:['The RO skid in the utilities CSV is an option row sized for boiler feed, not for this (galvanics.md)','0.2 m³/h make-up here (estimate)']}, zld:{t:'Water treatment, zero discharge',w:'Galvanics rinse water and the VSF\'s nickel-bearing loop water go through closed-loop treatment and metal recovery with an evaporator; nothing goes to the drain. Neither Pheenix nor Digital Matrix supplies this; it is a separate vendor.',c:['Rinse conductivity, evaporator state'],f:['Zero contaminated water commitment (sustainability.md)','USD 90k to 240k (total investment)']}, - energy:{t:'Energy',w:'247 kWp of roof PV, a 271 kWh battery for ride-through, and a medium-voltage PEA connection. Solar follows the clock; the battery covers the evening.',c:['Plant peak ~430 to 700 kW without an electric boiler (five-press plan, scale.md)'],f:['Galvanics ~27 kVA connected per line, far less drawn (galvanics.md)','PV covers roughly 28 to 45 % of consumption without electric steam']}, + energy:{t:'Energy',w:'247 kWp of roof PV, a 271 kWh battery for ride-through, and a medium-voltage PEA connection. Solar follows the clock; the battery covers the evening.',c:['Plant peak ~430 to 700 kW without an electric boiler (scale.md, sized for the five-press layout the backbone is built for)'],f:['Galvanics ~27 kVA connected per line, far less drawn (galvanics.md)','PV covers roughly 28 to 45 % of consumption without electric steam']}, trace:{t:'Traceability',w:'Every step logs at the source: press and rectifier PLCs, the lab, the XRF, the vision station; manual steps check in. Append-only, kept for the life of the customer relationship.',c:['Record key: stamper + press + cycle timestamp + side','Every part knows its parents: stamper, mother, father, lacquer'],f:['The part of the plan the industry responded to at Making Vinyl Europe 2026']}, hvac:{t:'Plant HVAC',w:'The press hall at 20 to 26 °C and 35 to 60 % RH; galvanics, archive and audio rooms in their own zones, logged on the production timeline.',c:['T, RH and PM per zone'],f:['~100 to 200 kW peak (estimate)']}, exh:{t:'Galvanics extraction',w:'Every tank unit is extracted (Ø63 mm per plating unit, Ø125 mm at 150 m³/h on the silvering unit) through a scrubber. The interlock is hard-wired: no extraction, no plating.',c:['Fan status logged, interlock hard-wired'],f:['Facility security: fume-extraction interlocks']}, @@ -1076,12 +1079,12 @@ function seed(){ seed(); // Two days of warm-up, then run on to a mid-shift moment with work on the metal path // and the presses (at ~25 % plating load an arbitrary 08:00 often shows idle cells). -const busy=()=>{const h=hourOf();return h>=7&&h<19&&CELLS.some(c=>c.ph==='plate')&&galvCount()>=3&&PRESS.filter(running).length>=3;}; +const busy=()=>{const h=hourOf();return h>=7&&h<19&&CELLS.some(c=>c.ph==='plate')&&galvCount()>=3&&PRESS.filter(running).length>=2;}; const t0=performance.now();while(S.t<2*DAY)tick(2); while(S.t<6*DAY&&!busy())tick(2); for(let i=0;i<480;i++)tick(0.25); // last two minutes at the 1x step S.quiet=false; -log('Two shifts, 06:00 to 22:00: Pheenix line, Sibert prep and four Newbilt presses at real duration (warm-up '+f0(performance.now()-t0)+' ms)','ok'); +log('Launch plant, two shifts 06:00 to 22:00: Pheenix line, Sibert prep and three Newbilt presses at real duration (warm-up '+f0(performance.now()-t0)+' ms)','ok'); log('Material lab: lot '+S.lab.lot+' released, moisture 0.03 %, heat stability OK','ok'); select('pC1',true);renderTags(); diff --git a/docs/steam-cooling.html b/docs/steam-cooling.html index 29edcf5..5115f4c 100644 --- a/docs/steam-cooling.html +++ b/docs/steam-cooling.html @@ -3,7 +3,7 @@ -CNX Vinyl · Steam and cooling plant (five-press fleet) +CNX Vinyl · Steam and cooling plant (launch plant)