Inline QC station: real 40x40 profiles, labelled investor render

User, 18 Oct 2026: use real 40x40 profiles, make a render with text
pointing out the parts to show the investor; the ring lights looked
like they were floating.

- build_station.py: frame drawn from the real 8-slot 40 series section
  (profile_shape: slots, centre bore, corner cavities; 40x80 with centre
  cavity) and 24 cast angle brackets; top beams now butt between the
  uprights; label-camera posts moved beside the cameras so both ring
  lights clamp straight to them; top line-scan on a side post with
  visible camera plate and light hangers; slide strips on carrier angles,
  pulley axles, end-stop posts, presence-sensor brackets, backlight post,
  cabinet on base crosses, chute on two supports and clear of the rail,
  pneumatics rail, stack light on the back upright, touch screen on the
  front end upright. A connectivity check at the end lists any part that
  does not reach the floor through touching parts: none.
- render_annotated.py (FreeCAD): front three-quarter view, camera backed
  off so nothing is clipped, no navigation cube or preselection, label
  positions projected from the camera and checked with marker renders.
- annotate_render.py (Pillow): title, 16 labels in two columns, leaders
  assigned so none cross -> inline-qc-station-annotated.png.
- render_station.py: same camera and preselection fixes; all six views
  re-rendered.
- BOM: 32 m of 40x40 in 45 pieces; total still USD 16k to 33k.
- inline-optical-qc.md and README updated; .gitignore for the render
  intermediates.
This commit is contained in:
grabowski committed 2026-10-18 14:07:41 +07:00
1 parent 609424b598
commit e8674795f5
16 files changed
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@@ -1,7 +1,7 @@
group,item,qty,example,unit_usd_low,unit_usd_high,line_usd_low,line_usd_high,source
Frame,"40x40 slot profile, cut to length",27 m (37 pieces),"8-slot 4040 (Misumi HFS8-4040 class, or Thai/Chinese generic)",11,21,297,567,per m; Shopee Thailand listing from THB 356; aluxprofile EUR 19 to 24 per m
Frame,"40x40 slot profile, cut to length",32 m (45 pieces),"8-slot 4040 (Misumi HFS8-4040 class, or Thai/Chinese generic)",11,21,354,676,per m; Shopee Thailand listing from THB 356; aluxprofile EUR 19 to 24 per m
Frame,"40x80 slot profile, base beams",3.8 m (2 pieces),8-slot 4080,22,42,84,160,"per m; estimate, about twice the 4040 price"
Frame,"Angle brackets, T-nuts, screws, end caps",1 lot (about 120 joints),,250,600,250,600,estimate
Frame,"Cast angle brackets (24 drawn), T-nuts, screws, end caps",1 lot,,250,600,250,600,estimate
Frame,Levelling feet M16,8,,8,25,64,200,each; estimate
Enclosure,"Black panels, 4 mm ACM or PP, light-tight tunnel",4.3 m2,,25,60,108,258,per m2; estimate
Enclosure,"Clear polycarbonate guard, reject zone",1.4 m2,,30,70,42,98,per m2; estimate
@@ -31,4 +31,4 @@ 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",,,,,16056,32715,sum of the lines above
Total,"Hardware per station, thermal camera excluded",,,,,16114,32824,sum of the lines above
1 group item qty example unit_usd_low unit_usd_high line_usd_low line_usd_high source
2 Frame 40x40 slot profile, cut to length 27 m (37 pieces) 32 m (45 pieces) 8-slot 4040 (Misumi HFS8-4040 class, or Thai/Chinese generic) 11 21 297 354 567 676 per m; Shopee Thailand listing from THB 356; aluxprofile EUR 19 to 24 per m
3 Frame 40x80 slot profile, base beams 3.8 m (2 pieces) 8-slot 4080 22 42 84 160 per m; estimate, about twice the 4040 price
4 Frame Angle brackets, T-nuts, screws, end caps Cast angle brackets (24 drawn), T-nuts, screws, end caps 1 lot (about 120 joints) 1 lot 250 600 250 600 estimate
5 Frame Levelling feet M16 8 8 25 64 200 each; estimate
6 Enclosure Black panels, 4 mm ACM or PP, light-tight tunnel 4.3 m2 25 60 108 258 per m2; estimate
7 Enclosure Clear polycarbonate guard, reject zone 1.4 m2 30 70 42 98 per m2; estimate
31 Control HMI touch panel, 10 inch 1 400 900 400 900 estimate
32 Control Safety relay, e-stop, door interlock wiring 1 lot 300 600 300 600 estimate
33 Control Cabinet, power supply, breakers, terminals, wiring, stack light 1 lot 800 2000 800 2000 estimate
34 Total Hardware per station, thermal camera excluded 16056 16114 32715 32824 sum of the lines above