Optical QC: EtherCAT control plan with geizhals.de prices

User, 19 Oct 2026: plan the current EtherCAT setup, keep the 100 W servo,
check prices on geizhals.de.

- New docs/equipment/inline-qc-control-plan.md: decisions, bus layout
  (drives at the end of the line because the A6-200EC takes control
  power from the main supply), I/O list for EL1809/EL2809/EL3152/EL5101
  and the drive touch probe, PDO and DC notes from the A6-EC manual,
  geizhals.de price table (EUR 1,891.60 to 2,104.39 + USD 246.58 for the
  servo kits, THB 80k to 88k), NixOS/EtherCrab software, safety circuit
  (PNOZ s3, two contactors, dump valve), bench test with pass marks
  (parts about THB 64k, all reused), build order, spares, open points.
- EL3102 replaced by EL3152: the optoNCDT 1420 output is 4 to 20 mA.
- Spindle encoder index goes to an EL5101 instead of the drive touch
  probe; encoder 2,000 to 2,500 pulses.
- BOM: control lines split per part with geizhals.de prices (+30% high
  end for shipping and Thai duty/VAT, estimate); total USD 16,912 to
  33,061 (THB 0.56M to 1.09M). Doc, render caption and fleet calculator
  text now say USD 17k to 33k.
- README links the plan.

docs/equipment/inline-qc-station/annotate_render.py

@@ -14,7 +14,7 @@ TITLE = "Inline optical QC station"
 SUBTITLE = ("Every record checked on both faces in one turn: surface, label, warp and centring. "
             "Failed records leave the line automatically.")
 FOOTER = ("CNX Vinyl, concept model (FreeCAD); bought parts drawn as outlines. 1.9 × 0.65 × 1.5 m, "
-          "front panels and lid removed for the view. Hardware about USD 16k to 33k per station (estimate).")
+          "front panels and lid removed for the view. Hardware about USD 17k to 33k per station (estimate).")
 NAVY, GREY, LINE = (18, 53, 91), (85, 95, 105), (60, 74, 90)
 
 

docs/equipment/inline-qc-station/inline-qc-station-bom.csv

@@ -13,7 +13,7 @@ Handling,"Guided lift cylinder, 20 mm bore, 75 mm stroke",1,SMC MGPM20-75,330,45
 Handling,"Spindle servo kit 100 W, EtherCAT (A6-200EC drive), cyclic synchronous position; 1:6 timing belt to the spindle",1,StepperOnline A6-EC100L2A1-M17,123,300,123,300,"USD 123.29 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
+Handling,"Valve terminal, FRL with a dump valve switched by the safety relay, pressure switch, tubing, fittings",1 lot,,400,1000,400,1000,estimate
 Vision,"4k monochrome line-scan camera, GigE",2,Basler racer 2 r2L4096 / Hikrobot MV-CL042-91GM,857,1088,1714,2176,Basler web shop via price listing
 Vision,"Line-scan lens, 50 mm",2,,300,800,600,1600,estimate
 Vision,Coaxial line light,2,,295,446,590,892,made-in-china listing USD 295 to 349; Vision Datum USD 420; light186 from USD 446
@@ -24,14 +24,19 @@ Vision,Lens 16 mm,2,,150,400,300,800,estimate
 Vision,Ring light,2,,150,400,300,800,estimate
 Vision,Strobe and light controllers,2,,300,800,600,1600,estimate
 Sensors,"Laser distance sensor, 50 mm range",2,Micro-Epsilon optoNCDT 1420,520,1600,1040,3200,"list from EUR 470 (Micro-Epsilon); ILD1420-25 about USD 1,600 (Radwell)"
-Sensors,Photoelectric presence sensors and one through-beam,5,,50,150,250,750,each; estimate
+Sensors,Photoelectric presence sensors and one through-beam (the through-beam also to the conveyor drive's touch probe),5,,50,150,250,750,each; estimate
 Sensors,"Cylinder position switches (lift up/down, pusher home/out, mandrel open/clamped)",6,SMC D-M9 class,25,60,150,360,each; estimate
-Sensors,"Spindle incremental encoder, RS-422 line driver, 2,500 to 5,000 pulses a turn: A/B clock both line-scans, index to the servo touch probe",1,Omron E6B2-CWZ1X class,60,300,60,300,estimate
+Sensors,"Spindle incremental encoder, RS-422 line driver, 5 V, 2,000 to 2,500 pulses a turn: A/B clock both line-scans, A/B/Z to the EL5101",1,Omron E6B2-CWZ1X 2000 P/R class,53,282,53,282,"E6B2-CWZ1X 2000 P/R listing EUR 45.52 to GHH60 2500 P/R line driver EUR 187.83 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT; marketplace sellers, test on the bench); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
 Sensors,"Thermal camera (option, not in the total)",0 (1 optional),Optris Xi 400,2100,3000,0,0,"from EUR 1,950 (Optris); USD 2,995 (moviTHERM)"
-Control,"EtherCAT station controller: fanless mini PC, Intel N100 class, 2x Intel i226, NixOS with PREEMPT_RT, open-source EtherCAT master (EtherCrab or IgH)",1,Topton / CWWK N100 2x i226 class,162,470,162,470,"from USD 162 (Alibaba listing) to 279 to 469 at retail (plugpcs.com, Newegg), Oct 2026"
-Control,"EtherCAT I/O: EK1100 coupler, EL1809 16 DI, EL2809 16 DO, EL3102 2 AI (warp lasers), end terminal",1 set,Beckhoff,430,780,430,780,EK1100 USD 131 (industrialsupplygroups); EL1809 EUR 78 net (industry-electronics); EL2809 USD 99 net (TME); EL3102 EUR 111 (automation-base) to USD 290 (plcpartssolution); Oct 2026
+Control,"EtherCAT station controller: fanless mini PC, Intel N100, 2 or more Intel i226-V ports, NixOS with PREEMPT_RT, open-source EtherCAT master (EtherCrab, IgH fallback)",1,ANDAQI RS55 / MNBOXCONET P2-N100 / AIOPCWA AI201-TF,455,685,455,685,"EUR 393.99 to 455.99 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/mini-pc-barebone-netzwerk-pc-intel-n100-a2926989.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,EtherCAT coupler,1,Beckhoff EK1100,174,295,174,295,"EUR 150.75 to 255.43, no current offer (geizhals.de/144468496, 19 Oct 2026)"
+Control,"16 digital inputs, 24 V: photoelectric sensors, cylinder switches, safety status",1,Beckhoff EL1809,109,141,109,141,"EUR 93.97 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/1371087148); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,"16 digital outputs, 24 V, 0.5 A: valves, stack light, light enable",1,Beckhoff EL2809,119,155,119,155,"EUR 102.97 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/1371087504); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,"2 analog inputs, 4 to 20 mA: the two warp lasers",1,Beckhoff EL3152,241,314,241,314,"EUR 208.90 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/185886294); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,"Incremental encoder interface, RS-422, 5 V encoder supply: spindle encoder count and index latch",1,Beckhoff EL5101,336,437,336,437,"EUR 291.04 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/2974477757); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,End cap,1,Beckhoff EL9011,5,7,5,7,"EUR 4.33 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/455904583); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
 Control,"Edge PC with GPU, 4 GigE PoE ports, NixOS",1,,1500,3200,1500,3200,"qscompute buying guides 2026: USD 1,490 to 3,200"
-Control,"HMI touch panel, 10 inch, showing the station's browser page",1,,400,900,400,900,estimate
-Control,"Safety relay, e-stop, door interlock wiring, contactor in the drive supply (the 100 W kit has no STO)",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",,,,,16112,32938,sum of the lines above
+Control,"HMI: 10.1 inch PCAP touch monitor, 7H glass, showing the station's browser page",1,iiyama ProLite TF1015MC-B3,360,468,360,468,"EUR 311.90 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/iiyama-prolite-tf1015mc-b3-a3228748.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,"Safety: relay for e-stop and door switch, 2 contactors in series in the drive supply (the 100 W kit has no STO), e-stop button, reset button",1 lot,"Pilz PNOZ s3 750103, Siemens 3RT2015 24 V DC coil, Schneider Harmony e-stop",300,389,300,389,"PNOZ s3 EUR 148.38, 3RT2015-1BB41 EUR 27.95 each, e-stop EUR 45.08 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT); reset button EUR 10 (estimate); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)"
+Control,"Cabinet, 24 V 120 W supply, breakers, terminals, wiring, shielded EtherCAT patch cables, stack light",1 lot,Mean Well SDR-120-24 supply,800,2000,800,2000,"estimate; Mean Well SDR-120-24 from EUR 38.87 and shielded Cat5e patch cables from EUR 0.62 (geizhals.de, 19 Oct 2026)"
+Total,"Hardware per station, thermal camera excluded",,,,,16912,33061,sum of the lines above