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Optical QC: EtherCAT control plan with geizhals.de prices
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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.
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grabowski committed 2026-10-19 10:43:59 +07:00
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docs/equipment/inline-qc-station/inline-qc-station-bom.csv
+14 -9
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@@ -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
1 group item qty example unit_usd_low unit_usd_high line_usd_low line_usd_high source
13 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)
14 Handling Spindle head: bearing housing, timing belt, label pad, pneumatic expanding mandrel 1 machined parts 600 1800 600 1800 estimate
15 Handling Rodless cylinder 25 mm, 350 mm stroke, with paddle 1 SMC MY1B / CY3B class 400 900 400 900 estimate
16 Handling Valve terminal, FRL, tubing, fittings Valve terminal, FRL with a dump valve switched by the safety relay, pressure switch, tubing, fittings 1 lot 400 1000 400 1000 estimate
17 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
18 Vision Line-scan lens, 50 mm 2 300 800 600 1600 estimate
19 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 Vision Ring light 2 150 400 300 800 estimate
25 Vision Strobe and light controllers 2 300 800 600 1600 estimate
26 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)
27 Sensors Photoelectric presence sensors and one through-beam 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
28 Sensors Cylinder position switches (lift up/down, pusher home/out, mandrel open/clamped) 6 SMC D-M9 class 25 60 150 360 each; estimate
29 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 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 class Omron E6B2-CWZ1X 2000 P/R class 60 53 300 282 60 53 300 282 estimate 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)
30 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)
31 Control EtherCAT station controller: fanless mini PC, Intel N100 class, 2x Intel i226, NixOS with PREEMPT_RT, open-source EtherCAT master (EtherCrab or IgH) 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 Topton / CWWK N100 2x i226 class ANDAQI RS55 / MNBOXCONET P2-N100 / AIOPCWA AI201-TF 162 455 470 685 162 455 470 685 from USD 162 (Alibaba listing) to 279 to 469 at retail (plugpcs.com, Newegg), Oct 2026 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)
32 Control EtherCAT I/O: EK1100 coupler, EL1809 16 DI, EL2809 16 DO, EL3102 2 AI (warp lasers), end terminal EtherCAT coupler 1 set 1 Beckhoff Beckhoff EK1100 430 174 780 295 430 174 780 295 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 EUR 150.75 to 255.43, no current offer (geizhals.de/144468496, 19 Oct 2026)
33 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)
34 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)
35 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)
36 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)
37 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)
38 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
39 Control HMI touch panel, 10 inch, showing the station's browser page HMI: 10.1 inch PCAP touch monitor, 7H glass, showing the station's browser page 1 iiyama ProLite TF1015MC-B3 400 360 900 468 400 360 900 468 estimate 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)
40 Control Safety relay, e-stop, door interlock wiring, contactor in the drive supply (the 100 W kit has no STO) 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 300 600 389 300 600 389 estimate 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)
41 Control Cabinet, power supply, breakers, terminals, wiring, stack light 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 estimate; Mean Well SDR-120-24 from EUR 38.87 and shielded Cat5e patch cables from EUR 0.62 (geizhals.de, 19 Oct 2026)
42 Total Hardware per station, thermal camera excluded 16112 16912 32938 33061 sum of the lines above