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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@@ -1609,7 +1609,7 @@ html[data-theme=light] .iso-svg .iso-glint { display: inline; }
sc.inf("colourstore", "Colour store, ~180 m2", "About 100 pallet positions on four levels for tens of colours (estimate); weighing, mixing and vacuum conveying");
sc.inf("plantroom", "Central hydraulic and air plant room, ~62 m2", "Pump sets on one manifold with the accumulators, one compressed-air plant; ring mains with a valved tee at every press position (pressing-line.md)");
sc.inf("aisle", "Crane and forklift aisle, 4.5 m", "Along the back wall from the machine door to the finishing block: heavy moves need a floor-level path");
sc.inf("trim", "Optical inspection after cooling", "One station checks every record of both presses after the cooling racks: surface (a line-scan camera per side), label, warp and centring in one turn. The finishing operator feeds it from the cooled stacks; good records go on to sleeving, rejects into the bin with the reason on the screen. Early lane: the first records of each run and after each stamper change go through warm. 1.9 x 0.65 x 1.5 m, about 10 to 12 records a minute against 5 to 6 from the launch plant; hardware about USD 16k to 33k (estimate) (inline-optical-qc.md). No separate trimmer: every Duplex cell and the Classic trim inline (pressing-line.md)");
sc.inf("trim", "Optical inspection after cooling", "One station checks every record of both presses after the cooling racks: surface (a line-scan camera per side), label, warp and centring in one turn. The finishing operator feeds it from the cooled stacks; good records go on to sleeving, rejects into the bin with the reason on the screen. Early lane: the first records of each run and after each stamper change go through warm. 1.9 x 0.65 x 1.5 m, about 10 to 12 records a minute against 5 to 6 from the launch plant; hardware about USD 17k to 33k (estimate) (inline-optical-qc.md). No separate trimmer: every Duplex cell and the Classic trim inline (pressing-line.md)");
sc.inf("cooling", "Cooling racks", "Spindle stacks from both presses, labelled at the press (press, stamper set, first and last cycle), first in, first out. 24 h of cooling before sleeving is accepted practice, 8 h at the shortest (Stamper Discs, in inline-optical-qc.md): about one day of output, 2,800 to 3,100 records at the launch plant");
sc.inf("qc", "QC and listening", "Sampled audio comparison (about 1 in 50) and the listening point on the tour (quality-automation.md)");
sc.inf("packaging", "Finishing and packaging", "Packing tables, shrink wrap and pallet wrapper, ~170 m2 on the ground floor of the finishing and print block (14 x 25 m on two levels, print room reserved upstairs)");