grabowski
face699a28
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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.
112 lines
5.1 KiB
Python
112 lines
5.1 KiB
Python
# Draw the part labels onto the investor render of the inline QC station.
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# uv run --with pillow python docs/equipment/inline-qc-station/annotate_render.py
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# Reads inline-qc-station-annotated-base.png and _anchors.json from render_annotated.py
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# (FreeCAD) and writes inline-qc-station-annotated.png.
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import json
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import os
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from PIL import Image, ImageChops, ImageDraw, ImageFont
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D = os.path.dirname(os.path.abspath(__file__))
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FONTS = "C:/Windows/Fonts/"
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SCALE = 0.75 # 4000 px render, drawn at 3/4 size (anti-aliased)
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TITLE = "Inline optical QC station"
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SUBTITLE = ("Every record checked on both faces in one turn: surface, label, warp and centring. "
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"Failed records leave the line automatically.")
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FOOTER = ("CNX Vinyl, concept model (FreeCAD); bought parts drawn as outlines. 1.9 × 0.65 × 1.5 m, "
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"front panels and lid removed for the view. Hardware about USD 17k to 33k per station (estimate).")
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NAVY, GREY, LINE = (18, 53, 91), (85, 95, 105), (60, 74, 90)
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def font(name, size):
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return ImageFont.truetype(FONTS + name, size)
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F_TITLE, F_SUB = font("seguisb.ttf", 76), font("segoeui.ttf", 36)
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F_LAB, F_DESC, F_FOOT = font("seguisb.ttf", 40), font("segoeui.ttf", 31), font("segoeui.ttf", 27)
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meta = json.load(open(os.path.join(D, "_anchors.json"), encoding="utf-8"))
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img = Image.open(os.path.join(D, "inline-qc-station-annotated-base.png")).convert("RGB")
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img = img.resize((round(img.width * SCALE), round(img.height * SCALE)), Image.LANCZOS)
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bb = ImageChops.difference(img, Image.new("RGB", img.size, (255, 255, 255))).getbbox()
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pad = 30
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crop = (max(0, bb[0] - pad), max(0, bb[1] - pad), min(img.width, bb[2] + pad), min(img.height, bb[3] + pad))
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img = img.crop(crop)
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anchors = [dict(a, xy=(a["xy"][0] * SCALE - crop[0], a["xy"][1] * SCALE - crop[1])) for a in meta["anchors"]]
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COL_W, GAP, TOP, BOTTOM, MX = 760, 90, 280, 140, 90
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W = img.width + 2 * (MX + COL_W + GAP)
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H = img.height + TOP + BOTTOM
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canvas = Image.new("RGB", (W, H), (255, 255, 255))
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ox, oy = MX + COL_W + GAP, TOP
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canvas.paste(img, (ox, oy))
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d = ImageDraw.Draw(canvas)
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d.text((MX, 60), TITLE, font=F_TITLE, fill=NAVY)
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d.text((MX + 4, 165), SUBTITLE, font=F_SUB, fill=GREY)
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d.line([(MX, 238), (W - MX, 238)], fill=(215, 220, 226), width=2)
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d.text((MX, H - 90), FOOTER, font=F_FOOT, fill=GREY)
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# split: the left-most half of the anchors on the left, the rest on the right
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order = sorted(anchors, key=lambda a: a["xy"][0])
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half = (len(order) + 1) // 2
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cols = {"L": order[:half], "R": order[half:]}
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BLOCK = 108 # label height incl. spacing
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def _cross(p1, p2, p3, p4):
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def o(a, b, c):
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return (b[0] - a[0]) * (c[1] - a[1]) - (b[1] - a[1]) * (c[0] - a[0])
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return (o(p1, p2, p3) > 0) != (o(p1, p2, p4) > 0) and (o(p3, p4, p1) > 0) != (o(p3, p4, p2) > 0)
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def place(items, edge_x):
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"""Label slots kept near each anchor's height without overlapping, then the anchor-to-slot
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assignment that makes no two leader lines cross (fewest crossings, then least drift)."""
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import itertools
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items = sorted(items, key=lambda a: a["xy"][1])
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lo, hi = oy - 20, oy + img.height - BLOCK + 20
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ys = [min(max(a["xy"][1] + oy - 26, lo), hi) for a in items]
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for i in range(1, len(ys)):
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ys[i] = max(ys[i], ys[i - 1] + BLOCK)
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over = ys[-1] - hi
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if over > 0:
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ys = [y - over for y in ys]
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for i in range(len(ys) - 2, -1, -1):
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ys[i] = min(ys[i], ys[i + 1] - BLOCK)
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best = None
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for perm in itertools.permutations(range(len(items))):
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segs = [((edge_x, ys[k] + 26), (items[i]["xy"][0] + ox, items[i]["xy"][1] + oy)) for k, i in enumerate(perm)]
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n = sum(_cross(*segs[a], *segs[b]) for a in range(len(segs)) for b in range(a + 1, len(segs)))
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drift = sum(abs(ys[k] + 26 - items[i]["xy"][1] - oy) for k, i in enumerate(perm))
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score = n * 1e6 + drift
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if best is None or score < best[0]:
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best = (score, perm)
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print("crossings", int(best[0] // 1e6))
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return [(items[i], ys[k]) for k, i in enumerate(best[1])]
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for side, items in cols.items():
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edge = MX + COL_W + GAP - 20 if side == "L" else ox + img.width + 20
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for a, y in place(items, edge):
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ax, ay = a["xy"][0] + ox, a["xy"][1] + oy
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# text in a fixed column, left-aligned; the leader leaves from the end of the title line,
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# runs level to the column edge, then straight to the part
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tl = d.textlength(a["title"], font=F_LAB)
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ly = y + 26
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if side == "L":
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tx = MX
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pts = [(tx + tl + 16, ly), (MX + COL_W + GAP - 20, ly), (ax, ay)]
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else:
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tx = ox + img.width + GAP
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pts = [(tx - 16, ly), (ox + img.width + 20, ly), (ax, ay)]
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d.line(pts, fill=LINE, width=3, joint="curve")
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d.ellipse([ax - 10, ay - 10, ax + 10, ay + 10], fill=(255, 255, 255))
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d.ellipse([ax - 7, ay - 7, ax + 7, ay + 7], fill=NAVY)
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d.text((tx, y), a["title"], font=F_LAB, fill=NAVY)
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d.text((tx, y + 52), a["desc"], font=F_DESC, fill=GREY)
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out = os.path.join(D, "inline-qc-station-annotated.png")
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canvas.save(out, optimize=True)
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print("saved", out, canvas.size)
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