grabowski
609424b598
User, 18 Oct 2026: create a setup for the inline optical QC, an aluminium extrusion frame with all sensors and a conveyor mounted to it. - docs/equipment/inline-qc-station/: FreeCAD script (build_station.py) and model (.FCStd) of one station, 1.9 x 0.65 x 1.5 m on 27 m of 40x40 and 3.8 m of 40x80 profile: rim-belt conveyor (two 6 mm PU round belts under the unrecorded rim, open centre), label gate with top and bottom colour cameras on the fly, inspection position with a lift and rotate chuck (75 mm lift, expanding mandrel, belt-driven servo), top and bottom 4k line-scans on opposite radii with coaxial, dark-field and backlights, two warp lasers, optional thermal camera, light-tight black tunnel with door switch, rodless-cylinder reject pusher with chute and bin, outfeed stop, cabinet, PLC, NixOS edge PC, HMI, stack light. - render_station.py renders six views (open and closed iso, front, plan, inspection detail and elevation via clipped temporary documents). - inline-qc-station-bom.csv: 32 lines with sources; USD 16k to 33k per station without the thermal camera. - inline-optical-qc.md: new section "The station setup" (flow table, inspection zone, cycle ~5 to 6 s, control, BOM by group, open points); cost table updated (two launch stations ~USD 50k to 105k, still inside the metrology launch tier); Duplex/Classic flow now via the conveyor. - README bullet and tree.
3.7 KiB
3.7 KiB
| 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) | 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 |
| 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 | 1 lot (about 120 joints) | 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 | |
| 8 | Enclosure | Door hinges, handle, safety door switch | 1 lot | 120 | 350 | 120 | 350 | estimate | |
| 9 | Conveyor | PU round belt 6 mm, welded endless | 2 x 3.8 m | 15 | 40 | 30 | 80 | each; PU round belt listings (RS, Amazon) plus welding | |
| 10 | Conveyor | Round-belt pulleys, shaft, bearings, UHMW slide strips, side guides | 1 lot | 250 | 700 | 250 | 700 | pulleys USD 5 to 11 each (ServoCity, REV); rest estimate | |
| 11 | Conveyor | Conveyor drive: small gear motor with drive, or servo | 1 | 250 | 600 | 250 | 600 | estimate | |
| 12 | Handling | Guided lift cylinder, 20 mm bore, 75 mm stroke | 1 | SMC MGPM20-75 | 330 | 450 | 330 | 450 | SMC MGPM20-30 USD 322 (Misumi US) to 390 (Motion); 75 mm stroke a little more |
| 13 | Handling | Spindle servo 200 W with drive (encoder triggers the line-scans) | 1 | Delta ASDA-B3 class | 300 | 700 | 300 | 700 | drive USD 119 to 200 (listings); motor and cable 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 | 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 | |
| 20 | Vision | Dark-field line light, about 150 mm | 4 | Vision Datum LiN+ class | 250 | 400 | 1000 | 1600 | Vision Datum LiN+ USD 380 |
| 21 | Vision | Diffuse line backlight | 2 | 200 | 400 | 400 | 800 | estimate | |
| 22 | Vision | Colour area camera, 8 MP, GigE | 2 | Basler ace 2 a2A2840-14gcPRO | 1119 | 1119 | 2238 | 2238 | Basler web shop via price listing |
| 23 | Vision | Lens 16 mm | 2 | 150 | 400 | 300 | 800 | estimate | |
| 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 | 5 | 50 | 150 | 250 | 750 | each; estimate | |
| 28 | 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) |
| 29 | Control | PLC for sequence and safety I/O | 1 | Mitsubishi FX5U-32MT or Delta class | 500 | 1096 | 500 | 1096 | FX5U-32MT/ES USD 1,096 (Mitsubishi US shop); resale from about USD 470 |
| 30 | 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 | |
| 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 | 32715 | sum of the lines above |