grabowski
ba1f5fc3a9
User, 18 Oct 2026: use an EtherCAT based system. - Spindle and conveyor on the StepperOnline A6-EC100L2A1-M17 kit (100 W, A6-200EC drive, USD 123.29), spindle through a 1:6 belt in cyclic synchronous position, conveyor in cyclic synchronous velocity. - The A6-EC drive has no divided encoder output, so an RS-422 incremental encoder on the spindle shaft clocks both line-scans; its index goes to the drive touch probe for one angle reference. - Station controller: fanless N100 mini PC with 2x Intel i226, NixOS PREEMPT_RT, EtherCAT master EtherCrab (Rust, MIT/Apache) first, IgH (nixpkgs, igc native driver on 6.12 LTS) as fallback; no PLC. - EtherCAT I/O: EK1100, EL1809, EL2809, EL3102 (warp lasers sampled with the spindle position, ~1,000 points a turn at 1 ms). - Safety stays hardwired (safety relay, contactor; no STO at 100 W). - Edge PC with the GPU stays off the real-time loop. - BOM: drives, encoder, controller and I/O lines with sources; total USD 16,112 to 32,938 (THB 0.53M to 1.09M). Next step: EtherCAT bench. - Investor render: cabinet and outfeed labels.
4.8 KiB
4.8 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 | 32 m (45 pieces) | 8-slot 4040 (Misumi HFS8-4040 class, or Thai/Chinese generic) | 11 | 21 | 354 | 676 | 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 | Cast angle brackets (24 drawn), T-nuts, screws, end caps | 1 lot | 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: 100 W EtherCAT servo kit (same as the spindle), cyclic synchronous velocity | 1 | StepperOnline A6-EC100L2A1-M17 | 123 | 300 | 123 | 300 | USD 123.29 kit, China warehouse (StepperOnline, Oct 2026); high end allows for shipping, duty and a small belt reduction (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 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 | 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 | 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 | 1 | Omron E6B2-CWZ1X class | 60 | 300 | 60 | 300 | 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) | 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 |
| 32 | 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 |
| 33 | 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 | |
| 34 | Control | HMI touch panel, 10 inch, showing the station's browser page | 1 | 400 | 900 | 400 | 900 | estimate | |
| 35 | 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 | |
| 36 | Control | Cabinet, power supply, breakers, terminals, wiring, stack light | 1 lot | 800 | 2000 | 800 | 2000 | estimate | |
| 37 | Total | Hardware per station, thermal camera excluded | 16112 | 32938 | sum of the lines above |