grabowski
e8674795f5
User, 18 Oct 2026: use real 40x40 profiles, make a render with text pointing out the parts to show the investor; the ring lights looked like they were floating. - build_station.py: frame drawn from the real 8-slot 40 series section (profile_shape: slots, centre bore, corner cavities; 40x80 with centre cavity) and 24 cast angle brackets; top beams now butt between the uprights; label-camera posts moved beside the cameras so both ring lights clamp straight to them; top line-scan on a side post with visible camera plate and light hangers; slide strips on carrier angles, pulley axles, end-stop posts, presence-sensor brackets, backlight post, cabinet on base crosses, chute on two supports and clear of the rail, pneumatics rail, stack light on the back upright, touch screen on the front end upright. A connectivity check at the end lists any part that does not reach the floor through touching parts: none. - render_annotated.py (FreeCAD): front three-quarter view, camera backed off so nothing is clipped, no navigation cube or preselection, label positions projected from the camera and checked with marker renders. - annotate_render.py (Pillow): title, 16 labels in two columns, leaders assigned so none cross -> inline-qc-station-annotated.png. - render_station.py: same camera and preselection fixes; all six views re-rendered. - BOM: 32 m of 40x40 in 45 pieces; total still USD 16k to 33k. - inline-optical-qc.md and README updated; .gitignore for the render intermediates.
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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 | 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: 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 | 16114 | 32824 | sum of the lines above |