cnx_vinyl/docs/equipment/inline-qc-station/inline-qc-station-bom.csv at face699a284ac81718537026ee0a7207bc92ee70

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Optical QC: EtherCAT control plan with geizhals.de prices

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.

2026-10-19 10:43:59 +07:00

7.4 KiB

Raw Blame History

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 with a dump valve switched by the safety relay, pressure switch, 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 (the through-beam also to the conveyor drive's touch probe)	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, 5 V, 2,000 to 2,500 pulses a turn: A/B clock both line-scans, A/B/Z to the EL5101	1	Omron E6B2-CWZ1X 2000 P/R class	53	282	53	282	E6B2-CWZ1X 2000 P/R listing EUR 45.52 to GHH60 2500 P/R line driver EUR 187.83 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT; marketplace sellers, test on the bench); high end +30% for shipping, Thai duty and VAT or a Thai distributor (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, 2 or more Intel i226-V ports, NixOS with PREEMPT_RT, open-source EtherCAT master (EtherCrab, IgH fallback)	1	ANDAQI RS55 / MNBOXCONET P2-N100 / AIOPCWA AI201-TF	455	685	455	685	EUR 393.99 to 455.99 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/mini-pc-barebone-netzwerk-pc-intel-n100-a2926989.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
32	Control	EtherCAT coupler	1	Beckhoff EK1100	174	295	174	295	EUR 150.75 to 255.43, no current offer (geizhals.de/144468496, 19 Oct 2026)
33	Control	16 digital inputs, 24 V: photoelectric sensors, cylinder switches, safety status	1	Beckhoff EL1809	109	141	109	141	EUR 93.97 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/1371087148); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
34	Control	16 digital outputs, 24 V, 0.5 A: valves, stack light, light enable	1	Beckhoff EL2809	119	155	119	155	EUR 102.97 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/1371087504); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
35	Control	2 analog inputs, 4 to 20 mA: the two warp lasers	1	Beckhoff EL3152	241	314	241	314	EUR 208.90 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/185886294); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
36	Control	Incremental encoder interface, RS-422, 5 V encoder supply: spindle encoder count and index latch	1	Beckhoff EL5101	336	437	336	437	EUR 291.04 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/2974477757); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
37	Control	End cap	1	Beckhoff EL9011	5	7	5	7	EUR 4.33 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/455904583); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
38	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
39	Control	HMI: 10.1 inch PCAP touch monitor, 7H glass, showing the station's browser page	1	iiyama ProLite TF1015MC-B3	360	468	360	468	EUR 311.90 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT: geizhals.de/iiyama-prolite-tf1015mc-b3-a3228748.html); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
40	Control	Safety: relay for e-stop and door switch, 2 contactors in series in the drive supply (the 100 W kit has no STO), e-stop button, reset button	1 lot	Pilz PNOZ s3 750103, Siemens 3RT2015 24 V DC coil, Schneider Harmony e-stop	300	389	300	389	PNOZ s3 EUR 148.38, 3RT2015-1BB41 EUR 27.95 each, e-stop EUR 45.08 (geizhals.de, 19 Oct 2026, lowest listed price incl. 19% German VAT); reset button EUR 10 (estimate); high end +30% for shipping, Thai duty and VAT or a Thai distributor (estimate)
41	Control	Cabinet, 24 V 120 W supply, breakers, terminals, wiring, shielded EtherCAT patch cables, stack light	1 lot	Mean Well SDR-120-24 supply	800	2000	800	2000	estimate; Mean Well SDR-120-24 from EUR 38.87 and shielded Cat5e patch cables from EUR 0.62 (geizhals.de, 19 Oct 2026)
42	Total	Hardware per station, thermal camera excluded					16912	33061	sum of the lines above

7.4 KiB Raw Blame History

7.4 KiB

Raw Blame History