AI Borescope Block Inspection - Engineering Data Register

00Project basisSystem scope, keputusan awal, dan asset basis

Jumlah kamera18Target konsep

Resolusi kamera1280×720Vividia FC-3850 · 5 m

InterfaceUSB 2.0Per kamera

RobotExistingTM5X-900 · HPP Rp0

Sampel checksheet22M1 + M2 + M3

Arsitektur utama1 PC2 kartu Basler

Baseline konsep

1 PC vision, 2 kartu Basler, 18 kamera FC-3850 5 m, dan robot TM5X-900 existing. Alternatif 2 PC disimpan sebagai opsi bila audit PCIe atau uji stabilitas 18 channel tidak memenuhi acceptance.

Robot existing - tidak masuk pengadaan

TM5X-900 yang sudah tersedia dipakai sebagai customer-supplied asset dengan nilai pengadaan Rp0. Pekerjaan yang tetap masuk HPP adalah audit kondisi, backup TMflow, TCP/payload/CoG setup, safety configuration, I/O, teaching, dan SAT. Lifecycle HW3.2 dicatat untuk strategi spare dan support, bukan sebagai alasan membeli robot baru.

Rancangan arsitektur sistem

Alur utama memisahkan motion control, akuisisi kamera, komputasi AI, dan penyimpanan evidence. Koneksi PLC/MES final masih mengikuti interface line customer.

SYS-FLOW-01 · BASELINE 1 PC

PLC / line controlPart ready, part ID, recipe, start, reset, dan interlock.

TM5X-900 + jigApproach, align, insert, settle, retract; robot existing.

18 × FC-3850Probe 5 m, USB 2.0, 1280×720; fixed camera-target mapping.

USB controller layer2 kartu Basler untuk 16 kamera + 2 jalur onboard yang tervalidasi.

Vision PCCamera health, burst capture, quality gate, ROI, AI, dan rule engine.

Result + evidenceOK / NG / UNCERTAIN / ERROR, image, metadata, audit trail, PLC/MES.

Control / handshakeRobot motionImage sourceCompute / data

Urutan inspeksi dan kontrol

Urutan ini adalah konsep kontrol. Strategi memasukkan 18 probe secara serentak, per zona, atau bergantian masih harus diputuskan dari CAD, collision study, dan cycle time.

SYS-FLOW-02 · CYCLE

01 · Part readyNest locked, safety clear, part ID valid.

02 · Pre-check18 camera connected, map benar, recipe aktif.

03 · ApproachRobot ke safe approach pose.

04 · Align / insertLead-in dan compliance menjaga probe.

05 · Settle / captureAt-pose, vibration settle, burst bertimestamp.

06 · Quality gateBlur, glare, exposure, occlusion, target not found.

07 · AI + ruleROI, ukuran, confidence, M1/M2/M3, aggregate.

08 · Retract / resultEvidence committed; COMPLETE atau controlled error.

Exception path wajib

MISSING, WRONG_MAP, BLUR, GLARE, OCCLUDED, atau TARGET_NOT_FOUND harus menghasilkan inspection error/retry yang terkontrol. Jangan mengubah kegagalan inspeksi menjadi NG produk tanpa aturan acceptance yang disetujui.

Topologi USB baseline 1 PC

Pemetaan ini menjaga maksimum dua kamera per host controller Basler. Dua kamera onboard hanya boleh dipakai setelah Windows USB topology dan root-controller path terbukti terpisah dan stabil.

SYS-FLOW-03 · PORT MAP

Basler card A · PCIe x44 × FL1100EX host controller · CAM01-CAM08

HC-A1CAM01 + CAM02

HC-A2CAM03 + CAM04

HC-A3CAM05 + CAM06

HC-A4CAM07 + CAM08

Basler card B · PCIe x44 × FL1100EX host controller · CAM09-CAM16

HC-B1CAM09 + CAM10

HC-B2CAM11 + CAM12

HC-B3CAM13 + CAM14

HC-B4CAM15 + CAM16

Motherboard onboard · wajib auditBukan sekadar dua konektor fisik; harus dua jalur root-controller yang tervalidasi.

ROOT PATH 1CAM17 · TBD after audit

ROOT PATH 2CAM18 · TBD after audit

Gate: USBTreeView map + FourCC/fps + dropped-frame test + 72-hour soak

01Data checksheet MejashiInspection sample and acceptance context

Keputusan data: seluruh 22 sampel adalah NG karena terdapat burr. PDF adalah checksheet sampel/percobaan, bukan drawing 22 titik pada satu engine block. Jumlah 18 kamera tetap belum dapat divalidasi dari file ini.

Kategori	Kriteria ukuran	Sign	Jumlah sampel	Bore pada checksheet	Status inspeksi	Catatan
M1	< 5 mm	A1-A10	10	Mayoritas bore 1	NG · BURR	10/10 sampel NG; burr kurang dari 5 mm
M2	5-10 mm	B1-B10	10	Bore 1; B5/B10 bore 2	NG · BURR	10/10 sampel NG; burr 5-10 mm, dengan variasi glare/occlusion
M3	> 10 mm	C1-C2	2	Bore 1 & 2	NG · BURR	2/2 sampel NG; burr lebih dari 10 mm
Total	-	A1-C2	22	Bore 1 dan 2	22/22 NG	Semua sampel memiliki burr; bukan camera-to-bore map produksi

Lampiran visual checksheet

Enam frame representatif diekstrak langsung dari PDF sumber tanpa enhancement. Semua frame berstatus NG karena terdapat burr. Badge tambahan menunjukkan masalah kualitas citra seperti glare, occlusion, atau off-axis. Status NG/burr mengikuti konfirmasi project owner.

Buka PDF sumber

Frame borescope A1 dengan target berbentuk lingkaran terlihat jelas — **A1 · M1 <5 mm · Bore 1**NG · BURR TARGET VISIBLE
Sampel NG karena terdapat burr. Target cukup jelas dan relatif terpusat; berguna sebagai referensi awal localization.

Frame borescope A4 dengan target sebagian tertutup objek foreground — **A4 · M1 <5 mm · Bore 1**NG · BURR OCCLUSION
Sampel NG karena terdapat burr. Target masih terlihat, tetapi bagian kanan dan atas tertutup; quality gate perlu mengukur visible-area.

Frame borescope B3 dengan pantulan terang pada area target — **B3 · M2 5-10 mm · Bore 1**NG · BURR GLARE
Sampel NG karena terdapat burr. Pantulan specular menghilangkan tekstur; LED, exposure, standoff, dan sudut probe harus repeatable.

Frame borescope B4 dengan area overexposure dan target gelap — **B4 · M2 5-10 mm · Bore 1**NG · BURR QUALITY FAIL
Sampel NG karena terdapat burr. Area putih besar dan target gelap membuat measurement tidak andal; frame harus berhenti di quality gate.

Frame borescope B5 dengan target di tepi dan foreground besar — **B5 · M2 5-10 mm · Bore 2**NG · BURR OFF-AXIS
Sampel NG karena terdapat burr. Target dekat tepi dengan foreground dominan; guide bushing dan fixed standoff perlu distabilkan.

Frame borescope C2 dengan occlusion berat dan pantulan pada foreground — **C2 · M3 >10 mm · Bore 1 & 2**NG · BURR SEVERE OCCLUSION
Sampel NG karena terdapat burr. Foreground dan pantulan menutup sebagian besar area; perlu kriteria target-not-found dan prosedur retry.

Register gambar engineering

Gambar berikut paling membantu review konsep. Diagram alur dan lampiran checksheet sudah tersedia; drawing fisik harus berasal dari data aktual agar tidak menyesatkan.

ID	Gambar / diagram	Tujuan keputusan	Sumber yang benar	Status
VIS-01	System context & control flow	Menjelaskan batas PLC, robot, camera, PC, AI, dan traceability	Rancangan engineering proyek	TERSEDIA
VIS-02	Inspection sequence / state flow	Menetapkan handshake, capture window, retry, dan error behavior	URS + interface PLC/robot	TERSEDIA
VIS-03	USB controller-port map	Mencegah 18 kamera bertumpuk pada satu root controller	Basler topology + USBTreeView hasil POC	KONSEP ADA
VIS-04	Engine block dengan 18 target bernomor	Mengunci jumlah kamera, target map, arah pandang, dan insertion depth	Customer drawing / sample block 3D scan	P0 WAJIB
VIS-05	Jig CAD: front, side, section, exploded	Review cartridge, bushing, compliance, service access, mass, CoG	Mechanical design setelah VIS-04 freeze	BELUM ADA
VIS-06	Robot workspace + cable routing elevation	Validasi reach 900 mm, bend radius, service loop, drag, dan collision	Layout line + robot pose export + dress-pack study	BELUM ADA
VIS-07	18-channel health / live-view mockup	Menentukan HMI untuk missing camera, wrong map, frame drop, dan focus	Software POC screenshot, bukan gambar marketing	POC OUTPUT
VIS-08	AI evidence overlay	Menampilkan ROI, mask, size, confidence, reason code, dan model version	Validated model output pada image aktual	SETELAH DATASET
VIS-09	Mejashi variation montage	Menunjukkan glare, occlusion, off-axis, dan kebutuhan quality gate	Mejashi checking.pdf	TERSEDIA

02Hardware utamaCamera, USB extension, interface card, and support hardware

Komponen	Spesifikasi utama	Kelebihan	Data belum tersedia / risiko	Status
Vividia FC-3850 Borescope camera · 5 m	USB 2.0; 1280×720; probe Ø3.8 ±0.1 mm; head 32 mm; focus 10-100 mm; FOV 90°; 6 LED dimmable; semi-rigid tube 5 m	Diameter kecil; Windows compatible; biaya relatif rendah; lighting tersedia di tip	FourCC/fps live; serial unik; exposure lock; arus; latency; bend radius; cycle life; coolant resistance	WAJIB · VALIDASI POC
Basler 4HC 5G 8-Port USB interface card	8 USB Type-A; 4× FL1100EX host controller; 2 port/controller; PCIe 2.0 x4; backward USB 2.0; power max. 50 W	Memisahkan traffic ke empat controller; proteksi overload/short circuit; SATA auxiliary power tersedia	USB Vision certification card tidak memvalidasi FC-3850; FourCC, bandwidth efektif, lane topology, dan kestabilan 18 channel tetap harus diuji	WAJIB
Techman TM5X-900 Collaborative robot	Payload 4 kg; reach 900 mm; repeatability ±0.05 mm; IP54 arm; Ethernet/Modbus; 6 axis	Reach dan repeatability mendukung positioning; interface industrial tersedia	Payload, CoG, inertia, cable drag 18×5 m, service loop, collision, dan tool safety belum dihitung; lifecycle HW3.2 perlu spare plan	OWNER SUPPLIED · Rp0
UGREEN US175 / 20826 Active USB extension · 5 m	USB-A male/female; active signal booster; hingga 5 Gb/s; input daya tambahan Micro-USB; 5 m	Tersedia lokal/marketplace; port power terpisah; USB 3.0 backward-compatible dengan kamera USB 2.0	Hanya dipakai jika routing 5 m bawaan kamera belum mencapai PC; adaptor daya tidak selalu termasuk dan wajib soak test	OPTIONAL

Pilihan active extension 5 m · optional

Priority	Brand / model	Power method	Local price snapshot	Engineering assessment
1 · Optional primary	UGREEN US175 / 20826, USB 3.0 active 5 m	Micro-USB auxiliary power port; adapter budgeted separately	Rp209.000	Pilihan lokal dengan dokumentasi paling jelas; beli hanya bila mock-up routing membuktikan kabel kamera 5 m tidak cukup
2 · Optional alternate	Vention CBK, USB 2.0 active 5 m	USB-C power input; rated current 2 A; up to 480 Mb/s	Rp220.700-236.028	Protocol sesuai FC-3850 USB 2.0; gunakan bila POC lebih stabil daripada UGREEN

Status optional: baseline memakai kabel kamera FC-3850 sepanjang 5 m tanpa extension. Lakukan mock-up jalur dari jig, mengikuti lengan robot dan service loop, sampai PC. Jika masih kurang, uji satu UGREEN atau Vention dengan external power sebelum membeli hingga 20 unit. Harga extension tidak masuk HPP medium dasar.

03Budgetary BoM & Part listLanded cost Indonesia and total project HPP

Cost basis 22 Juli 2026 · satu skenario medium Indonesia. Semua nilai ditampilkan dalam IDR. Konversi memakai kurs jual BI 20 Juli 2026 yang dibulatkan untuk procurement: USD 1 = Rp18.100 dan EUR 1 = Rp20.700. Harga marketplace adalah snapshot; harga final, stok, ongkir, HS code, bea/pajak, dan invoice pajak wajib dikonfirmasi sebelum PO.

20 kamera landedRp123,80 jtGoods + US shipment + 20% provision

2 Basler landedRp13,36 jtGoods + EU shipment + 20% provision

Extension + powerRp0 dasarOptional · tidak masuk HPP

Recommended PCRp70,00 jt1 workstation + UPS

Robot purchaseRp0Existing TM5X-900

Total project · 1 PCRp584,38 jtHardware + seluruh jasa

Imported package · base	Goods	International shipment allowance	CIF planning	Landed provision	Estimated landed IDR
20 × Vividia FC-3850 18 operation + 2 spare	Rp90.492.760 20 × USD 249.98 proxy	Rp12.670.000 USD 700 medium allowance	Rp103.162.760	Rp20.632.552 20% reserve on CIF	Rp123.795.312
2 × Basler 4HC card	Rp6.996.600 2 × EUR 169 net	Rp4.140.000 EUR 200 medium allowance	Rp11.136.600	Rp2.227.320 20% reserve on CIF	Rp13.363.920

Basis HPP	Hardware + landed + contingency	Software + seluruh jasa	Biaya jasa tambahan	Total project HPP	Asumsi utama
Medium Indonesia · 1 PC	Rp464,38 jt	Rp120,00 jt All-in fixed package	Rp0 FAT/SAT/training/site included	Rp584,38 jt	Import provision 20%; PC+UPS Rp70 jt; jig Rp120 jt; controls/safety Rp75 jt; active extension optional tidak dimasukkan

Definisi HPP pada register ini

Hardware HPP memasukkan 18 kamera operasi + 2 spare, dua kartu Basler wajib, shipment internasional, 20% landed-cost provision, PC/UPS, jig, panel/safety allowance, local logistics, dan 10% hardware contingency. Active extension dan power supply tidak dimasukkan karena optional. Harga USD 249.98 adalah proxy harga publik keluarga produk; quotation tertulis FC-3850 5 m wajib diminta sebelum PO. Total software dan seluruh jasa dibatasi Rp120 jt all-in, termasuk robot teaching, integrasi, FAT/SAT, training, dokumentasi, standard site work, dan hypercare.

Offline HPP calculator · medium Indonesia dapat diedit

USD / IDRBI sell rounded

EUR / IDRBI sell rounded

Camera shipment (USD)20 units, planning allowance

Basler shipment (EUR)2 cards, planning allowance

Landed provision (%)Duty/tax/broker reserve on CIF

PC + UPS (Rp jt)Recommended one-PC build

Jig + mechanics (Rp jt)Design/fabrication allowance

Controls + safety (Rp jt)Panel, I/O, guarding allowance

Software + seluruh jasa (Rp jt)All-in: robot, integration, FAT/SAT, training, docs, site

Contingency hardware (%)Applied after hardware allowances

Imported vision landedRp137,16 jt

Hardware HPPRp464,38 jt

Software + seluruh jasaRp120,00 jt

Total project HPPRp584,38 jt

Item ID	System	Part / description	Part no. / minimum specification	Qty	Unit price	Public subtotal	Cost basis	Procurement status
BOM-VIS-001	Vision	Operational borescope camera	Vividia FC-3850; USB 2.0; 720p; Ø3.8 mm; semi-rigid cable 5 m	18 ea	Rp4.524.638	Rp81.443.484	USD 249.98 public family-price proxy × Rp18.100; confirm FC-3850 5 m quote	WAJIB · POC VALIDATE
BOM-VIS-002	Vision	Spare borescope camera	FC-3850; same production lot as BOM-VIS-001 where possible	2 ea	Rp4.524.638	Rp9.049.276	Same planning proxy; confirm FC-3850 5 m quote	RECOMMENDED SPARE
BOM-VIS-003	Vision	USB interface card	Basler 4HC, 5G, 8-Port; order no. 2200002208	2 ea	Rp3.498.300	Rp6.996.600	EUR 169 net × Rp20.700; goods only	WAJIB
BOM-VIS-004	Vision	Spare USB interface card	Basler 2200002208; excluded from base HPP	1 ea	Rp3.498.300	Rp3.498.300	Optional; add landed cost if approved	OPTIONAL SPARE
BOM-VIS-005	Vision	Powered active USB extension · 5 m	UGREEN US175 / 20826 atau Vention CBK; satu kabel per kamera, no shared hub	0 base maks. 20	Rp209.000-236.028	Excluded	Optional setelah mock-up routing; landed HPP tidak memasukkan item ini	OPTIONAL
BOM-VIS-005A	Vision	5 V power supply for active extension	5 VDC, minimum 2 A, certified; individual adapter or fused industrial distribution after electrical design	0 base maks. 20 ch	Rp75.000	Excluded	Hanya jika extension dipakai	OPTIONAL
BOM-VIS-006	Vision	USB connector retention & strain relief	Panel clamp/locking bracket; one per channel	20 ea	RFQ	-	Custom / local	REQUIRED
BOM-VIS-007	Vision	Camera ID and port label set	CAM01-CAM18 + 2 spares; controller/port/target mapping	1 lot	RFQ	-	Local fabrication	REQUIRED
BOM-PC-001	Compute	Recommended AI workstation PC	Core Ultra 7 265K class; 64 GB; RTX 5060 Ti 16 GB; OS/app NVMe + evidence NVMe; GPU x8/x16 + 2× PCIe x4 electrical simultaneously	1 set	Rp61.600.000	Rp61.600.000	Local component budget incl. Windows/monitor, excl. UPS	PRIMARY 1-PC
BOM-PC-002	Compute	NVIDIA GPU	Gainward RTX 5060 Ti Python III 16 GB, 2-slot; included in BOM-PC-001	1 ea	Rp9.690.000	Included	Local retailer snapshot	RECOMMENDED
BOM-PC-003	Compute	NVMe evidence storage	2 TB OS/application + 4 TB evidence; included in BOM-PC-001	1 lot	Rp8.000.000	Included	Capacity allowance; finalize from retention policy	REQUIRED
BOM-PC-004	Compute	Online UPS	APC SRV2KI-E; 2000 VA / 1800 W; online; USB/communication capable	1 ea	Rp8.400.000	Rp8.400.000	Local retailer snapshot	RECOMMENDED
BOM-PC-005	Compute	Operator monitor and input devices	24-inch industrial/commercial monitor; keyboard; mouse	1 set	RFQ / existing	-	Local procurement	AS REQUIRED
BOM-NET-001	Network	Industrial Ethernet switch	Managed 8-port Gigabit; DIN rail; 24 VDC	1 ea	RFQ	-	Plant standard	REQUIRED
BOM-NET-002	Network	Industrial Ethernet patch cables	Shielded Cat6; robot/PLC/PC/MES; length per layout	1 lot	RFQ	-	Layout dependent	REQUIRED
BOM-ROB-001	Robot	Existing TM5X-900 HW3.2	Customer-supplied; verify exact part number, HW version, TMflow, cable, controller, accessories, and backup	1 set	Rp0	Rp0	Existing asset; no robot order	OWNER SUPPLIED
BOM-ROB-002	Robot	Teach pendant	OMRON RT6-A000020; 10.1-inch TP-100-1	1 ea	RFQ / verify included	-	Vendor quotation	OPTIONAL / SERVICE
BOM-ROB-003	Robot	TCP calibration kit	OMRON RT6-A000002	1 kit	RFQ	-	Vendor quotation	RECOMMENDED
BOM-ROB-004	Robot	Robot stick stand	OMRON RT6-A000000; only if not included in cell design	1 ea	RFQ	-	Vendor quotation	VERIFY BUNDLE
BOM-ROB-005	Robot	Robot base / pedestal	Custom welded/machined; anchor calculation; leveling; datum pins	1 set	RFQ	-	Custom fabrication	REQUIRED
BOM-MEC-001	Mechanical	18-camera main jig	Lightweight rigid frame; tool flange adapter; datum and service access	1 set	RFQ	-	After CAD/FEA	MENUNGGU CAD
BOM-MEC-002	Mechanical	Replaceable camera cartridge	CAM01-CAM18 plus 2 spares; keyed orientation and quick replacement	20 ea	RFQ	-	Custom machining	REQUIRED
BOM-MEC-003	Mechanical	Guide bushing	Non-abrasive; target clearance; replaceable wear component	20 ea	RFQ	-	Material trial	REQUIRED
BOM-MEC-004	Mechanical	Floating compliance mount	Per-channel radial/axial compliance after tolerance stack study	18 ea	RFQ	-	Engineering design	TBC
BOM-MEC-005	Mechanical	Robot cable dress pack	Energy chain/umbilical support; validated bend radius and drag force	1 set	RFQ	-	Trajectory dependent	REQUIRED
BOM-MEC-006	Mechanical	Calibration master / dummy block	Known target positions and optical reference; safe dry-cycle block	1 set	RFQ	-	Custom metrology	RECOMMENDED
BOM-MEC-007	Mechanical	Protective covers and lens cleaning kit	Coolant/oil compatible; lint-free consumables; poka-yoke cleaning	1 lot	RFQ	-	Environment dependent	REQUIRED
BOM-CTL-001	Controls	Electrical enclosure and 24 VDC distribution	DIN rail, MCB/fuse, terminal blocks, filtered fan, service outlet	1 set	RFQ	-	Plant standard	REQUIRED
BOM-CTL-002	Controls	Machine I/O interface	Interposing relays / remote I/O as required by PLC handshake	1 set	RFQ	-	PLC dependent	TBC
BOM-CTL-003	Controls	Status stack light and operator buttons	Ready/Busy/OK/NG/Error; reset; cycle start if required	1 set	RFQ	-	Control philosophy	RECOMMENDED
BOM-SAF-001	Safety	Safety system	Scanner, guarding, interlock, safety relay/controller, E-stop per risk assessment	1 lot	RFQ	-	Safety engineer design	MANDATORY STUDY
BOM-SW-001	Software	Windows license	Windows 11 Pro/IoT Enterprise per Toyota IT standard	1 lic	RFQ / existing	-	IT standard	REQUIRED
BOM-SW-002	Software	TMflow matching robot generation	Validated robot firmware/software pair; project backup before changes	1 inst	Verify entitlement	-	Robot bundle/support	REQUIRED
BOM-SW-003	Software	AI/runtime software stack	GPU driver, CUDA/TensorRT or ONNX Runtime, OpenCV/GStreamer as selected	1 inst	No base license / verify terms	-	Integration service	REQUIRED
BOM-SW-004	Software	Backup and recovery media	Golden image, application installer, model package, config export, rollback	1 set	RFQ	-	IT/integration service	RECOMMENDED

Procurement gate

Beli satu FC-3850 untuk Gate 1, lalu empat kamera dan satu kartu Basler untuk Gate 2 sebelum PO 18+2 kamera. Uji kabel 5 m bawaan terlebih dahulu; extension hanya dibeli bila mock-up routing membuktikan panjang tidak cukup dan sample powered extension lulus soak test. Robot tidak dibeli; lakukan condition audit, backup, payload/CoG validation, dan availability check atas accessory existing.

04Engineering servicesRobot teaching, configuration, software installation, and SAT

Total final software + seluruh jasa: Rp120 juta. Harga ini all-in untuk scope konsep saat ini dan tidak lagi dihitung dari person-day. FAT, SAT, training, dokumentasi, standard site work, serta production hypercare tidak menjadi baris charge terpisah.

Arti POC dan basis harga

POC = Proof of Concept, pembuktian konsep teknis sebelum pembelian massal. Breakdown komersial final: complete software/AI Rp85 jt, robot teaching/configuration Rp20 jt, dan project engineering/integration Rp15 jt. PC build termasuk harga pengadaan PC; jig design/fabrication termasuk allowance jig di hardware BoM.

Total software + jasaRp120 jtAll-in fixed package

Software + AIRp85 jtComplete package

Project integrationRp15 jtEngineering + commissioning

Additional service chargeRp0FAT/SAT/training included

Robot hardwareRp0Existing TM5X-900

Robot workRp20 jtTeaching/configuration package

Service ID	Work package	Scope yang termasuk	Fixed package price	Acceptance / handover	Catatan biaya
SVC-SW-001	Complete software & AI	18-camera acquisition, mapping/reconnect/watchdog, dataset workflow, AI model, HMI, traceability, database, deployment, software FAT/SAT, training, documentation, dan hypercare	Rp85 jt	Application, source/version manifest, model card, test record, operator handover	Harga final software package
SVC-ROB-001	Robot teaching & configuration	Audit/backup TMflow, TCP, payload/CoG, tool config, paths, safety zones, I/O, recovery, dry cycle, robot SAT, dan maintenance handover	Rp20 jt	Dry-cycle acceptance + TMflow backup	Robot existing; pembelian robot Rp0
SVC-INT-001	Project engineering & integration	Requirement review, optical POC coordination, electrical drawing, PC/USB commissioning, integration, standard site installation, FAT/SAT coordination, training, dan final documentation	Rp15 jt	Approved requirement, as-built package, signed FAT/SAT punch list	PC build included PC BoM; jig engineering/fabrication included jig allowance
TOTAL SOFTWARE + SELURUH JASA			Rp120 jt	Tidak ada charge FAT/SAT/training/site terpisah

Robot teaching/configuration deliverables

Backup robot/TMflow project and record hardware/firmware baseline
Configure TCP, payload, center of gravity, tool I/O, speed and acceleration
Teach Home, Approach, Inspect, Retreat, Maintenance, and Recovery poses
Configure operation/safety spaces and validate collision-free path
Configure PLC handshake over Modbus TCP or agreed I/O
Settle-time tuning before capture and fault recovery sequence
Dry cycle on dummy block and save version-controlled project backup

Software installation/commissioning deliverables

OS hardening/update baseline per Toyota IT standard
Basler/FL1100EX, camera, network, and GPU drivers
CUDA/TensorRT or ONNX Runtime/OpenCV stack as selected
18-camera service, auto-start, watchdog, reconnect, and log rotation
AI model/config deployment with version and checksum
Database/evidence retention, PLC/MES interface, and time synchronization
Golden image, offline installer, rollback procedure, and recovery test

05PC requirementsMinimum, recommended, and 1 PC versus 2 PC architecture

Rekomendasi utama adalah satu PC dengan dua kartu Basler. Seperti requirement game di Steam, tabel berikut membedakan minimum POC dan recommended production. Minimum bukan jaminan 18-channel production; keputusan final tetap berdasarkan benchmark model, PCIe topology audit, dan soak test 72 jam.

PC item	Minimum requirement · POC / engineering	Recommended requirement · production baseline	Acceptance note
Operating system	Windows 11 Pro 64-bit	Windows 11 Pro 64-bit; IoT Enterprise/LTSC hanya jika menjadi standard Toyota IT	Driver GPU, FL1100EX, camera, network, dan security policy harus kompatibel
CPU	8 physical cores / 16 threads, modern x86-64, AVX2	Intel Core Ultra 7 265K class, 20 cores; atau setara dengan sustained cooling	CPU tidak boleh thermal-throttle pada capture + decode + inference + logging
Memory	32 GB DDR5	64 GB DDR5; 2 × 32 GB agar masih ada upgrade path	Peak commit selama 72-hour test di bawah 80%
GPU	NVIDIA CUDA, minimum 12 GB VRAM; contoh RTX 3060 12 GB untuk POC	RTX 5060 Ti 16 GB, model 2-slot; workstation GPU 20 GB+ bila model/IT policy menuntut	Jangan membeli varian 8 GB sebelum model benchmark; P99 inference harus memenuhi cycle time
Storage	1 TB NVMe OS/app + 2 TB NVMe evidence	2 TB NVMe OS/app + 4 TB NVMe evidence; high-endurance; backup terpisah	Kapasitas final = image size × 18 × parts/day × retention days
PCIe topology	Tiga physical slots yang dapat aktif bersamaan: GPU minimum x8 electrical + Basler card #1 x4 electrical + Basler card #2 x4 electrical. Contoh basis: ASUS ProArt Z890-Creator WiFi, dua slot CPU x8/x8 dan satu chipset x4.		Wajib cek manual lane-sharing. Pada ProArt Z890, jangan gunakan M.2_5 karena menonaktifkan slot PCIe x4 chipset.
USB topology	16 kamera pada 2 Basler cards + 2 kamera pada dua port onboard yang telah terbukti berasal dari controller/root path yang sesuai. Baseline memakai kabel FC-3850 5 m; active extension individual hanya bila layout membutuhkan.		Tidak memakai shared consumer USB hub
Network	1 × 1 GbE dedicated machine LAN	Dual LAN; minimum 2.5 GbE machine + plant/MES network terpisah	Robot, PLC, dan MES mengikuti segment/VLAN plant
Power supply	850 W, 80 Plus Gold, reputable brand	1000 W, 80 Plus Gold/Platinum, modular, industrial cabinet derating considered	Termasuk GPU transient dan power dua USB cards
UPS	1500 VA line-interactive, shutdown signaling	2000 VA / 1800 W online, pure sine, monitored; contoh APC SRV2KI-E	Runtime minimum untuk controlled stop + evidence flush
Thermal / chassis	ATX tower, front-to-back airflow, dust control	Full ATX workstation chassis; GPU maksimum 2-slot untuk slot clearance; filtered positive pressure	Uji suhu dalam cabinet pada ambient line tertinggi

Recommended one-PC build · local budget snapshot

Component	Candidate / specification	Budget IDR	Reason / constraint
CPU	Intel Core Ultra 7 265K	Rp5.560.000	20 cores; local retail snapshot
Motherboard	ASUS ProArt Z890-Creator WiFi	Rp9.300.000	2 × PCIe 5.0 x16 (x8/x8) + 1 × PCIe 4.0 x4; dual 10/2.5 GbE
GPU	Gainward RTX 5060 Ti Python III 16 GB, 2-slot	Rp9.690.000	16 GB VRAM and slot clearance; benchmark required
RAM	64 GB DDR5, 2 × 32 GB; Crucial Pro class	Rp12.409.000	Local snapshot; equivalent approved brand acceptable
Storage	2 TB NVMe OS/app + 4 TB NVMe evidence	Rp8.000.000	Budget allowance; do not populate M.2_5 on this motherboard
PSU	Corsair RM1000e 1000 W Gold/Platinum class	Rp2.851.000	Power and transient headroom
Case + cooling	Full ATX airflow case + sustained-duty CPU cooling	Rp5.500.000	Budget allowance; verify PCIe card clearance
OS + monitor/input	Windows 11 Pro + 24-inch monitor + keyboard/mouse	Rp6.000.000	Budget allowance; follow corporate license policy
Build / local shipment	Assembly, BIOS setup, burn-in, packing, local delivery	Rp2.290.000	Planning allowance
Online UPS	APC SRV2KI-E, 2000 VA / 1800 W	Rp8.400.000	Local retail snapshot
Recommended PC + UPS budget		Rp70.000.000	Before the two Basler cards, which are in vision BoM

Aspek	1 PC + 2 kartu Basler	2 PC × 9 kamera	Penilaian
Arsitektur	16 kamera pada dua Basler card + 2 port onboard terverifikasi	Per PC: 8 Basler + 1 onboard	1 PC lebih sederhana
PCIe	GPU dapat berjalan x8 + dua kartu masing-masing x4; semua slot aktif bersamaan	Per PC cukup GPU + satu slot x4	1 PC butuh motherboard khusus
GPU	Satu GPU, satu inference batch	Dua GPU atau acquisition terpisah dengan inference terpusat	1 PC lebih efisien
Camera mapping	Satu service dan satu mapping database	Perlu mapping per node dan result aggregation	1 PC lebih mudah
Maintenance	Satu OS, satu deployment, satu spare image	Dua OS dan dua deployment	1 PC lebih rendah
Fault domain	PC gagal: semua inspeksi berhenti	Satu PC gagal: 9 kamera hilang; part tetap error/line stop	2 PC tidak otomatis membuat proses tetap jalan
Cable placement	Semua kabel menuju satu cabinet	Dapat dibagi ke dua lokasi	2 PC dapat membantu mekanik
Budget delta	PC + UPS medium Rp70 jt	Dua PC medium: total Rp120 jt	HPP hardware 2 PC bertambah Rp55 jt termasuk contingency
Keputusan	PRIMARY	FALLBACK	Final setelah audit dan soak test

Minimum acceptance tests

18 cameras enumerate to the same CAM01-CAM18 mapping after 50 cold boots
72-hour streaming/capture soak test with zero unrecovered camera loss
CPU, GPU, RAM, storage, and USB telemetry logged during full load
P99 capture + inference + result latency below line timeout
No thermal throttle and at least 20% RAM/storage throughput margin
Controlled recovery after USB disconnect, robot fault, and power interruption

Audit PC existing yang dibutuhkan

Manufacturer/model PC dan motherboard
CPU, RAM, GPU, VRAM, PSU
PCIe lane map dari motherboard manual
NVMe/SATA/device lain yang memakai lane
OS/build dan driver constraints
Target cycle time dan image retention

06Perhitungan bandwidthMJPEG planning basis and actual camera measurement procedure

Basis proyek: MJPEG. Format ini dipakai sebagai asumsi kerja karena kamera diperkirakan mengirim video terkompresi. Namun mode live FC-3850, fps, dan bit rate belum dipublikasikan sebagai data vendor, sehingga angka di bawah tetap wajib diverifikasi pada unit nyata. Uji kabel 5 m bawaan terlebih dahulu; active extension hanya diuji jika benar-benar diperlukan.

Mode kerja	Asumsi medium	Per kamera	2 kamera / controller	Total 18 kamera	Dengan 25% headroom	Assessment
MJPEG 1280×720 FPS aktual TBD	10 Mb/s per kamera untuk planning; bukan spesifikasi vendor	10 Mb/s	20 Mb/s	180 Mb/s	225 Mb/s	BASIS POC · WAJIB UKUR Controller margin terlihat memadai hanya jika MJPEG terkonfirmasi

Gate: konfirmasi FourCC benar-benar MJPEG, requested/actual fps, transfer type, average/peak bandwidth, dan frame drop dengan satu kamera sebelum membeli 18 unit. Jika kamera hanya menyediakan YUY2 pada mode target, arsitektur bandwidth harus dihitung ulang.

Cara mendapatkan data bandwidth aktual

Nilai MJPEG 10 Mb/s di atas belum berasal dari pengukuran kamera. Data produksi harus diambil dari FC-3850 nyata dengan kabel bawaan 5 m, memakai PC dan kartu USB yang akan digunakan. Powered extension diuji sebagai konfigurasi kedua hanya bila layout memerlukannya.

STEP 01

Identifikasi device

Catat FriendlyName, VID/PID, InstanceId, controller, hub, dan physical port. Ulangi sesudah cold boot untuk memastikan CAM01-CAM18 tidak bertukar.

STEP 02

Baca mode kamera

Ambil daftar FourCC, resolusi, dan FPS melalui DirectShow/FFmpeg. Uji kabel FC-3850 5 m dahulu; ulangi dengan powered extension hanya jika diperlukan.

STEP 03

Ukur stream

Log jumlah frame expected/received, timestamp gap, compressed bytes, actual FPS, disconnect, reconnect time, CPU, GPU, dan temperatur.

STEP 04

Scale-up bertahap

1 kamera 30 menit → 4 kamera 24 jam → 9 kamera 72 jam → 18 kamera 72 jam. Jangan lanjut jika mapping berubah atau disconnect tidak pulih.

Perintah pengambilan data di Windows

Jalankan dari PowerShell pada PC uji. FFmpeg harus tersedia untuk membaca kemampuan DirectShow. Ganti nama USB Camera dengan FriendlyName aktual.

# 1. Daftar kamera dan InstanceId Windows Get-PnpDevice -PresentOnly | Where-Object { $_.Class -in 'Camera','Image' } | Select-Object Status,Class,FriendlyName,InstanceId # 2. Daftar mode/FourCC/resolusi/FPS yang dilaporkan kamera ffmpeg -hide_banner -f dshow -list_options true -i video="USB Camera" # 3. Contoh soak capture 10 menit, MJPEG 1280×720 @ 30 fps ffmpeg -hide_banner -f dshow -input_format mjpeg -video_size 1280x720 -framerate 30 -i video="USB Camera" -t 600 -f null -

Data minimum yang harus dikumpulkan

FourCC aktual; requested dan actual FPS; average/peak Mb/s per kamera; controller/port mapping; frame expected/received/dropped; disconnect count; reconnect time; CPU/GPU/RAM; temperatur; extension dan power-supply model; serta checksum konfigurasi software.

Test record template

Test ID	Camera	Controller / port	Extension / power	FourCC	Resolution / requested FPS	Duration	Expected frames	Received frames	Dropped	Actual FPS	Avg / peak Mb/s	Disconnect / reconnect	CPU / GPU peak	Result / notes
BW-001	CAM01	Baseline / direct	FC-3850 5 m / none	MJPEG?	1280×720 / TBD	30 min	TBD	TBD	TBD	TBD	TBD	TBD	TBD	Baseline wajib
BW-002	CAM01	Basler HC1 / P1	Optional UGREEN/Vention 5 m / external 5 V	MJPEG?	1280×720 / TBD	30 min	TBD	TBD	TBD	TBD	TBD	TBD	TBD	Hanya jika layout butuh extension
BW-003	CAM01-CAM04	Basler HC1-HC2	4 × FC-3850 5 m; extension per final routing	MJPEG?	1280×720 / TBD	24 h	TBD	TBD	TBD	TBD	TBD	TBD	TBD	Gate 2 scale-up

07Fungsi software dan AIAcquisition, inference, traceability, and claim limitations

Urutan	Modul	Fungsi	Output / reason code
1	Inspection orchestrator	Handshake dengan PLC/robot; validasi part ID; tunggu at-pose + settled	READY / BUSY / COMPLETE / ERROR
2	Camera service	Bind CAM01-CAM18 berdasarkan serial atau physical controller/port path	CONNECTED / MISSING / WRONG_MAP
3	Capture	Ambil burst saat part berhenti; timestamp dan simpan metadata	FRAME_OK / TIMEOUT / DROPPED
4	Image quality gate	Periksa blur, over/under exposure, glare, occlusion, dan target not found	QUALITY_OK / BLUR / GLARE / OCCLUDED
5	ROI & AI inference	Localization, segmentation/classification, dan measurement per kamera	Presence; mask; confidence; size pixel
6	Calibration & rule engine	Konversi pixel ke mm; aturan M1/M2/M3; gabungkan semua channel	OK / NG / UNCERTAIN / INSPECTION_ERROR
7	Evidence & traceability	Simpan image, part ID, camera ID, robot pose, model version, hasil peel/leak	Database record dan evidence path

Batas klaim AI

Image AI dapat mengukur kondisi visual, presence, ukuran, dan indikasi abnormal. Sifat fisik “easy to peel-off” tetap membutuhkan label dari peel test/leak test dan tidak boleh dianggap terbukti hanya dari gambar.

08Robot, jig, dan cable managementPayload, mechanical design, and integration requirements

Payload calculation harus memasukkan

Frame/jig untuk 18 kamera
Probe cartridge, clamp, guide bushing
Bagian kabel dan connector yang bergerak
Strain relief dan dress pack
Center of gravity dan inertia
Gaya drag kabel sepanjang trajectory

Requirement mekanik

Plate ringan dan kaku; deflection check
Guide bushing non-abrasif dan floating compliance
Hard nest/datum dan mechanical lead-in
Replaceable cartridge CAM01-CAM18
Label camera/controller/port/target
Collision study dan machine safety assessment

Open question

Apakah 18 probe masuk bersamaan atau bergantian?

Open question

Berapa massa, center of gravity, dan inertia jig lengkap?

Open question

Berapa standoff kamera-target dan toleransi posisi block di nest?

Open question

Apakah terdapat oil, coolant, chips, vibration, atau temperatur tinggi?

09Risk registerTechnical, procurement, integration, and production risks

Filter level:

ID	Risiko	Level	Dampak	Mitigasi / gate
R-01	Live stream raw YUY2	HIGH	Bandwidth host controller habis	Verifikasi FourCC; gunakan MJPEG/lower fps bila tersedia
R-02	Camera index berubah	HIGH	CAM logical membaca target yang salah	Serial/device path/topology mapping + startup validation
R-03	Exposure/LED berbeda	HIGH	AI drift dan hasil antar-camera tidak konsisten	Lock setting, calibration reference, quality gate
R-04	Fokus berubah	HIGH	Target blur atau skala mm/pixel berubah	Fixed standoff, guide bushing, rigid cartridge
R-05	Payload/inertia berlebih	HIGH	Robot overload, repeatability turun, unsafe motion	Timbang prototype; hitung CoG/inertia; kurangi moving mass
R-06	Cable fatigue/disconnect	HIGH	Camera drop saat produksi	Dress pack, bend radius, strain relief, cycle test
R-07	Visual vs peel-off mismatch	HIGH	Model mengklaim sifat fisik yang tidak terlihat	Gunakan peel/leak ground truth; batasi claim output
R-08	Coolant/oil/lens contamination	HIGH	Image quality turun dan kamera rusak	Compatibility test, cleaning poka-yoke, contamination detector
R-09	Single PC failure	MEDIUM	Seluruh inspeksi berhenti	Spare imaged PC, watchdog, auto-recovery, UPS
R-10	Dua PC tidak sinkron	MEDIUM	Result berbeda part/cycle	Central orchestrator, part ID, timestamp, heartbeat
R-11	Data leakage model	HIGH	Accuracy validasi palsu	Split dataset berdasarkan part/lot/time, bukan frame acak
R-12	Collision 18 probe	HIGH	Probe, block, atau jig rusak	Dummy block dry cycle, lead-in, compliance, collision study
R-13	TM5X-900 lifecycle	MEDIUM	Existing asset membutuhkan rencana spare dan support sampai akhir lifecycle	Record hardware/firmware, full backup, condition audit, dan spare strategy; tidak ada robot purchase di HPP
R-14	Optional active USB repeaters	MEDIUM	Jika diperlukan oleh layout, repeater menambah titik kegagalan, power drop, EMI, dan reconnect	Gunakan kabel FC-3850 5 m sebagai baseline; extension hanya per channel yang perlu, external 5 V, retention, dan 72-hour soak

10POC scale-up planControlled validation from one camera to 18 cameras

POC itu apa?

POC (Proof of Concept) adalah uji pembuktian bahwa konsep teknis benar-benar bekerja pada skala kecil sebelum design freeze dan pembelian massal. Di proyek ini, POC harus membuktikan kualitas gambar, mode MJPEG, bandwidth, fokus, mapping kamera, reconnect, ketahanan coolant, dan repeatability insertion. Lulus POC belum sama dengan production ready; sistem masih harus melewati FAT, SAT, dan production trial.

Gate	Scope	Pengujian utama	Exit criteria ringkas	Status
0	Requirement freeze	Drawing 18 target; OK/NG; cycle time; engine variant; interface line	Requirement disetujui production dan quality	OPEN
1	1 camera / 1 target	FourCC, fps, focus, glare, exposure, insertion repeatability, coolant	Target selalu terlihat; setting dan skala stabil	PLANNED
2	4 cameras	2 camera/controller; mapping; power; frame drop; stream 24 jam	Tidak ada disconnect/index swap; bandwidth margin cukup	PLANNED
3	9 cameras / PC	1 Basler card + onboard; batching; logging; inference; soak 72 jam	Uptime, latency, recovery, mapping memenuhi target	PLANNED
4	18 cameras + robot	Dummy block; payload; collision; cable drag; focus; latency P99	Dry cycle aman dan 18 channel stabil	PLANNED
5	Production trial	Shadow mode; AI vs inspector; peel/leak comparison; drift monitoring	False accept/reject, uptime, cycle time memenuhi acceptance	PLANNED

11Data yang dibutuhkan berikutnyaOpen inputs before design freeze and procurement

Prioritas	Data / dokumen	Detail minimum	Dipakai untuk keputusan	Status
P0	Spesifikasi PC existing	CPU, RAM, GPU/VRAM, PSU, motherboard, manual lane map, slot terpakai	1 PC atau 2 PC	BELUM ADA
P0	Drawing 18 target	XYZ, arah pandang, bore, depth, clearance, datum, engine variant	Jumlah kamera dan desain jig	BELUM ADA
P0	Cycle time line	Part stop time, capture window, response timeout, target UPH	FPS, inference, dan PC sizing	BELUM ADA
P0	Definisi quality	Presence, size, peel-off, leak prediction, threshold dan error handling	Model output dan acceptance	BELUM ADA
P0	Robot asset audit	Existing TM5X-900 confirmed; collect exact part number, HW version, TMflow version, cable/controller, accessory list, service history, and backup	Condition, compatibility, spare, teaching scope	DETAIL OPEN
P1	Sample image/video	30-50 per posisi; OK/NG; oil/glare/blur; seluruh shift/lot	Optical feasibility dan dataset plan	REQUEST
P1	Jig mass concept	CAD, mass, CoG, inertia, cable routing, trajectory	TM5X-900 feasibility	REQUEST
P1	Line interface	PLC brand/protocol, MES, barcode/part ID, handshake timing	Software architecture	REQUEST
P2	Environment data	Coolant/oil type, temperature, chips, cleaning method, vibration	Camera protection dan lifetime test	REQUEST

12Sumber dan file referensiLocal documents, vendor data, and research links

Local project files

Mejashi checking.pdf - checksheet sumber lokal
Concept review lengkap (README.md)

Research and supplier links

13Ringkasan proyek dan hargaKeputusan utama serta HPP 1 PC versus 2 PC

Basis hargaMediumIndonesia · budgetary

Arsitektur utama1 PC2 kartu Basler wajib

Kamera20 unit18 operasi + 2 spare

Kabel kamera5 mFC-3850 baseline

USB extensionOptional0 unit dalam HPP dasar

Robot purchaseRp0Existing TM5X-900

Rekomendasi keputusan

Mulai dengan arsitektur 1 PC karena lebih sederhana, lebih murah, dan hanya membutuhkan satu deployment software. Dua kartu Basler tetap wajib. Beralih ke 2 PC hanya jika audit PCIe/USB, benchmark, atau soak test 72 jam menunjukkan bottleneck atau kebutuhan fault isolation yang lebih kuat.

Komponen biaya	1 PC · rekomendasi	2 PC · alternatif	Keterangan
20 kamera landed	Rp123,80 jt	Rp123,80 jt	18 operasi + 2 spare; shipment dan 20% landed provision
2 kartu Basler landed	Rp13,36 jt	Rp13,36 jt	Wajib; 2 kartu total pada kedua arsitektur
Pendukung vision/local logistics	Rp20,00 jt	Rp20,00 jt	Allowance lokal; active extension tidak termasuk
PC + UPS	Rp70,00 jt	Rp120,00 jt	1 workstation recommended versus 2 node medium
Jig + mekanik	Rp120,00 jt	Rp120,00 jt	All-in allowance untuk engineering, material, fabrication, dan assembly
Controls + safety	Rp75,00 jt	Rp75,00 jt	Panel, I/O, guarding/safety allowance
Hardware contingency 10%	Rp42,22 jt	Rp47,22 jt	Diterapkan setelah allowance hardware
Total hardware HPP	Rp464,38 jt	Rp519,38 jt	Selisih arsitektur Rp55,00 jt
Software + seluruh jasa	Rp120,00 jt	Rp120,00 jt	All-in: robot, integration, FAT/SAT, training, documentation, site, hypercare
Biaya jasa tambahan	Rp0	Rp0	Tidak ada site/travel/commissioning charge terpisah untuk scope standar
TOTAL PROJECT HPP	Rp584,38 jt	Rp639,38 jt	Robot existing Rp0; sebelum pajak final/quotation

Sudah termasuk dalam HPP

20 kamera planning proxy dan shipment internasional
2 kartu Basler wajib dan shipment
PC/UPS, jig allowance, controls/safety, dan contingency
Software dan seluruh jasa Rp120 jt: software/AI Rp85 jt, robot Rp20 jt, integration Rp15 jt
FAT/SAT, training, dokumentasi, standard site work, dan hypercare tanpa charge terpisah

Optional / belum termasuk

Active USB extension: maksimum Rp5,68 jt sebelum contingency untuk 20 channel
VAT/pajak final, import duty aktual, broker/forwarder actual, overtime, dan production downtime
Perubahan scope besar MES/PLC, lisensi komersial, serta test parts tambahan
Perjalanan di luar standard site scope atau tambahan pekerjaan setelah acceptance

Istilah penting

POC = Proof of Concept, uji pembuktian konsep sebelum pembelian massal. HPP di register ini = total budget hardware landed + contingency + engineering + site/travel. MD = man-day/person-day, satu hari kerja satu engineer. FAT = Factory Acceptance Test di workshop integrator. SAT = Site Acceptance Test setelah sistem dipasang di lokasi customer.