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Revision 1 as of 2011-11-24 12:02:49
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Editor: BobAdamson
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Revision 40 as of 2011-12-03 01:43:57
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Editor: NickBannon
Comment: Wire, connectors, LEDs
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Ideas, comments, stuff - goes here. === Aims ===
 * redo all internal wiring and logic, except the refrigeration parts
 * make the machine more safe by doing things properly and reducing the voltage of exposed components
 * keep the software interface as simple or more simple than before
 * make the buttons on the front of the machine work for dispense
 * make it extensible so things can be added on
 * give the machine a general service where necessary (seals, rust protection, oil)

=== Draft Bill of Materials ===

||Amount||Item||Use||Model||Unit Cost||Total||
||7||microswitches||front button switches|| [[http://au.element14.com/honeywell-s-c/v7-1v19e9/micro-switch-pin-plunger-spdt-21a/dp/1796579|au.element14.com]] || $2.16|| $15.12||
||20||microswitches||each slot has double microswitches, there are 10 slots, 0.15N|| [[http://au.element14.com/honeywell-s-c/v7-5f17d8/micro-switch-pin-plunger-spdt-3a/dp/1796593|au.element14.com]] || $3.60 || $72||
||7||5mm round white LED's||replace empty slot globes|| [[http://au.element14.com/vcc-visual-communications-company/vaol-5701wy4/led-5mm-white-1800mcd/dp/1712795|Standard 5mm LEDs, au.element14.com]] White? Or red for empty, green for non-empty? ||0.616 ||$6.16 ||
||7||resistors||empty slot LED protection|| || < $0.05 || ||
||1||stripboard or veroboard||mount LED resistors|| || || ||
||10||4 pin connectors||one for each slot actuator unit|| http://www.altronics.com.au/index.asp?area=item&id=P5474 , http://www.altronics.com.au/index.asp?area=item&id=P5704 , http://www.altronics.com.au/index.asp?area=item&id=P5644 or related || < $0.90 || < $9.00 ||
||1||9 pin connector||interface with distribution box|| || || ||
||2||16 pin connectors||base of door connectors (left and right stack)|| || || ||
||1||8 pin connector||base of door connector (middle stack)|| || || ||
||1||manual drop button|| || || || ||
||1||PLC||brain||FMD88-10 starter kit, i-STK88-10, http://www.tri-plc.com/ISTK-FMD88-10.htm (including http://www.tri-plc.com/fmd88-10.htm , software, data cable) || || $420 ||
||1||PLC expansion card||additional IO||EXP1616R, http://www.tri-plc.com/exp1616r.htm || || $190 ||
||42m||4 core wire, 1mm minimum diameter (to carry 2A) || actuator and empty switch wiring|| http://www.altronics.com.au/index.asp?area=item&id=W2341 4 core, 7 strands, 2.2A rated, $45/100m minus trade discount. 6 core W2360 available at cost price? - double the solenoid lines?; [[http://cgi.ebay.com.au/ws/eBayISAPI.dll?ViewItem&item=170619406538|5 core trailer wire]] (if it's big enough); Quote wanted for 4 core mains flex e.g. http://www.blackwoods.com.au/PartDetail.aspx?part_no=04418902 || $0.85/m || Under $45.00 ||
||8m||9 core wire || front buttons and lights wiring|| [[http://www.ebay.com.au/itm/0-5mm-9-Core-Irrigation-Cable-per-metre-/300341913942|ebay.com.au 201111]] || $2.15/m|| $17.20||
|| ||cable ties|| || || Donation? || ||
|| ||cable loom/heatshrink tube/electrical tape|| || || || ||
|| ||terminal blocks|| || || || ||
||2||galvanising paint|| recoating everything|| Cold gal aerosol [[http://www.diytools.com.au/MOTOSPRAY-Silva-Gal--Pressure-Pack-400g.html|diytools.com.au]] or Wattyl killrust Cold Galvit 375g (Bunnings?) || $12 || $24 ||
||3||Fans to replace refrigeration fans|| || 24V? [[http://www.frozencpu.com/cat/l3/g36/c265/s668/list/p1/Fans-AC_115V_Fans-120mm_AC_Fans-Page1.html|frozencpu.com 110V?]] || || ||
|| Total || || || || || ||

=== Internal PLC IO Requirements ===
 * 10x24V DC input for can sensing (would it be worth multiplexing this?)
 * 7x24V DC input for front door buttons (ditto with the multiplexing question)
 * 1x24V DC input for manual dispense mode button
 * 10x100V AC relay outputs
 * 7x DC outputs for empty slot display

=== Process ===
 * empty the machine and bring it into the clubroom. This means everything won't have to be packed up at the end of the day while we're working on it
 * remove one of the stacks and test a slot actuator to see what it runs off. This determines what hardware we use to drive everything, so we need to know.
 * purchase all required hardware (PLC, wiring, connectors, switches, etc.)
 * write software (state machine based programming implemented in ladder logic, ''should'' be quite trivial)
 * wire up on the bench and test
 * service the machine. A can of zinc spraypaint wouldn't go astray on some of the rust spots I think. Check all the seals. Oil what needs oiling. Clean what needs cleaning.
 * install everything into the machine and test

=== Measured things ===
 * Can drop process: 400ms on, 500ms off, 660ms on, 300VAC peak-to-peak, 1.8A
 * Wire lengths:
  * Actuator units 0,1,2,3: 80cm actuator to wire harness, 210cm harness to corner of machine door, 40cm up door, 45cm across, 40cm up to terminal block (4-core minimum) (16.6m)
  * Actuator units 4,5: 80cm actuator to wire harness, 170cm harness to corner of machine door, 40cm up door, 45cm across, 40cm up to terminal block (4-core minimum) (7.5m)
  * Actuator units 6,7,8,9: 80cm actuator to wire harness, 140cm harness to corner of machine door, 40cm up door, 45cm across, 40cm up to terminal block (4-core minimum) (13.8m)
  * Buttons: 75cm across front of door, 60cm down edge of door, 45cm across, 40cm up to terminal block (8-core minimum) (2.2m)
  * Lights: 75cm across front of door, 60cm down edge of door, 45cm across, 40cm up to terminal block (8-core minimum) (2.2m)

Aims

  • redo all internal wiring and logic, except the refrigeration parts
  • make the machine more safe by doing things properly and reducing the voltage of exposed components
  • keep the software interface as simple or more simple than before
  • make the buttons on the front of the machine work for dispense
  • make it extensible so things can be added on
  • give the machine a general service where necessary (seals, rust protection, oil)

Draft Bill of Materials

Amount

Item

Use

Model

Unit Cost

Total

7

microswitches

front button switches

au.element14.com

$2.16

$15.12

20

microswitches

each slot has double microswitches, there are 10 slots, 0.15N

au.element14.com

$3.60

$72

7

5mm round white LED's

replace empty slot globes

Standard 5mm LEDs, au.element14.com White? Or red for empty, green for non-empty?

0.616

$6.16

7

resistors

empty slot LED protection

< $0.05

1

stripboard or veroboard

mount LED resistors

10

4 pin connectors

one for each slot actuator unit

http://www.altronics.com.au/index.asp?area=item&id=P5474 , http://www.altronics.com.au/index.asp?area=item&id=P5704 , http://www.altronics.com.au/index.asp?area=item&id=P5644 or related

< $0.90

< $9.00

1

9 pin connector

interface with distribution box

2

16 pin connectors

base of door connectors (left and right stack)

1

8 pin connector

base of door connector (middle stack)

1

manual drop button

1

PLC

brain

FMD88-10 starter kit, i-STK88-10, http://www.tri-plc.com/ISTK-FMD88-10.htm (including http://www.tri-plc.com/fmd88-10.htm , software, data cable)

$420

1

PLC expansion card

additional IO

EXP1616R, http://www.tri-plc.com/exp1616r.htm

$190

42m

4 core wire, 1mm minimum diameter (to carry 2A)

actuator and empty switch wiring

http://www.altronics.com.au/index.asp?area=item&id=W2341 4 core, 7 strands, 2.2A rated, $45/100m minus trade discount. 6 core W2360 available at cost price? - double the solenoid lines?; 5 core trailer wire (if it's big enough); Quote wanted for 4 core mains flex e.g. http://www.blackwoods.com.au/PartDetail.aspx?part_no=04418902

$0.85/m

Under $45.00

8m

9 core wire

front buttons and lights wiring

ebay.com.au 201111

$2.15/m

$17.20

cable ties

Donation?

cable loom/heatshrink tube/electrical tape

terminal blocks

2

galvanising paint

recoating everything

Cold gal aerosol diytools.com.au or Wattyl killrust Cold Galvit 375g (Bunnings?)

$12

$24

3

Fans to replace refrigeration fans

24V? frozencpu.com 110V?

Total

Internal PLC IO Requirements

  • 10x24V DC input for can sensing (would it be worth multiplexing this?)
  • 7x24V DC input for front door buttons (ditto with the multiplexing question)
  • 1x24V DC input for manual dispense mode button
  • 10x100V AC relay outputs
  • 7x DC outputs for empty slot display

Process

  • empty the machine and bring it into the clubroom. This means everything won't have to be packed up at the end of the day while we're working on it
  • remove one of the stacks and test a slot actuator to see what it runs off. This determines what hardware we use to drive everything, so we need to know.
  • purchase all required hardware (PLC, wiring, connectors, switches, etc.)
  • write software (state machine based programming implemented in ladder logic, should be quite trivial)

  • wire up on the bench and test
  • service the machine. A can of zinc spraypaint wouldn't go astray on some of the rust spots I think. Check all the seals. Oil what needs oiling. Clean what needs cleaning.
  • install everything into the machine and test

Measured things

  • Can drop process: 400ms on, 500ms off, 660ms on, 300VAC peak-to-peak, 1.8A
  • Wire lengths:
    • Actuator units 0,1,2,3: 80cm actuator to wire harness, 210cm harness to corner of machine door, 40cm up door, 45cm across, 40cm up to terminal block (4-core minimum) (16.6m)
    • Actuator units 4,5: 80cm actuator to wire harness, 170cm harness to corner of machine door, 40cm up door, 45cm across, 40cm up to terminal block (4-core minimum) (7.5m)
    • Actuator units 6,7,8,9: 80cm actuator to wire harness, 140cm harness to corner of machine door, 40cm up door, 45cm across, 40cm up to terminal block (4-core minimum) (13.8m)
    • Buttons: 75cm across front of door, 60cm down edge of door, 45cm across, 40cm up to terminal block (8-core minimum) (2.2m)
    • Lights: 75cm across front of door, 60cm down edge of door, 45cm across, 40cm up to terminal block (8-core minimum) (2.2m)