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Revision 1 as of 2011-11-24 12:02:49
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Revision 7 as of 2011-11-25 13:47:52
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Editor: BobAdamson
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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||Cost||
||7||microswitches||front button switches|| || ||
||20||microswitches||each slot has double microswitches, there are 10 slots|| || ||
||7||5mm round white LED's||replace empty slot globes|| || ||
||7||led mounts for empty slot display||may not be needed, depends on how we mount the LEDs|| || ||
||7||resistors||empty slot LED protection|| || ||
||1||stripboard or veroboard||mount LED resistors|| || ||
||10||6 pin connectors||one for each slot actuator unit|| || ||
||??||? pin connectors||assorted connections between cables|| || ||
||1||manual drop button|| || || ||
||1||PLC||brain||FMD88-10|| ||
||1||PLC expansion card||additional IO||EXP4040|| ||
||50m?||20 different coloured wires||general rewiring|| || ||
|| ||cable ties|| || || ||
|| ||cable loom/heatshrink tube/electrical tape|| || || ||
|| ||terminal blocks|| || || ||
||1||can rust proofing spraypaint|| || || ||
||1||110V fan to replace 12V case fan|| || || ||
http://www.frozencpu.com/cat/l3/g36/c265/s668/list/p1/Fans-AC_115V_Fans-120mm_AC_Fans-Page1.html

=== 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
 * 10x?110V? relay outputs (this assumes linear actuators return by themselves)
 * 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

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

Cost

7

microswitches

front button switches

20

microswitches

each slot has double microswitches, there are 10 slots

7

5mm round white LED's

replace empty slot globes

7

led mounts for empty slot display

may not be needed, depends on how we mount the LEDs

7

resistors

empty slot LED protection

1

stripboard or veroboard

mount LED resistors

10

6 pin connectors

one for each slot actuator unit

??

? pin connectors

assorted connections between cables

1

manual drop button

1

PLC

brain

FMD88-10

1

PLC expansion card

additional IO

EXP4040

50m?

20 different coloured wires

general rewiring

cable ties

cable loom/heatshrink tube/electrical tape

terminal blocks

1

can rust proofing spraypaint

1

110V fan to replace 12V case fan

http://www.frozencpu.com/cat/l3/g36/c265/s668/list/p1/Fans-AC_115V_Fans-120mm_AC_Fans-Page1.html

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
  • 10x?110V? relay outputs (this assumes linear actuators return by themselves)
  • 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