4545
Comment: whups
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4574
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Deletions are marked like this. | Additions are marked like this. |
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||1||PLC||brain||FMD88-10|| || $360 || ||1||PLC expansion card||additional IO||EXP1616R|| || || ||42m||5 core wire, 1mm minimum diameter (to carry 2A) || actuator and empty switch wiring|| http://www.ebay.com.au/itm/5-Core-Cable-Wiring-Wire-Trailer-Parts-Lights-per-Meter-/110609219198 || $1.55/m|| || |
||1||PLC||brain||FMD88-10 starter kit, i-STK88-10|| || $420 || ||1||PLC expansion card||additional IO||EXP1616R|| || $190 || ||42m||4 core wire, 1mm minimum diameter (to carry 2A) || actuator and empty switch wiring|| http://www.ebay.com.au/itm/5-Core-Cable-Wiring-Wire-Trailer-Parts-Lights-per-Meter-/110609219198 || $1.55/m|| || |
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 |
$2.16 |
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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 |
$3.60 |
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7 |
5mm round white LED's |
replace empty slot globes |
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7 |
led mounts for empty slot display |
may not be needed, depends on how we mount the LEDs |
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7 |
resistors |
empty slot LED protection |
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1 |
stripboard or veroboard |
mount LED resistors |
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10 |
6 pin connectors |
one for each slot actuator unit |
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?? |
? pin connectors |
assorted connections between cables |
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1 |
manual drop button |
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1 |
PLC |
brain |
FMD88-10 starter kit, i-STK88-10 |
|
$420 |
1 |
PLC expansion card |
additional IO |
EXP1616R |
|
$190 |
42m |
4 core wire, 1mm minimum diameter (to carry 2A) |
actuator and empty switch wiring |
http://www.ebay.com.au/itm/5-Core-Cable-Wiring-Wire-Trailer-Parts-Lights-per-Meter-/110609219198 |
$1.55/m |
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8m |
9 core wire |
front buttons and lights wiring |
http://www.ebay.com.au/itm/0-5mm-9-Core-Irrigation-Cable-per-metre-/300341913942 |
$2.15/m |
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cable ties |
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cable loom/heatshrink tube/electrical tape |
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terminal blocks |
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2 |
galvanising paint |
recoating everything |
http://www.diytools.com.au/MOTOSPRAY-Silva-Gal--Pressure-Pack-400g.html |
$12 |
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3 |
110V fan to replace refrigeration fans |
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Total |
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http://www.frozencpu.com/cat/l3/g36/c265/s668/list/p1/Fans-AC_115V_Fans-120mm_AC_Fans-Page1.html
http://cgi.ebay.com.au/ws/eBayISAPI.dll?ViewItem&item=170619406538 (if it's big enough)
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
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)