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Revision 59 as of 2011-12-10 19:14:11
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Revision 61 as of 2011-12-13 12:40:57
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||10 (./) ||4 pin connectors||one for each slot actuator unit|| Molex mini-fit jr series 4way connectors || || $31.26 || ||10 (./) ||4 pin connectors||one for each slot actuator unit|| Molex mini-fit jr series 4way connectors [[http://au.element14.com/multicomp/mc34507/receptacle-free-4way/dp/1578469?Ntt=157-8469 | Also compatible]] || || $31.26 ||
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||1||4V regulator|| LED PSU || || || || ||1 (./) ||5V PSU|| led power and future expansion power || [[http://www.inasolutions.com.au/Shop/ALLOY-DR4505-DIN-Rail-5V5Amp-power-supply-for-Converters-Serial-devices-P1839.aspx|INA Solutions]] ||62.83|| 62.83 ||

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, 2.21N

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

Molex mini-fit jr series 4way connectors Also compatible

$31.26

1 (./)

9 pin connector

interface with distribution box

recycle old connector

free

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)

$475 kit

1 (./)

PLC expansion card

additional IO

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

kit

1 (./)

24V PSU

kinda need a power supply

automationmart.com

kit

1 (./)

5V PSU

led power and future expansion power

INA Solutions

62.83

62.83

42m (./)

4 core wire, 1mm minimum diameter (to carry 2A), 18AWG

actuator and empty switch wiring

http://www.altronics.com.au/index.asp?area=item&id=W3121

$1.22/m

$51.63

11m (./)

9 core wire

front buttons and lights wiring

http://www.altronics.com.au/index.asp?area=item&id=W2712

43c/m

$4.72

5m (./)

2 core wire

refrigeration fan power

http://www.altronics.com.au/index.asp?area=item&id=W2139

80c/m

$4.00

cable ties

Donation?

10m (./)

cable loom

cable loom for fans and actuators

http://www.altronics.com.au/index.asp?area=item&id=H3814

$12.90

$12.90

terminal blocks

3 (./)

galvanising paint

recoating everything

Dy-Mark Zinc Gal from Bunnings

$13.95

$13.95

1 (./)

pack 100 female quick connectors 4.8mm

attach to microswitches

http://www.altronics.com.au/index.asp?area=item&id=H1992A

$11.35

$11.35

1 (./)

pack 100 bullet male connectors

cable loom

http://www.altronics.com.au/index.asp?area=item&id=H2152A

$8.13

$8.13

1 (./)

pack 100 bullet female connectors

cable loom

http://www.altronics.com.au/index.asp?area=item&id=H2122A

$13.08

$13.08

1 (./)

pack 100 terminal pin connectors

terminal block

http://www.altronics.com.au/index.asp?area=item&id=H1902

$8.34

$8.34

1 (./)

pack 10 male quick connectors 4.8mm

fridge fans

http://www.altronics.com.au/index.asp?area=item&id=H1851

$2.90

$2.90

3 (./)

Fans to replace refrigeration fans

24V Altronics

$11.07

$33.21

3 (./)

Finger guards

base refrigeration fan covers

$1.09

$3.27

12 (./)

sheet metal screws

attach fans to cooler cover

60 (./)

2mm spacers (washers?)

otherwise fans will jam on lip of cover

1 (./)

electrical tape (white)

$1.55

$1.55

1

putty/sealant

put in corners so water can't sit there and cause rust

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

Wiring it up

  • Terminal Blocks
    • None required for the door buttons
    • End cap
    • 20 for slot microswitches
    • Spacer
    • X for 24V power positive and negative
    • Spacer
    • Spacer
    • Isolator for 110V
    • X for 110V distribution
    • 20 for slot solenoids
    • X for 110V neutral
    • Spacer
    • Commoning bars
    • Din rail
    • Slotted duct 3 metres
    • Earth
  • Network cable connection
    • Panduit CFPHS2IW Faceplate or similar
    • Panduit Cat 6 Mech and cable

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)
  • The fans suck air through the fridge unit, they don't blow it

Extra Things To Consider