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Size: 7163
Comment:
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Size: 7708
Comment:
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| Deletions are marked like this. | Additions are marked like this. |
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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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=== Stuff to fix in future === * The crimps on the fan loom where two wires go into a crimp should be replaced with the bigger blue crimps instead of the small red ones (you'll need 2 blue female 4.8mm and two male 4.8mm) * The 5x1mm washers acting as spacers for the bottom refigeration fans should be replaced with a 5mm piece of tube instead - the washers will be impossible to put back on if the fans ever need to be removed |
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 |
$2.16 |
$15.12 |
|
20 |
microswitches |
each slot has double microswitches, there are 10 slots, 0.15N |
$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 |
|
kit |
|
1 |
5V PSU |
led power and future expansion power |
62.83 |
62.83 |
|
42m |
4 core wire, 1mm minimum diameter (to carry 2A), 18AWG |
actuator and empty switch wiring |
$1.22/m |
$51.63 |
|
11m |
9 core wire |
front buttons and lights wiring |
43c/m |
$4.72 |
|
5m |
2 core wire |
refrigeration fan power |
80c/m |
$4.00 |
|
|
cable ties |
|
|
Donation? |
|
10m |
cable loom |
cable loom for fans and actuators |
$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 |
$11.35 |
$11.35 |
|
1 |
pack 100 bullet male connectors |
cable loom |
$8.13 |
$8.13 |
|
1 |
pack 100 bullet female connectors |
cable loom |
$13.08 |
$13.08 |
|
1 |
pack 100 terminal pin connectors |
terminal block |
$8.34 |
$8.34 |
|
1 |
pack 10 male quick connectors 4.8mm |
fridge fans |
$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
- Snubber circuit for solenoids
Stuff to fix in future
- The crimps on the fan loom where two wires go into a crimp should be replaced with the bigger blue crimps instead of the small red ones (you'll need 2 blue female 4.8mm and two male 4.8mm)
- The 5x1mm washers acting as spacers for the bottom refigeration fans should be replaced with a 5mm piece of tube instead - the washers will be impossible to put back on if the fans ever need to be removed
