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 |
$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 |
$3.60 |
$72 |
7 |
5mm round white LED's |
replace empty slot globes |
0.616 |
$6.16 |
|
7 |
resistors |
empty slot LED protection |
|
|
|
1 |
stripboard or veroboard |
mount LED resistors |
|
|
|
10 |
4 pin connectors |
one for each slot actuator unit |
|
|
|
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 |
|
$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.thecableconnection.com.au/ 50-metres-Professional-Home-Theatre-in-Wall-Speaker- Cable-4-Core-16-AWG-- --Bi-Wire-cable.html#producttabs |
|
$170.86 |
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 |
$17.20 |
|
cable ties |
|
|
|
|
|
cable loom/heatshrink tube/electrical tape |
|
|
|
|
|
terminal blocks |
|
|
|
|
2 |
galvanising paint |
recoating everything |
http://www.diytools.com.au/MOTOSPRAY-Silva-Gal--Pressure-Pack-400g.html |
$12 |
|
3 |
110V fan to replace refrigeration fans |
|
|
|
|
Total |
|
|
|
|
|
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)
Check price on http://www.blackwoods.com.au/PartDetail.aspx?part_no=04418902 in case it's cheaper
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)
