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 |
reuse old button new button bought from altronics |
|
|
|
1 |
PLC |
brain |
FMD88-10 starter kit, i-STK88-10, http://www.tri-plc.com/ISTK-FMD88-10.htm (including http://www.triplc.com/fmd8810.htm , software, data cable) |
|
$475 kit |
1 |
PLC expansion card |
additional IO |
EXP1616R, http://www.triplc.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 |
|
|
reuseable cable ties |
|
|
Altronics |
|
10m |
cable loom |
cable loom for fans and actuators |
$12.90 |
$12.90 |
|
(./) |
terminal blocks |
|
Altronics (see below) |
|
|
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
- 7x24V DC input for front door buttons
- 1x24V DC input for manual dispense mode button
- 10x110V AC relay outputs
- 7x 5V 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
- Earth (green/yellow) doubles as end clamp
- End cap
- 3 red - 24V power distribution positive (bridged)
- 3 black - 24V power distribution ground (bridged)
- Partition
- 10 red - slot microswitches positive
- 10 black - slot microswitch ground (bridged)
- Partition
- 10 grey - solenoid active
- 10 blue - solenoid neutral (bridged)
- Partition
- 4 grey - 110V power distribution active (bridged)
- 4 blue - 100V power distribution neutral (bridged)
- 2 earth (green/yellow) doubles as end clamp
- Commoning bars/shorting links (come in strips of ten that you can cut to length)
- 8 (7 plus one spare)
- Din rail
- 2m
- Slotted duct 3 metres
Total Order:
- 13 red
- 13 black
- 14 grey
- 14 blue
- 3 green/yellow
- 2 end caps
- 2 end clamps
- 4 partitions
- 8 shorting links (2 of each colour)
- 2m din rail
- 1 Label set numbers 1 to 50
- 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
- Plug coming from the back of the distrubution box (red 9 way):
- Brown/White 110V
- Blue/White Neutral
- Red/White 100V
Extra Things To Consider
- Snubber circuit for solenoids
- RC snubber component/circuit with 0.1uF (approx 400V rating) and 150 Ohm resistance in parallel with the load should do
- Need to test this on a breadboard before looking for a permanent way of implementing it
Stuff to fix in future
- The 5x1mm washers acting as spacers for the bottom refigeration fans should be replaced with a 5mm spacer or piece of pipe instead - the washers will be impossible to put back on if the fans ever need to be removed
small can support Done! A small bracket has been made which can fit on any of the front slots. Ask BobAdamson how to use it.
- coin return magic
- coin counter
- more LEDs, not blue
- redo fan wiring (again)
- front perspex lights
- screens
- button screens
snack machine keypad, 3 key needs more debouncing Sortof done. BobAdamson pulled it apart and cleaned the contacts. It could probably do with some small capacitors across each button if it keeps happening.
- documentation and all code up-to-date in ~coke
