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| Ideas, comments, stuff - goes here. | === 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 || [[http://au.element14.com/honeywell-s-c/v7-1v19e9/micro-switch-pin-plunger-spdt-21a/dp/1796579|au.element14.com]] || $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|au.element14.com]] || $3.60 || $72|| ||7 (./) ||5mm round white LED's||replace empty slot globes|| [[http://au.element14.com/vcc-visual-communications-company/vaol-5701wy4/led-5mm-white-1800mcd/dp/1712795|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 || || $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 || [[http://www.automationmart.com/product_info.php?cPath=51&products_id=174&osCsid=1ce326631e601b08c3d427e08036612b| automationmart.com]] || || kit || ||1||4V regulator|| LED PSU || || || || ||42m (./) ||4 core wire, 1mm minimum diameter (to carry 2A) || 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|| || ||cable ties|| || || Donation? || || || ||cable loom/heatshrink tube/electrical tape|| || || || || || ||terminal blocks|| || || || || ||3 (./) ||galvanising paint|| recoating everything|| Dy-Mark Zinc Gal from Bunnings || $13.95 || $13.95|| ||1 (./) || pack 100 female quick connectors || 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 || ||3 (./) ||Fans to replace refrigeration fans|| || 24V [[http://www.altronics.com.au/index.asp?area=item&id=F1160#|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|| || || || ||12 (./) ||2mm spacers (washers?)|| otherwise fans will jam on lip of cover|| || || || || 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 === 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 |
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 |
|
$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 |
4V regulator |
LED PSU |
|
|
|
42m |
4 core wire, 1mm minimum diameter (to carry 2A) |
actuator and empty switch wiring |
$1.22/m |
$51.63 |
|
11m |
9 core wire |
front buttons and lights wiring |
43c/m |
$4.72 |
|
|
cable ties |
|
|
Donation? |
|
|
cable loom/heatshrink tube/electrical tape |
|
|
|
|
|
terminal blocks |
|
|
|
|
3 |
galvanising paint |
recoating everything |
Dy-Mark Zinc Gal from Bunnings |
$13.95 |
$13.95 |
1 |
pack 100 female quick connectors |
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 |
|
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 |
|
|
|
12 |
2mm spacers (washers?) |
otherwise fans will jam on lip of cover |
|
|
|
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
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
