|
Size: 849
Comment:
|
Size: 6161
Comment:
|
| Deletions are marked like this. | Additions are marked like this. |
| Line 1: | Line 1: |
| Draft Bill of Materials | === 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) |
| Line 3: | Line 9: |
| ||Amount||Item||Use|| ||7||microswitches||front button switches|| ||20||microswitches||each slot has double microswitches, there are 10 slots|| ||7||5mm round white LED's||replace empty slot globes|| ||7||led mounts for empty slot display||may not be needed, depends on how we mount the LEDs|| ||7||resistors||empty slot LED protection|| ||1||stripboard or veroboard||mount LED resistors|| ||10||6 pin connectors||one for each slot actuator unit|| ||??||? pin connectors||assorted connections between cables|| ||1||manual drop button|||| ||1||FMD88-10 PLC||brain|| ||1||EXP4040 expansion card||additional IO|| ||50m?||20 different coloured wires||general rewiring|| || ||cable ties|| || || ||cable loom/heatshrink tube/electrical tape|| || || ||terminal blocks|| || ||1||can rust proofing spraypaint|| || |
=== Draft Bill of Materials === ---- /!\ '''Edit conflict - other version:''' ---- ||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|| || ||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 || || ||7||5mm round white LED's||replace empty slot globes|| || || || ||7||led mounts for empty slot display||may not be needed, depends on how we mount the LEDs|| || || || ||7||resistors||empty slot LED protection|| || || || ||1||stripboard or veroboard||mount LED resistors|| || || || ||10||6 pin connectors||one for each slot actuator unit|| || || || ||??||? pin connectors||assorted connections between cables|| || || || ||1||manual drop button|| || || || || ||1||PLC||brain||FMD88-10|| || $360 || ||1||PLC expansion card||additional IO||EXP1616R|| || || ||42m||5 core wire, 1mm minimum diameter (to carry 2A) || actuator and empty switch wiring|| http://www.ebay.com.au/itm/5-Core-Cable-Wiring-Wire-Trailer-Parts-Lights-per-Meter-/110609219198 || $1.55/m|| || ||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|| || || ||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 || || || || || || ---- /!\ '''Edit conflict - your version:''' ---- ||Amount||Item||Use||Model||Unit Cost|| ||7||microswitches||front button switches||http://au.element14.com/honeywell-s-c/v7-1v19e9/micro-switch-pin-plunger-spdt-21a/dp/1796579|| $2.16|| ||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 || ||7||5mm round white LED's||replace empty slot globes|| || || ||7||led mounts for empty slot display||may not be needed, depends on how we mount the LEDs|| || || ||7||resistors||empty slot LED protection|| || || ||1||stripboard or veroboard||mount LED resistors|| || || ||10||4 pin connectors||one for each slot actuator unit|| || || ||??||? pin connectors||assorted connections between cables|| || || ||1||manual drop button|| || || || ||1||PLC||brain||FMD88-10|| || ||1||PLC expansion card||additional IO||EXP1616R|| || ||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 || 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|| || ||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|| || || || ---- /!\ '''End of edit conflict''' ---- . 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) === 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 * 10x?110V? relay outputs (this assumes linear actuators return by themselves) * 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) |
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
![/!\](/wiki/ucc/img/alert.png "/!\"){kind=small}
Edit conflict - other version:
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 |
|
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 |
|
7 |
5mm round white LED's |
replace empty slot globes |
|
|
|
7 |
led mounts for empty slot display |
may not be needed, depends on how we mount the LEDs |
|
|
|
7 |
resistors |
empty slot LED protection |
|
|
|
1 |
stripboard or veroboard |
mount LED resistors |
|
|
|
10 |
6 pin connectors |
one for each slot actuator unit |
|
|
|
?? |
? pin connectors |
assorted connections between cables |
|
|
|
1 |
manual drop button |
|
|
|
|
1 |
PLC |
brain |
FMD88-10 |
|
$360 |
1 |
PLC expansion card |
additional IO |
EXP1616R |
|
|
42m |
5 core wire, 1mm minimum diameter (to carry 2A) |
actuator and empty switch wiring |
http://www.ebay.com.au/itm/5-Core-Cable-Wiring-Wire-Trailer-Parts-Lights-per-Meter-/110609219198 |
$1.55/m |
|
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 |
|
|
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 |
|
|
|
|
|
Edit conflict - your version:
Amount |
Item |
Use |
Model |
Unit Cost |
7 |
microswitches |
front button switches |
http://au.element14.com/honeywell-s-c/v7-1v19e9/micro-switch-pin-plunger-spdt-21a/dp/1796579 |
$2.16 |
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 |
7 |
5mm round white LED's |
replace empty slot globes |
|
|
7 |
led mounts for empty slot display |
may not be needed, depends on how we mount the LEDs |
|
|
7 |
resistors |
empty slot LED protection |
|
|
1 |
stripboard or veroboard |
mount LED resistors |
|
|
10 |
4 pin connectors |
one for each slot actuator unit |
|
|
?? |
? pin connectors |
assorted connections between cables |
|
|
1 |
manual drop button |
|
|
|
1 |
PLC |
brain |
FMD88-10 |
|
1 |
PLC expansion card |
additional IO |
EXP1616R |
|
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 |
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 |
|
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 |
|
|
|
End of edit conflict
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)
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
- 10x?110V? relay outputs (this assumes linear actuators return by themselves)
- 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)
