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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 ===

||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 (./) ||5V PSU|| led power and future expansion power || [[http://www.inasolutions.com.au/Shop/ALLOY-DR4505-DIN-Rail-5V5Amp-power-supply-for-Converters-Serial-devices-P1839.aspx|INA Solutions]] ||62.83|| 62.83 ||
||42m (./) ||4 core wire, 1mm minimum diameter (to carry 2A), 18AWG || 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||
||5m (./) ||2 core wire || refrigeration fan power|| http://www.altronics.com.au/index.asp?area=item&id=W2139 || 80c/m|| $4.00||
|| ||cable ties|| || || Donation? || ||
|| 10m (./) ||cable loom || cable loom for fans and actuators|| http://www.altronics.com.au/index.asp?area=item&id=H3814|| $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 || 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 ||
||1 (./) || pack 10 male quick connectors 4.8mm || fridge fans || http://www.altronics.com.au/index.asp?area=item&id=H1851 || $2.90 || $2.90 ||
||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|| || || ||
||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
  * Something like http://jnf.indiansecurityproducts.info/downloads/Oct06_Vending%20mc.pdf

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

au.element14.com

$2.16

$15.12

20 (./)

microswitches

each slot has double microswitches, there are 10 slots, 0.15N

au.element14.com

$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

automationmart.com

kit

1 (./)

5V PSU

led power and future expansion power

INA Solutions

62.83

62.83

42m (./)

4 core wire, 1mm minimum diameter (to carry 2A), 18AWG

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

5m (./)

2 core wire

refrigeration fan power

http://www.altronics.com.au/index.asp?area=item&id=W2139

80c/m

$4.00

cable ties

Donation?

10m (./)

cable loom

cable loom for fans and actuators

http://www.altronics.com.au/index.asp?area=item&id=H3814

$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

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

1 (./)

pack 10 male quick connectors 4.8mm

fridge fans

http://www.altronics.com.au/index.asp?area=item&id=H1851

$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

uccwiki: CokeMachineRebuild (last edited 2013-09-13 15:21:23 by NickBannon)

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