Difference between revisions of "Lifefix"

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{{pf_top_nav}}
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{{T_Lifefix}}
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=assembly=
 +
*isolate (vibration and electrical) Aeon PC from LF chassis
 +
**use vibration damping material and some sort of nylon screw - or rubber screw (a nylon screw seems as though it will allow for 1 side vibration still)
 +
**the Aeon PC connects the electrical negative to the chassis - possibly we don't want to connect the EARTH ground to the PC chassis??
 +
 +
fixture misc
 +
*attach 5" blower to fixture - blowing onto internal EC30 and to 24V supply between the circuit breaker and power meter
 +
*install limit switches - wire to Copley amplifier
 +
 +
 +
==24 V supply==
 +
Use SWS600L-24 (24V 648W 27A), adjust to 24.0 +- 0.2V
 +
* requires 3 outputs:
 +
**direct (fused 2 amps?) connection to the PC
 +
**direct 1 amp fused connection (use 2 wire red/black power inline fuse) to the charge amp  (would be nice if this was also switched - possibly a PB?)
 +
**high power connection to robot (USE 14 AWG wire):
 +
*** connect 100V high power diode  to power supply (please build a powerpole cable with both red and black wires, diode on red, and with orientation label)
 +
*** followed by at least 0.1F 25V capacitor (w/1000 ohm 10watt bleeder resistor)
 +
*** followed by 15amp circuit breaker / switch
 +
*** split the connection here and attached to blower motor(s)
 +
*** followed by watts up power meter (with load and source orientated correctly)
 +
*** followed by 5000uF, 50V cap
 +
*** followed by the FET board
 +
 +
 +
==48V Copley supply==
 +
Use SWS600L-48 (48V 624W), adjust to 47.0 +- 0.4V
 +
* connect 100V high power diode  to power supply(please build a powerpole cable with both red and black wires, diode on red, and with orientation label)
 +
* connect a 0.1F 50V capacitor (w 4000 ohm, 10 watt bleeder resistor)
 +
* connect a 10amp circuit breaker
 +
* connect a watts up power meter with correct load orientation
 +
* connect to Copley primary power input
 +
 +
==24V Copley backup supply==
 +
*attach 24V, 1amp supply to the AUX power inputs on the Copley amp.  Will need to share a ground with the primary power input
 +
 +
 +
==Copley Motor connections==
 +
*Attach a 3 pole DIN circuit breaker (15amp) to the 3 phase copley output
 +
*then each of the 3 phase Copley outputs needs to pass though a >90uH air-core, low resistance inductor.  We have sleected a 110uH, 70mohm device from partsexpress.
 +
*then onto the backdrive EC30 motor
 +
 +
==Robot motor connections==
 +
*Attach a 3 pole DIN circuit breaker (15amp) to the 3 phase copley output
 +
*Then onto the internal robot motor
 +
 +
=components=
 +
==communications==
 +
*isolated USB serial to charge amp : http://www.usbgear.com/USBG-SSRS1.html  (we have 2 of these)
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*[PSER2h http://mediawiki.dideas.com/index.php?title=Pser2h] + USB cable
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*[LDWASH2 http://mediawiki.dideas.com/index.php?title=Ldwash2]
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 +
==caps==
 +
*[http://search.digikey.com/scripts/DkSearch/dksus.dll?vendor=0&keywords=p10011-nd 10011-ND]  (digikey) 0.1F 25V solder terminal  $12.07 (WE HAVE 10 OF THESE ALREADY) 
 +
*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=565-3310-ND 565-3310-ND] 0.068F 25V SCREW terminal $10.24
 +
*[http://search.digikey.com/scripts/DkSearch/dksus.dll?vendor=0&keywords=565-3323-ND 565-3323-ND] (digikey) 0.1F 50V screwterminal $20.71 (WE HAVE 3 of THESE)
 +
==power suppy==
 +
*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1791-ND SWS600L-48] (48V 624W) - thin version untested - http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1791-ND
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1742-ND SWS600L-24] (24V 648W 27A) - this version untested -http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1742-ND
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1633-ND SWS60048] - (48V 600W) (present think supply)
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 +
==fans / circuit breakers / fuse / misc ==
 +
 +
*battery backup for copley?
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 +
*[http://search.digikey.com/scripts/DkSearch/dksus.dll?lang=en&site=US&WT.z_homepage_link=hp_go_button&KeyWords=T957-P5P-ND&x=0&y=0 24V 1amp] backup power supply
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=T966-P5P-ND 24V 2.5amp] separate 24V supply for the AEON
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 +
 +
 +
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*2 of [http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=1N1184A-ND 100V 40A protection diode]
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===breakers===
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=ADR3515-S1300-ND DIN rail, 13"]
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=288-1207-ND 10amp DIN breaker for copley primary power?]
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=288-1208-ND 15amp DIN breaker for robot primary power?]
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=288-1230-ND C25A3P 25amp -  3 pole DIN breakers for brushless motors?]
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<br>
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=PB428-ND 15 amp breaker / switch for robot side primary power]
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*[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=PB412-ND 1 amp breaker]  or 1 amp inline fuse for charge amp
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===blowers===
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*blower to keep robot motor cool
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*[http://www.mpja.com/prodinfo.asp?number=15718+FN  24V 5" blower]
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*[http://www.mpja.com/prodinfo.asp?number=18016+FN  24V 4-11/16" blower]
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 +
==powerwerx==
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*2 power meters : http://www.powerwerx.com/tools-meters/watts-up-meter-dc-inline.html
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*splitters - http://www.powerwerx.com/powerpole-power-splitters/
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*6 way splitter - http://www.powerwerx.com/powerpole-power-splitters/ps-6aa-inline-6-way.html
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*possibly this is better?  : http://www.powerwerx.com/powerpole-power-splitters/rigrunner-4005.html
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 +
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==inductors==
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*[http://www.parts-express.com/pe/pshowdetl.cfm?PartNumber=255-704&DID=7      0.11mH, 70mohm air core inductor]
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<br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br><br>
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=OLD=
 +
 +
=Power / Grounding =
 +
*~48V to power copley and backdrive
 +
*~24V to power the PC
 +
*~24V to power the robot
 +
 +
* loadwasher case appears to be isolated from charge amp case and ground.  (The load washer case does have electrical contact with the COAX outside.)
 +
 
=Copley supply voltage =
 
=Copley supply voltage =
  
Line 23: Line 135:
 
*max PWM = 96% (estimate) -> 86 volts needed on copley
 
*max PWM = 96% (estimate) -> 86 volts needed on copley
  
−
=What if only 4.2 amps at peak speed=
+
==What if only 4.2 amps at peak speed==
 
*LdI/dt = 4.4V
 
*LdI/dt = 4.4V
 
*IR = 1.7V
 
*IR = 1.7V
Line 29: Line 141:
 
*total supply = 76.5/.96 = 79.7V
 
*total supply = 76.5/.96 = 79.7V
  
−
=What if 4.2 amps at 23000 rpm=
+
==What if 4.2 amps at 23000 rpm==
 
*LdI/dt = 4.05V
 
*LdI/dt = 4.05V
 
*IR = 1.7V
 
*IR = 1.7V
 
*back EMF = 64.8V  
 
*back EMF = 64.8V  
 
*total supply = 70.55/0.96 = 73.5V
 
*total supply = 70.55/0.96 = 73.5V
 +
 +
=Inductors=
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*[[http://www.parts-express.com/pe/pshowdetl.cfm?PartNumber=255-704&DID=7  12 awg, 110uH, 70mohm air core]]
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*[[http://www.parts-express.com/pe/pshowdetl.cfm?PartNumber=255-702&DID=7  12 awg, 80uH, 50mohm air core]]
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*[[http://www.wcmagnetics.com/catalog/highcurrent_inductor.php  500 KHZ, 85uH, Isat=17A, PN: 323-18 (WCM323 series)]]
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*[[http://www.cooperbussmann.com/pdf/4935b080-1881-43db-b73d-e2176f2c5e73.pdf PDF (Switcher as application) 100uH, Isat=13.0A]]
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*[[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=M8377-ND  Digikey 1KHZ : 100uH, 14A, 18mohm]]
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*[[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=1539M26-ND Digikey 1KHZ : 100uH, 14.4A, 25mohm]]
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 +
=Power Supplies=
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*[[http://www.thomasglobal.com/news/article/15970-500_watts_of_compact_power_at_72V_SPH500_7207_from_MGV/ 54V-80V, 500W DIN rail]]
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*[[http://www.mpja.com/prodinfo.asp?number=6644+PS Open frame unregulated linear $204]]
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*[[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1620-ND  28.8-40V 8.7A 313W $125  ]]
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*[[http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1621-ND  40-57V 6.7A 321W $125]]
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<nowiki>Insert non-formatted text here</nowiki>

Latest revision as of 22:33, 23 August 2010

PF Users Navigation:

Edit

assembly

  • isolate (vibration and electrical) Aeon PC from LF chassis
    • use vibration damping material and some sort of nylon screw - or rubber screw (a nylon screw seems as though it will allow for 1 side vibration still)
    • the Aeon PC connects the electrical negative to the chassis - possibly we don't want to connect the EARTH ground to the PC chassis??

fixture misc

  • attach 5" blower to fixture - blowing onto internal EC30 and to 24V supply between the circuit breaker and power meter
  • install limit switches - wire to Copley amplifier


24 V supply

Use SWS600L-24 (24V 648W 27A), adjust to 24.0 +- 0.2V

  • requires 3 outputs:
    • direct (fused 2 amps?) connection to the PC
    • direct 1 amp fused connection (use 2 wire red/black power inline fuse) to the charge amp (would be nice if this was also switched - possibly a PB?)
    • high power connection to robot (USE 14 AWG wire):
      • connect 100V high power diode to power supply (please build a powerpole cable with both red and black wires, diode on red, and with orientation label)
      • followed by at least 0.1F 25V capacitor (w/1000 ohm 10watt bleeder resistor)
      • followed by 15amp circuit breaker / switch
      • split the connection here and attached to blower motor(s)
      • followed by watts up power meter (with load and source orientated correctly)
      • followed by 5000uF, 50V cap
      • followed by the FET board


48V Copley supply

Use SWS600L-48 (48V 624W), adjust to 47.0 +- 0.4V

  • connect 100V high power diode to power supply(please build a powerpole cable with both red and black wires, diode on red, and with orientation label)
  • connect a 0.1F 50V capacitor (w 4000 ohm, 10 watt bleeder resistor)
  • connect a 10amp circuit breaker
  • connect a watts up power meter with correct load orientation
  • connect to Copley primary power input

24V Copley backup supply

  • attach 24V, 1amp supply to the AUX power inputs on the Copley amp. Will need to share a ground with the primary power input


Copley Motor connections

  • Attach a 3 pole DIN circuit breaker (15amp) to the 3 phase copley output
  • then each of the 3 phase Copley outputs needs to pass though a >90uH air-core, low resistance inductor. We have sleected a 110uH, 70mohm device from partsexpress.
  • then onto the backdrive EC30 motor

Robot motor connections

  • Attach a 3 pole DIN circuit breaker (15amp) to the 3 phase copley output
  • Then onto the internal robot motor

components

communications

caps

  • 10011-ND (digikey) 0.1F 25V solder terminal $12.07 (WE HAVE 10 OF THESE ALREADY)
  • 565-3310-ND 0.068F 25V SCREW terminal $10.24
  • 565-3323-ND (digikey) 0.1F 50V screwterminal $20.71 (WE HAVE 3 of THESE)

power suppy

fans / circuit breakers / fuse / misc

  • battery backup for copley?



breakers


blowers

powerwerx


inductors





















OLD

Power / Grounding

  • ~48V to power copley and backdrive
  • ~24V to power the PC
  • ~24V to power the robot
  • loadwasher case appears to be isolated from charge amp case and ground. (The load washer case does have electrical contact with the COAX outside.)

Copley supply voltage

  • Peak motor input power : 25.2V * 30 amps = 756 watts
  • torque advantage : 25k/7k = 3.57
  • Maximum motor current = 30amps / 3.57 = 8.4amps

ir drop

  • R = (450mohm + 160 mohm) * 3/4 (R of motor and inductors)
  • IR = 3.4V

V=Ldi/dt

  • L = (102uH + 160uH) * 3/4 = 200uH
  • I=Io * sin(ft)
  • f = 25krpm/60 * 2 elec cycles * 2pi = 5236 rads
  • dI/dt=f * Io * cos(t) = f * Io (peak) = 5236 * 8.4 = 44e3 Amps/sec
  • V = 200uH * 44e3 = 8.8V

back EMF

  • EC30 speed const = 355 rpm/volt : 25000 = 70.4V

total supply

  • total voltage = 70.4 + 3.4 + 8.8 = 82.6V
  • max PWM = 96% (estimate) -> 86 volts needed on copley

What if only 4.2 amps at peak speed

  • LdI/dt = 4.4V
  • IR = 1.7V
  • back EMF = 70.4VV
  • total supply = 76.5/.96 = 79.7V

What if 4.2 amps at 23000 rpm

  • LdI/dt = 4.05V
  • IR = 1.7V
  • back EMF = 64.8V
  • total supply = 70.55/0.96 = 73.5V

Inductors

Power Supplies

Insert non-formatted text here

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