Latest revision as of 22:33, 23 August 2010

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• LF: Lifefix_users; Ltf_science; lifefix_log ; Loadwasher ; Lifefix;

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)
• [PSER2h http://mediawiki.dideas.com/index.php?title=Pser2h] + USB cable
• [LDWASH2 http://mediawiki.dideas.com/index.php?title=Ldwash2]

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

• SWS600L-48 (48V 624W) - thin version untested - http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1791-ND
• SWS600L-24 (24V 648W 27A) - this version untested -http://search.digikey.com/scripts/DkSearch/dksus.dll?Detail&name=285-1742-ND
• SWS60048 - (48V 600W) (present think supply)

fans / circuit breakers / fuse / misc

• battery backup for copley?

• 24V 1amp backup power supply
• 24V 2.5amp separate 24V supply for the AEON

• 2 of 100V 40A protection diode

breakers

• DIN rail, 13"
• 10amp DIN breaker for copley primary power?
• 15amp DIN breaker for robot primary power?
• C25A3P 25amp - 3 pole DIN breakers for brushless motors?

• 15 amp breaker / switch for robot side primary power
• 1 amp breaker or 1 amp inline fuse for charge amp

blowers

• blower to keep robot motor cool
• 24V 5" blower
• 24V 4-11/16" blower

powerwerx

• 2 power meters : http://www.powerwerx.com/tools-meters/watts-up-meter-dc-inline.html
• splitters - http://www.powerwerx.com/powerpole-power-splitters/
• 6 way splitter - http://www.powerwerx.com/powerpole-power-splitters/ps-6aa-inline-6-way.html
• possibly this is better?  : http://www.powerwerx.com/powerpole-power-splitters/rigrunner-4005.html

inductors

• 0.11mH, 70mohm air core inductor

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

• [12 awg, 110uH, 70mohm air core]
• [12 awg, 80uH, 50mohm air core]
• [500 KHZ, 85uH, Isat=17A, PN: 323-18 (WCM323 series)]
• [PDF (Switcher as application) 100uH, Isat=13.0A]
• [Digikey 1KHZ : 100uH, 14A, 18mohm]
• [Digikey 1KHZ : 100uH, 14.4A, 25mohm]

Power Supplies

• [54V-80V, 500W DIN rail]

• [Open frame unregulated linear $204]

• [28.8-40V 8.7A 313W $125 ]
• [40-57V 6.7A 321W $125]

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