CEB Press/Manufacturing Instructions/Controller Box: Difference between revisions

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[[Image:ceb-controller.jpg|thumb]]
The CEB Press's controller box houses the switches and electronics that are used to operate the hudraulics of the CEB Press and to process data from sensors on the machine.


=Video=


= Tools Required =
<html>
<iframe src="https://player.vimeo.com/video/33885023?title=0&amp;byline=0&amp;portrait=0" width="400" height="225" frameborder="0" webkitAllowFullScreen allowFullScreen></iframe>
</html>
 
=Tools=


*Wire Cutters
*Straight Pattern Tin Snips
*Soldering Iron Kit
*PC
*Hand Drill
*Wire Crimper Cutter
=Materials Required =
[[Image:Cutlerhammerbox.jpg|thumb]]
[[Image:Breakoutparts.jpg|thumb|Breakout Shield & Arduino]]
[[Image:Correctedboard.jpg|thumb|PWM Driver]]


*Outdoor Main Lug Box - 125Amp, 2Spaces, 4Circuits, 1Phase, 3Wire, 120/240VAC
*Wire Strippers Compatible with 18 and 22 Gauge
*Extension Cord
*Alligator clips (2)
*Home wiring box [http://www.homedepot.com/webapp/wcs/stores/servlet/Navigation?storeId=10051&N=+90001+544955&langId=-1&catalogId=10053&cm_sp=d27-_-electrical-_-category_page-_-Electrical-_-electrical_essentials-_-plugs_outlets_cords-_-shop_now]
*Fuse holder - 30Amp Inline Mini Blade-Type [http://www.radioshack.com/product/index.jsp?productId=2102783 Buy]
*12v quick connect plugs (5 pairs)
*Stranded 5A wire ?
*Spade terminals (10)
*Underground phone cable
*Potting compound [http://cgi.ebay.com/EPOXY-RESIN-CIRCUIT-BOARD-POTTING-COMPOUND-CASTING-48OZ-/310186942108?pt=LH_DefaultDomain_0&hash=item4838951e9c Buy]
*PVC pipe
*PVC pipe cap
*Stranded Cat 5 cable
*Supermagnets (6) - N42 [http://www.gaussboys.com/ndfeb-magnets/D1203E-N42.html Buy]
*Arduino (Duemilanove) [http://www.amazon.com/Arduino-Duemilanove/dp/B001VK18HC Buy]
*MOSFET replacements (5) - Single 35A 70V 0.028Ω TO-220-3 [http://www.futureelectronics.com/en/technologies/semiconductors/analog/drivers/mosfet-igbt-drivers/Pages/3890498-VNP35N07-E.aspx Buy]  [http://octopart.com/partsearch/#search/requestData&q=VNP14NV04-E Buy]
*Hall Effect sensors (2) - US1881 TO-92 [http://www.sparkfun.com/commerce/product_info.php?products_id=9312 Buy]
*3/8" V-groove bearings (4) [http://www.vxb.com/page/bearings/PROD/V-Groove-Bearings/Kit8405 Buy]
*Molex connector [http://www.newegg.com/Product/Product.aspx?Item=N82E16812198025&cm_re=molex-_-12-198-025-_-Product Buy] [http://www.monoprice.com/products/product.asp?c_id=102&cp_id=10245&cs_id=1024501&p_id=1313&seq=1&format=1#largeimage Buy] [http://www.monoprice.com/products/product.asp?c_id=102&cp_id=10245&cs_id=1024501&p_id=1316&seq=1&format=2 Buy]


*Crimpers


*2.3mm Flathead Screwdriver


'''Sub-project Materials'''
*Screwdriver with Number 2 Philips Bit


*Arduino breakout shield [http://store.makerbot.com/arduino-breakout-shield-v1-4-kit.html Buy Parts] [http://www.reprap.org/wiki/Arduino_Breakout_1_4 Assembly instructions]
*Needlenose Pliers


*PWM Solenoid drivers (2) [http://store.makerbot.com/pwm-driver-v1-1-kit.html Buy Parts] [http://www.reprap.org/wiki/PWM_Driver_1_1 Assembly instructions]
*Measuring Tape


= Diagrams =
=Materials=
[[Image:controllerbox.jpg|400px]]


*need a diagram of the wires
*Case
*[https://docs.google.com/drawings/edit?id=1Gyv9hAaBZEX9v2RqlvqABIL2TwA2QJOKixl63OoM93o&hl=en google doc drawing of wire diagram (working on it)]


<html>
[http://opensourceecology.org/wiki/CEB_Press/Manufacturing_Instructions/Case Assembly Instructions]
<img src="https://docs.google.com/drawings/pub?id=1Gyv9hAaBZEX9v2RqlvqABIL2TwA2QJOKixl63OoM93o&amp;w=480&amp;h=360">
</html>


<html><embed src="http://blip.tv/play/AYHmjUcA" type="application/x-shockwave-flash" width="400" height="400" allowscriptaccess="always" allowfullscreen="true"></embed></html>
*[2] Sensor Units


= Fabrication Steps =
[http://opensourceecology.org/wiki/CEB_Press/Manufacturing_Instructions/Sensor_Unit Assembly Instructions]


*Assemble entire Control Box
*Solenoid Driver v2
**Blue spacer box - Arduino attached on top with 2 small screws. Slightly slanted attachment to make screw holes fit on blue spacer box
**Terminal in electrical outlet box cut in half on metal cutoff saw to create + and - terminals
**Plastic mount on bottom of electrical box was shaved to allow 2 solenoid drivers to fit


[http://opensourceecology.org/wiki/CEB_Press/Manufacturing_Instructions/Detroit_Fab_Lab_Solenoid_Driver_v2 Assembly Instructions]


= Test from Zero=
*18 Gauge Red Wire


*Arduino Testing - Preparation
*18 Gauge Black Wire
*Note: For this testing procedure, you will need a computer with Arduino software, Python and pyserial loaded.
# Solder 100 Ohm resistors to the negative (short) ends of three LEDs.
# Connect the Positive ends of the LEDs to Ports 11, 12 and 13 of the Breakout Shield
# Connect the resistor ends to GND port of the Breakout Shield
# Double-check the connections!
# Connect the Arduino to the Computer using a USB Cable
# Download [[Arduino Environment]]
# Open the Arduino Environment
##Double click on executable text file in Ubuntu
##Select the board that you are using (Duemilanove 328) under Tools / Board.
# Select the Appropriate Serial Connection under Tools / Serial Ports.
##Troubleshooting - if Tools / Serial Ports is blanked out, connect Arduino board
##Generally, the appropriate serial connection will be the number of the lowest unused USB port starting at 0.
# Download the <html><a href = "http://openpario.mime.oregonstate.edu/documents/1250">CEB_Testing_Program.pde</a></html>
# Open the CEB Testing program in last step in the Arduino program by going to File / Open...
##Note: if the above file is not in its own folder, Arduino Environment will create a folder in Ubuntu
# Load the CEB Testing Program into the Arduino using the Upload Button in File / Upload to I/O Board
# Download the Python-based <html><a href = "https://docs.google.com/viewer?a=v&pid=explorer&chrome=true&srcid=0B2ZOu2AF-TF5MTgzMjM1MjgtYzQwMS00ODQ5LTlkMTgtYjg3YmI1NzRkNmY0&hl=en_US">Arduino Testing Program</a></html>
# Open the Python-based <html><a href = "https://docs.google.com/viewer?a=v&pid=explorer&chrome=true&srcid=0B2ZOu2AF-TF5MTgzMjM1MjgtYzQwMS00ODQ5LTlkMTgtYjg3YmI1NzRkNmY0&hl=en_US">Arduino Testing Program</a></html>
##Run python code in Terminal - python CEB_Testing.py
##I had to install python_tk package in Ubuntu to make it work
# Connect to the Arduino using the GUI button


* Arduino - Testing
*Ring Insulated Connector with Small Hole for 10-12 Gauge


# Click the Blink Test Button to Check if the Arduino is working.  LED 13 should blink on and off.
*[14] Ring Insulated Connectors for 10-12 Gauge
# Click the Sensor Test Button.  The Arduino’s sensors should cause LEDs 11, 12 and 13 to blink on and off in the presence of the magnets.
# Click the MOSFET Testing Buttons.  The green LEDs on the MOSFET should blink on and off accordingly.


* Solenoid Connections
*[6] Ring Insulated Connectors for 14-16 Gauge


# Cut five 2’ pieces of 16-gauge black wire and five 2’ pieces of 16-gauge red wire.
=Steps=
# Strip ¼” off each of the five black and five red wires.
# Tin the ends of each of the wires.
# Attach black wires to each of the negative terminals of the MOSFET connectors on the Detroit Fab-Lab board.
# Attach red wires to each of the positive terminals of the MOSFET connectors on the Detroit Fab-Lab Board.
# Run the black and red wires through an available hole in the Electronics Box.(Should we use the left-side hole for this???)
# When all wires have been checked, tighten each of the cable clamps.


* Solenoid Testing
*Mount the solenoid driver on top of the Arduino microcontroller.


# Remove the bridge connector between the Common Ports of each solenoid unit.
*Using the tin snips, cut 6 pieces of 20cm black wire, 2 pieces of 20cm red wire, 5 pieces of 1.5m black wire, and 1 piece of 1.5m red wire.
# Connect each of the five red-black solenoid wire pairs to terminals in the solenoids. Black wires should attach to the Common ports and Red Wires to the Solenoid a and Solenoid b Ports
# Double-check the connections!
# Test the Solenoids with the Python-based CEB Press Testing program.


==Notes==
*Using the wire strippers at 22 gauge, strip half a centimetre at one end of the 6 pieces of 20cm black wire and 1 piece of 20cm red wire.


Here are errors upon running the Python script and upon trying to upload the CEB Testing Program to the arduino:
*Using the wire strippers at 18 gauge, strip a centimetre at the other ends of the 6 pieces of 20cm black wire and the 1 piece of 20cm red wire, as well as both ends of the other 1 piece of 20cm red wire, the 5 pieces of 1.5m black wire, and the 1 piece of 1.5m red wire.


[[Image:conttesterrors.jpg|500px]]
*Using the crimper, crimp the 10 to 12 gauge ring insulated connector at one of the 1 centimetre stripped ends of the 6 pieces of 20cm black wire, the 2 pieces of 20cm red wire, the 5 pieces of 1.5m black wire, and the 1 piece of 1.5m red wire.
Also crimp the 10 to 12 gauge small hole ring insulated connector at the remaining 1cm end of the 20cm red wire and crimp the 14 to 16 gauge ring connector to the remaining 1cm ends of the 5 pieces of 1.5m black wire and 1 piece of 1.5m red wire.


=<html><H2>Previous Testing Procedure</H2></html>=
*Using the screwdriver with the number 2 philips bit, connect the small ring end of the 20cm red wire to the remaining power switch terminal.


*Test Arduino on laptop - for example by [http://www.arduino.cc/en/Tutorial/Blink blinking Channel 13 output on Duemilanove].
*Insert the large ring end of the 6 1.5m wires through the bottom-middle hole of the lug box.


*Test sensors by passing magnets over them. See this sample code.
*Using the screwdriver with the number 2 philips bit, connect the large ring end of the 1.5m red wire, the remaining ring end of the switch-connected 20cm red wire, and the ring end of the other 20cm red wire to the bottom-left screw of the terminal platform.
**[http://www.sparkfun.com/datasheets/Components/General/Hall-US1881EUA.pdf Data Sheet]
**Supply voltage is 5V from the Arduino breakout shield
**The pins are +,-, OUT reading from top (printed / smaller face)
**The output is "Open Drain" - this means you need a "pull up" resistor on the output (10K connected to +)
**This model is "latching" which means it turns on from one pole, and off by the other, remembering its state in the meantime.


Controller checklist (ie, So you don't burn your components, check these):
*Connect the large ring end of the 5 1.5m black wires and the ring end of 5 20cm black wires to the top 5 screws of the terminal platform. Then connect the ring end of the remaining 20cm black wire to the bottom-right screw of the terminal platform.


#Arduino powers on with USB cord? Check.
*Using the flathead screwdriver, connect the half centimetre ends of the 6 pieces of 20cm black wire to the lower terminal of the 5 mosfet terminal blocks, and the left terminal of the power terminal block. Note that the mosfet connections from left to right on the terminal platform should go from bottom to top on the solenoid driver. Also connect the half centimetre end of the 1 piece of 20cm red wire to the right terminal of the power terminal block.
#Arduino works - ex. blink Channel 13 with an LED? Check. Atmega 328 Duemilanove - on Ubuntu 10.04.
#Controller main power switch light red when battery is connected and switch is turned on? Check.
#With Molex connectors disconnected, 12V appears at pins 1 and 2?
#With Molex connectors plugged into solenoid driver boards, main power switch turns the drivers on?
#Arduino powers on with battery supply after flipping main switch on?
#Solenoid drivers are turned on with main switch?
#Solenoids turn all of their MOSFETS as seen via indicator lights?
#Solenoids can cycle the solenoid valves?
C


*Insert the 2 sensor units by their wire end into the right-bottom hole of the lug box.


*Using the flathead screwdriver, connect the bluewhite wires, orange wires, and blue wires into the top, middle, and bottom terminal blocks, respectively, on the right side of the solenoid driver.


*Test solenoid valves by attaching power to battery and running this sample code for 2 solenoid channels.
*Using the screwdriver with the number 2 philips bit, screw-tighten the wire clamp at the right-bottom hole of the lug box.
**Note we can reduce 3 solenoid channels to 2 by running both the shaker motor and the drawer cylinder from the same channel - the shaker is activated at every stroke of the drawer, as there is ample hydraulic fluid flow available in that part of the overall CEB operation cycle.


----
==Previous Versions==


other pages with info that should end up on this page
*[[CEB Press/Manufacturing Instructions/Controller Box/Automation Prototype II|CEB Press Automation Prototype II]]
*[[CEB Press/Manufacturing Instructions/Controller Box/Arduino Control of CEB Prototype 2|Arduino Control of CEB Prototype 2]]
*[[CEB Press/Manufacturing Instructions/Controller Box/FeF Liberator Controller|FeF Liberator Controller]]


{{mergefrom|CEB_Automation_Prototype_II}}
==Future Versions==
{{mergefrom|Arduino_Control_of_CEB_Prototype_2}}
*[[CEB Controller Box]]
{{mergefrom|FeF_Liberator_Fabrication}}


[[Category: CEB Press]]
[[Category: CEB Press]]
[[Category:CEB Press Fabrication]]
[[Category:CEB Press Fabrication]]
==See Also==
*[[Terminal Block]] - replacing screw platform in these instructions
*[[CEB_Press/Pictures_of_Newest_Controller|Pictures of Newest Controller]] - these pictures are of a controller box that is newer than the one described here

Latest revision as of 02:20, 17 February 2017

The CEB Press's controller box houses the switches and electronics that are used to operate the hudraulics of the CEB Press and to process data from sensors on the machine.

Video

Tools

  • Straight Pattern Tin Snips
  • Wire Strippers Compatible with 18 and 22 Gauge
  • Crimpers
  • 2.3mm Flathead Screwdriver
  • Screwdriver with Number 2 Philips Bit
  • Needlenose Pliers
  • Measuring Tape

Materials

  • Case

Assembly Instructions

  • [2] Sensor Units

Assembly Instructions

  • Solenoid Driver v2

Assembly Instructions

  • 18 Gauge Red Wire
  • 18 Gauge Black Wire
  • Ring Insulated Connector with Small Hole for 10-12 Gauge
  • [14] Ring Insulated Connectors for 10-12 Gauge
  • [6] Ring Insulated Connectors for 14-16 Gauge

Steps

  • Mount the solenoid driver on top of the Arduino microcontroller.
  • Using the tin snips, cut 6 pieces of 20cm black wire, 2 pieces of 20cm red wire, 5 pieces of 1.5m black wire, and 1 piece of 1.5m red wire.
  • Using the wire strippers at 22 gauge, strip half a centimetre at one end of the 6 pieces of 20cm black wire and 1 piece of 20cm red wire.
  • Using the wire strippers at 18 gauge, strip a centimetre at the other ends of the 6 pieces of 20cm black wire and the 1 piece of 20cm red wire, as well as both ends of the other 1 piece of 20cm red wire, the 5 pieces of 1.5m black wire, and the 1 piece of 1.5m red wire.
  • Using the crimper, crimp the 10 to 12 gauge ring insulated connector at one of the 1 centimetre stripped ends of the 6 pieces of 20cm black wire, the 2 pieces of 20cm red wire, the 5 pieces of 1.5m black wire, and the 1 piece of 1.5m red wire.

Also crimp the 10 to 12 gauge small hole ring insulated connector at the remaining 1cm end of the 20cm red wire and crimp the 14 to 16 gauge ring connector to the remaining 1cm ends of the 5 pieces of 1.5m black wire and 1 piece of 1.5m red wire.

  • Using the screwdriver with the number 2 philips bit, connect the small ring end of the 20cm red wire to the remaining power switch terminal.
  • Insert the large ring end of the 6 1.5m wires through the bottom-middle hole of the lug box.
  • Using the screwdriver with the number 2 philips bit, connect the large ring end of the 1.5m red wire, the remaining ring end of the switch-connected 20cm red wire, and the ring end of the other 20cm red wire to the bottom-left screw of the terminal platform.
  • Connect the large ring end of the 5 1.5m black wires and the ring end of 5 20cm black wires to the top 5 screws of the terminal platform. Then connect the ring end of the remaining 20cm black wire to the bottom-right screw of the terminal platform.
  • Using the flathead screwdriver, connect the half centimetre ends of the 6 pieces of 20cm black wire to the lower terminal of the 5 mosfet terminal blocks, and the left terminal of the power terminal block. Note that the mosfet connections from left to right on the terminal platform should go from bottom to top on the solenoid driver. Also connect the half centimetre end of the 1 piece of 20cm red wire to the right terminal of the power terminal block.
  • Insert the 2 sensor units by their wire end into the right-bottom hole of the lug box.
  • Using the flathead screwdriver, connect the bluewhite wires, orange wires, and blue wires into the top, middle, and bottom terminal blocks, respectively, on the right side of the solenoid driver.
  • Using the screwdriver with the number 2 philips bit, screw-tighten the wire clamp at the right-bottom hole of the lug box.

Previous Versions

Future Versions

See Also

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