EE Detailed Design Review

Wire Movement Team: Spooling Motors Specification Process

Take-up Spool Motor Selection Process: Solid Take-up

Inertia: 0.4236 kg-m2

Full Mass: 102 kgSpeed: 2390 rpm

Take-up Spool Motor Selection Process: 3 Supply Spool Take-up

Inertia: 1.6088 kg-m2

Full Mass: 157 kgSpeed: 1432 rpm

Take-up Spool Motor Selection Process: 2 Supply Spool Take-up

Inertia: 1.1461 kg-m2

Full Mass: 110 kgSpeed: 1432 rpm

Supply Spool Motor Selection Process

Inertia: 0.1273 kg-m2

Full Mass: 26.5 kgSpeed: 2450 rpm

Guide Roller Team: Roller Motors Specification Process

Guide Roller Team: Roller Motors Specification Process

Inertia: 1.03 kg-m2 (0.9 kg-m2)

Friction: 30N-mFull Mass: 65 kg (55.9 kg)Max Speed: 900 rpmNominal Speed: 716 rpmMotor Price: $5280

Guide Roller Team: Roller Motors Specification Process With GearboxInertia: 1.03 kg-m2 (0.9 kg-m2)

Friction: 30N-mFull Mass: 65 kg (55.9 kg)Max Speed: 3040 rpm (900 rpm)Nominal Speed: 2149 rpm (716 rpm)Motor Price: ~$4800 + ~$1386 for gearboxBacklash: 14-20 arcminute (0.23-0.33 degrees)

Work Piece Movement Team: Linear Actuator Specification Process

Work Piece Movement Team: Specification Process

Mass: 317.5 kgForce: 3114.7 N Max Mass: 444.5 kg Max Force: 4356 NSpeed: 0.1 mm/min Max Speed: 2mm/minApplied Force (will vary): 200 N

Work Piece Movement Team: Specification Process

Options

Option 1 (120 V option)

Item Product Description Qty List Price Ext. Price

1 EL1405T Baldor EL1405T single phase 1 hp motor 1800 RPM 4 $557.00 $2228.00

2 PPA11-58B65-18EBXXX

Electrak PPA-AC Actuator Thomson 115 VAC @ 50/60Hz, 1ø Max Dynamic Load N (lbs): 6670 (1500) Max Static  Load N (lbs): 13350 (3000) No Load Speed mm/sec (in/sec): 4.3 (.17) Max Load Speed mm/sec (in/sec): 4.3 (.17) Std Stroke

Lengths mm (in): 460 (18) 1.5 A1 $1108.1

6$1108.1

6

        TOTAL: $3336.16

AC Motors Non-Inverter Inverter Ready Inverter Duty

VFD Compatible No Yes Yes

Cost Low (700-900$) Medium ($1000) High ($1700-3600)

Speed Type SIngle Speed Single Speed Variable Speed

Speed Variability none 20:1 max 1000:1

Feedback Device

None None EncoderOption

List Prices are compared at 1 hp, 230 VAC, 1200 RPM motor, 145 T Frame on Baldor website. Non-inverter AC motors can be found on ebay for very low prices.

Very good source on the topichttp://www.plantengineering.com/single-article/avoid-over-specifying-inverter-duty-motors/3b7ec86ea1d17050bff89dc353cde975.html

Note: 1-Phase Motors are not good choices for dynamic applications such as this. At best they are decent for variable speed applications but not precise position or following a profile.

3-Phase AC Motor Details

Options 2 (Microcontroller)Item Product Description Qty List Price Ext. Price

1 TMDSHVMTRPFCKIT High Voltage Motor Control and PFC Developer's Kit 5 $712.98 $3564.90

2 HVPMSMMTR High Voltage Synchronous PM Machine (Brushless DC Motor) 2 $299.00 $598.00

 3  DRV8312-69M-KIT Three Phase BLDC Motor Kit with DRV8312 and InstaSPIN-Enabled Piccolo TMS320F28069M MCU  2 $299.00 $598.00

4 AU-ZDH0100H Shaft Encoder (for pulleys in wire movement fixture) 2 ~≤ $379 ~≤ $758        TOTAL: $5518.90

Note: This does not include several sensors (i.e. thermocouples, over travel switches), linear actuators for workpiece movement, or various circuits that may be needed to condition the signals to be readable by a microcontroller.  As such, the price will be higher than shown above (*possibly* up to $10,000)

Option 3 (Controller Only)Item Product Description Qty List Price Ext. Price

1 1769-PB4 Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC 1 $495.00 $495.00

2 1769-L36ERM CompactLogix L3 controller, Dual Ethernet w/DLR capability, 3MB memory, 30 I/O Expansion, 48 Ethernet IP Nodes, 16 Axis CIP motion with Kinematics function. 1 $4,770.00 $4,770.00

        TOTAL: $5,265.00

Option 4 (120 V option realistic)

Item Product Description Qty List Price Ext. Price

1 25B-V6P0N104 PowerFlex 525 AC Drive, with Embedded EtherNet/IP and Safety, 120 VAC, 1 Phase, 1.5 HP, 1.1 kW Normal Duty; 1.5 HP, 1.1 kW Heavy Duty, Frame B, IP20 NEMA / Open Type, No Filter 4 $786.00 $3144.00

2 25-ENC-2 Incremental Encoder Interface for PowerFlex 527 4 $70.00 $280.00

3 1769-PB4 Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC 1 $495.00 $495.00

4 1769-L36ERM CompactLogix L3 controller, Dual Ethernet w/DLR capability, 3MB memory, 30 I/O Expansion, 48 Ethernet IP Nodes, 16 Axis CIP motion with Kinematics function. 1 $4,770.00 $4,770.00

5 IDM3667T 1.5HP, 1170 RPM, 3PH, 60HZ, 182TC, 0630M, TEBC 2 $2294.00 $4588.00

6 IDM3584T 1.5HP, 1760 RPM, 3PH, 60HZ, 145TC, 0530M, TEBC 2 $1837.00 $3674.00

7 ZUK2500H-ND Digikey Red Lion Encoder with 1.125 inch hollow diameter 2500 PPR 2 $472.31 $944.62

8 1427-0100-2048 Hohner Corporation Encoder 7/8 inch diameter hollow shaft 2048 PPR 2 $480.00 $960.00

        TOTAL: $18,855.62

Option 5 (Rockwell-Ebay Option) Item Product Description Qty List Price Ext. Price

1RDB-B21529-3B72AABulletin RDB - Bearingless Rotary Direct Drive Servo Motor, 400V Class, Frame Size 215mm BDC, 2 Magnet Stacks, 750 RPM, Single-turn High-Resolution Heidenhain, IP65 Housing / Blind Bore, Circular, Right Angle connector, 180° Rotatable, DIN, No Brake 2 $5,280.00 $10,560.00

22090-CPWM7DF-16AA15 Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, Standard (Non-Flex), 16AWG, 15M 2 $99.00 $198.00

32090-XXNFMF-S09 Cable,Feedback,DIN Type 4 Connector,Non-Flex,Flying Lead,9M 2 $179.00 $358.00

42094-BC02-M02-M Power Module, Integrated, 460V, 15kW Conv. 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module 1 $1,436.00 $1,436.00

4.12094-EN02D-M01-S0 EtherNet/IP Safe Torque-Off Control Module 1 $603.00 $603.00

4.22094-PRS8 Power Rail, Slim, 230V OR 460V, 8 Axis. 1 $290.00 $290.00

52094-BM02-M Power Module, Axis, 460V, 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module 3 $653.00 $1,959.00

5.12094-EN02D-M01-S0 EtherNet/IP Safe Torque-Off Control Module 3 $517.00 $1,551.00

61769-L36ERM CompactLogix L3 controller, Dual Ethernet w/DLR capability, 3MB memory, 30 I/O Expansion, 48 Ethernet IP Nodes, 16 Axis CIP motion with Kinematics function. 1 $2,895.00 $2,895.00

71769-PB4 Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC 1 $325.00 $325.00

8MPM-B2152F-SJ72AABulletin MPM - Medium-Inertia Servo Motors Product, 460 V, 3000 RPM, Single-turn High-resolution Encoder. Keyed Shaft Extension, SpeedTEC DIN Connector, Right Angle, 180° Rotatable (Quick Connect), No Brake, IEC Metric, Free Mounting Holes (Type FF) 1 $2,734.00 $2,734.00

8.12090-CPWM7DF-08AA12 SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters 1 $245.00 $245.00

8.22090-CFBM7DF-CEAA09 SpeedTEC Cable, Motor Feedback Only, SpeedTec DIN Connector, Drive-end, Flying-lead, SIN/COS High-Resolution/Resolver Encoder Type, Standard (Non-Flex), 9 Meters 1 $67.00 $67.00

9MPM-B2153F-SJ72AABulletin MPM - Medium-Inertia Servo Motors Product, 460 V, 3000 RPM, Single-turn High-resolution Encoder. Keyed Shaft Extension, SpeedTEC DIN Connector, Right Angle, 180° Rotatable (Quick Connect), No Brake, IEC Metric, Free Mounting Holes (Type FF) 1 $2,800.00 $2,800.00

9.12090-CPWM7DF-08AA16 SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 16 Meters 1 $245.00 $245.00

9.22090-CFBM7DF-CEAA09 SpeedTEC Cable, Motor Feedback Only, SpeedTec DIN Connector, Drive-end, Flying-lead, SIN/COS High-Resolution/Resolver Encoder Type, Standard (Non-Flex), 9 Meters 1 $67.00 $67.00

102090-K6CK-D15M Connector, Motor Feedback, D-Shell/Term Block, 15 Pin. 4 $39.00 $156.00

112090-K6CK-D44M Connector Kit, 44 pin, K6200/K6500 I/O, Auxiliary feedback, and safety 4 $168.00 $672.00

TOTAL: $27,161.00

Option 6 (Rockwell Solution) Item Product Description Qty List Price Ext. Price

1RDB-B21529-3B72AABulletin RDB - Bearingless Rotary Direct Drive Servo Motor, 400V Class, Frame Size 215mm BDC, 2 Magnet Stacks, 750 RPM, Single-turn High-Resolution Heidenhain, IP65 Housing / Blind Bore, Circular, Right Angle connector, 180° Rotatable, DIN, No Brake 2 $5,280.00 $10,560.00

22090-CPWM7DF-16AA09 Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, Standard (Non-Flex), 16AWG, 9M 2 $167.00 $334.00

32090-XXNFMF-S09 Cable,Feedback,DIN Type 4 Connector,Non-Flex,Flying Lead,9M 2 $323.00 $646.00

42094-BC02-M02-M Power Module, Integrated, 460V, 15kW Conv. 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module 1 $2,650.00 $2,650.00

4.12094-EN02D-M01-S0 EtherNet/IP Safe Torque-Off Control Module 1 $873.00 $873.00

4.22094-PRS8 Power Rail, Slim, 230V OR 460V, 8 Axis. 1 $624.00 $624.00

52094-BM02-M Power Module, Axis, 460V, 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module 3 $1,180.00 $3,540.00

5.12094-EN02D-M01-S0 EtherNet/IP Safe Torque-Off Control Module 3 $873.00 $2,619.00

61769-L36ERMCompactLogix L3 controller, Dual Ethernet w/DLR capability, 3MB memory, 30 I/O Expansion, 48 Ethernet IP Nodes, 16 Axis CIP motion with Kinematics function. 1 $4,770.00 $4,770.00

71769-PB4 Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC 1 $495.00 $495.00

8MPM-B2152F-SJ72AABulletin MPM - Medium-Inertia Servo Motors Product, 460 V, 3000 RPM, Single-turn High-resolution Encoder. Keyed Shaft Extension, SpeedTEC DIN Connector, Right Angle, 180° Rotatable (Quick Connect), No Brake, IEC Metric, Free Mounting Holes (Type FF) 1 $3,950.00 $3,950.00

8.12090-CPWM7DF-08AA09 SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters 1 $425.00 $425.00

8.22090-CFBM7DF-CEAA09SpeedTEC Cable, Motor Feedback Only, SpeedTec DIN Connector, Drive-end, Flying-lead, SIN/COS High-Resolution/Resolver Encoder Type, Standard (Non-Flex), 9 Meters 1 $170.00 $170.00

9MPM-B2153F-SJ72AABulletin MPM - Medium-Inertia Servo Motors Product, 460 V, 3000 RPM, Single-turn High-resolution Encoder. Keyed Shaft Extension, SpeedTEC DIN Connector, Right Angle, 180° Rotatable (Quick Connect), No Brake, IEC Metric, Free Mounting Holes (Type FF) 1 $5,040.00 $5,040.00

9.12090-CPWM7DF-08AA09 SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters 1 $425.00 $425.00

9.22090-CFBM7DF-CEAA09SpeedTEC Cable, Motor Feedback Only, SpeedTec DIN Connector, Drive-end, Flying-lead, SIN/COS High-Resolution/Resolver Encoder Type, Standard (Non-Flex), 9 Meters 1 $170.00 $170.00

102090-K6CK-D15M Connector, Motor Feedback, D-Shell/Term Block, 15 Pin. 4 $67.60 $270.40

112090-K6CK-D44M Connector Kit, 44 pin, K6200/K6500 I/O, Auxiliary feedback, and safety 4 $188.00 $752.00

TOTAL: $38,313.40

Deliverable Ideal Option Ebay Option Minimalist L36ERM OnlyCompromise

Option 𝜇Controller option

Acceleration of Wire

Speed of Wire

Torque Large Enough to cut glass

System Synchronized

Bidirectional

Machine Changes Movement Profile based off inputs

Option X (240 VAC Single-Phase)Item Product Description Qty List Price Ext. Price

1 25B-A011N104 PowerFlex 525 AC Drive, with Embedded EtherNet/IP and Safety, 240 VAC, 1 Phase, 3 HP, 2.2 kW Normal Duty; 3 HP, 2.2 kW Heavy Duty, Frame B, IP20 NEMA / Open Type, No Filter 4 $786.00 $3144.00

2 25-ENC-2 Incremental Encoder Interface for PowerFlex 527 4 $70.00 $280.00

3 1769-PB4 Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC 1 $495.00 $495.00

4 1769-L36ERM CompactLogix L3 controller, Dual Ethernet w/DLR capability, 3MB memory, 30 I/O Expansion, 48 Ethernet IP Nodes, 16 Axis CIP motion with Kinematics function. 1 $4,770.00 $4,770.00

5 IDNM3661T 3HP, 1755RPM, 3PH, 60HZ, 184TC, 0632M, TENV, F1 2 $1986.00 $3972.00

6 IDM3764T 3HP, 1165RPM, 3PH, 60HZ, 215TC, 0737M, TEBC, F1 2 $3082.00 $6164.00

7 H62048LT01CVV HS60 Hollow shaft Encoder, Single output PPR: 2048 No Index Wheel Bore: 1-1/8 in Termination: Latching Industrial Connector with 1/2 in NPT Electrical: 5-26 VDC in, 5-26V Line driver (IC-WE) out Seal: V-ring seal 2 $1708.00 $3416.00

8 H62048LT02CVV HS60 Hollow shaft Encoder, Single output PPR: 2048 No Index Wheel Bore: 1-3/8 in Termination: Latching Industrial Connector with 1/2 in NPT Electrical: 5-26 VDC in, 5-26V Line driver (IC-WE) out Seal: V-ring seal 2 $1708.00 $3416.00

        TOTAL: $25,657.00

Option Y (230 VAC Three-Phase) “most expensive”Item Product Description Qty List Price Ext. Price

1 25B-B024N104 PowerFlex 525 AC Drive, with Embedded EtherNet/IP and Safety, 240 VAC, 3 Phase, 7.5 HP, 5.5 kW Normal Duty; 7.5 HP, 5.5 kW Heavy Duty, Frame C, IP20 NEMA / Open Type, No Filter 3 $1610.00 $4830.00

1 25B-B032N104 PowerFlex 525 AC Drive, with Embedded EtherNet/IP and Safety, 240 VAC, 3 Phase, 10 HP, 7.5 kW Normal Duty; 10 HP, 7.5 kW Heavy Duty, Frame D, IP20 NEMA / Open Type, No Filter 1 $1850.00 $1850.00

2 25-ENC-2 Incremental Encoder Interface for PowerFlex 527 4 $70.00 $280.00

3 1769-PB4 Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC 1 $495.00 $495.00

4 1769-L36ERM CompactLogix L3 controller, Dual Ethernet w/DLR capability, 3MB memory, 30 I/O Expansion, 48 Ethernet IP Nodes, 16 Axis CIP motion with Kinematics function. 1 $4,770.00 $4,770.00

5 IDNM3770T 7.5HP, 1760RPM, 3PH, 60HZ, 213TC, 0748M, TENV 1 $2563.00 $2563.00

6 IDNM2238T 10HP, 1770RPM, 3PH, 60HZ, 256TC, 0948M, TENV 1 $3123.00 $3213.00

7 IDM2276T 7.5HP, 1180RPM, 3PH, 60HZ, 254TC, 0954M, TEBC 2 $5423.00 $10846.00

8 H62048LT01CVV HS60 Hollow shaft Encoder, Single output PPR: 2048 No Index Wheel Bore: 1-1/8 in Termination: Latching Industrial Connector with 1/2 in NPT Electrical: 5-26 VDC in, 5-26V Line driver (IC-WE) out Seal: V-ring seal 1 $1708.00 $1708.00

9 H60064LT03CVV HS60 Hollow shaft Encoder, Single output PPR: 2048 No Index Wheel Bore: 1-1/8 in Termination: Latching Industrial Connector with 1/2 in NPT Electrical: 5-26 VDC in, 5-26V Line driver (IC-WE) out Seal: V-ring seal 1 $1903.00 $1903.00

10 H62048LT02CVV HS60 Hollow shaft Encoder, Single output PPR: 2048 No Index Wheel Bore: 1-3/8 in Termination: Latching Industrial Connector with 1/2 in NPT Electrical: 5-26 VDC in, 5-26V Line driver (IC-WE) out Seal: V-ring seal 2 $1708.00 $3416.00

        TOTAL: $40,924.00