618 lines
15 KiB
Markdown
618 lines
15 KiB
Markdown
# 05FEB2024
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## TH Fab
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Car: 68 mi
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Time: 2 hr
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Hashed out details of arrangement, met guys
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Torque to turn while in ground: 120 in-lb
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# 07FEB2024 - 2.3
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Set up SOLIDWORKS
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clock "IN" 15:33
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clock "OUT" 17:52
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target = 100 in-lbf (8.5 ft-lbf)
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PG71 = 16.6 ft-lbf / 75rpm
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... ok so that's not so bad.
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builtin worm gearbox = 30:1 ratio
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shaft is a 5/8" shaft with a 1/2" long D-shaft stub: 1/2" diameter, 3/8" to the flat, with a cross-pin meant to capture a 1/4" (.266 actual) plate. The 5/8" section is 1" long.
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full range of spider angle is 120deg
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let's say 2 seconds to full completion
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that's 60deg/sec (10 rpm)
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times a 30:1 gear ratio is 300 rpm
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times a 2:1 gear ratio is 600 rpm
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which is NOT in range for a PG71; by about an order of magnitude
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The pg71 would take about 20 seconds to do a full changeover which is pretty long...
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how fast does a 5 deg adjustment need to take?
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ballpark 0.5s
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that's 10deg/s (1.6666666 rpm)
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times 30:1 times 2:1 is 100 rpm
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which *is* pretty similar to a pg71
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Sent email to https://www.klaubergear.com/contact-us-kmg asking for a motor with 100RPM free and 30 ft-lbf stall
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## HTD Pulley combo - Shaftloc
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[62T Pulley](https://shop.sdp-si.com/catalog/product/?id=A_6T25-H62DF1524)
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[19T Pulley](https://shop.sdp-si.com/catalog/product/?id=A_6T25-H19SF1520)
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ehhhh too small of diameters
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## GT2 Pulleys - Metal
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https://shop.sdp-si.com/catalog/?cid=p217&filter=a0%3A2%3A5%20mm%20(GT2)&sort=undefined&view=table
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https://shop.sdp-si.com/catalog/?cid=p342&filter=a0%3A2%3ASingle%20Sided%3Ba16%3A2%3A5%20mm%20(GT2)%3Ba185%3A2%3A15.0&sort=undefined&view=table
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[56T - $32.35 / $25.15](https://shop.sdp-si.com/catalog/product/?id=A_6A55-056NF1516)
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[17T - $15.02 / $ 9.74](https://shop.sdp-si.com/catalog/product/?id=A_6A55-017NF1508)
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[120T- $31.81 / $19.88](https://shop.sdp-si.com/catalog/product/?id=A_6R55M120150) (also not in stock)
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Total: $79.18 / $54.77
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## #25 Chain
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(Hey, this would need a tensioner right? Maybe that's a good thing anyways though...)
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[15T - $14.90](https://www.mcmaster.com/2737T109/)
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[30T - $23.81](https://www.mcmaster.com/2737T223/)
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[2ft - $13.68](https://www.mcmaster.com/6261K171-6261K282/)
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Total: $52.39
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[23T - $18.60](https://www.mcmaster.com/2737T154/)
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[45T - $36.67](https://www.mcmaster.com/2737T312/)
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[2ft - $13.68](https://www.mcmaster.com/6261K171-6261K282/)
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Total: $69.95
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## #35 Chain
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[15T - $18.21](https://www.mcmaster.com/6280k371/)
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[30T - $48.48](https://www.mcmaster.com/6236K231/)
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[2ft - $10.14](https://www.mcmaster.com/6261k172/)
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Total: $76.83
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... huh. Surprising that actually starts to get competitive with GT2 stuff.
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## 25 or 35?
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#25: 140lbf working
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#35: 480lbf working
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15T #25: 100 in*lbf / (0.250*15/pi)/2 = 167 lbf in chain which is a lot!
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15T #35: 100 in*lbf / (0.375*15/pi)/2 = 112 lbf in chain which is well within working
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#35 is probably the way to go, especially for now.
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## Final observations
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The drive shaft will need to be different.
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So you might as well put the drive mechanism on what is currently the nut side, so you don't have to worry about the locking mechanism.
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# 08FEB2024 - 0.5+0.2+3
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Clock in: 10:21
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12" long, 8" diameter $350 - $600-$700 sample
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not a very helpful call... except maybe that I need a very different motor
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maybe this is the right way to go: https://www.amazon.com/MOCW-Stabilizer-Replacement-K01285-C800-K01531-A800/dp/B09LM63RHY
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## C800 motor
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- 12VDC
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- 7A
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- 53:1 gear ratio
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- 68 RPM
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- 50 in-lbf run torque
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clock out 10:53
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clock in 10:58
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clock out 11:18
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clock in 15:27
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Advised to visit CSH Incorporated; sure enough, they have the C800 motor: https://www.cshincorporated.com/k01531a800-replaces-k01285-c800-klauber-gear-motor/
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clock out 18:09
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I specced 8+3+3 = 14 hours for the design phase and I've burned 6 so far.. ok
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# 12FEB2024
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clock in 1500
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clock out
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# 16FEB2024
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clock in 17:20
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clock out 18:15
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https://www.geartechnology.com/ext/resources/issues/0791x/errichello.pdf
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how fast are we going?
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300*2*pi/60/s*40mm to ft/min = 247.4 ft/min
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300*2*pi/60/s*40mm to m/s = 1.26 m/s
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https://khkgears.net/new/gear_knowledge/gear_technical_reference/lubrication-of-gears.html
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KHK seems to think that grease is appropriate.
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10-30 C - 200-245
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30-55 C - 350-510
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# 23FEB2024
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clock in 11:00
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clock out 11:02 - :02
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clock in 12:38
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clock out 13:42 - 1:04
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clock in 14:00
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clock out 16:24 - 2:24
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total: 3:30
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ack.
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clock in 8:06
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clock out 10:30
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todo:
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- [x] finalize tensioner
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- [ ] finalize cover
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- [/] add hardware
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- [ ] make BOM
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bison EP18864-1 looks interesting
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## pots
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https://www.digikey.com/en/products/detail/amphenol-piher-sensing-systems/MSC360-1A-C0007-ERA180-05K/13543612
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billed
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# 22MAR2024 - 3.5hr
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# 25MAR2024 - 2.5hr
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clock in 9:48
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clock out 10:48
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clock in 11:00
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clock out 12:30
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Vishay 981he is a reputable option
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981HE0B4WA1F16
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MODEL: 981HE
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Features: 0 continuous rotation
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Linearity: A 1% (B 0.5%)
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Electrical Angle: 4 (360)
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Output type: W wires
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Output signal: A or B (Analog CW/CCW)
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Shaft type: 1F16 (1: 6.35, F: flatted, 16: length (16mm, standard))
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$58: https://www.mouser.com/ProductDetail/Vishay-Spectrol/981HE0B4WA1F16?qs=IpR5h64PZJnosCtHP9bpXQ%3D%3D
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https://www.newark.com/vishay/981he0b4wa1f16/throttle-position-sensor/dp/15R3247
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981HE0B4WA8H01 could work too, it's CCW, hollow D shaft: https://www.mouser.com/ProductDetail/Vishay-Spectrol/981HE0B4WA8H01?qs=xBCDPT02SF1aAq7obDlm8w%3D%3D
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https://www.digikey.com/en/products/detail/tt-electronics-bi/6127V1A360L-5FS/2620662?_gl=1*129k53o*_up*MQ..&gclid=Cj0KCQjwwYSwBhDcARIsAOyL0fjJ-HkKXQrTdVH6HHXJhOSrwul2iJfY-HebIL0XmgPecjzIoHLtjhEaAtmFEALw_wcB
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# ZF CU103602
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Non-contact which is excellent
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https://www.digikey.com/en/products/detail/zf-electronics/CU103602/1642202 $59.74
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CU103601 is 180deg instead of 360
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https://www.digikey.com/en/products/detail/zf-electronics/CU103601/1642200 $59.74
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https://www.sager.com/product/cu103601-zf-electronics/2449228
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could also get the AS500106 magnet separately
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the AN820031 / 32 has 12" 18awg wire leads and 180degrees motion as opposed to the connector
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# I think this is the best option:
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AN820032 https://us.rs-online.com/product/zf-electronics/an820032/70386254/ - $28.54
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AS500106 https://us.rs-online.com/product/zf-electronics/as500106/70386256/ - $8.41
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- $36.95
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- wire leads
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- 360 deg
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- non-contact
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YOU CAN USE THE AS1010 OR 709-21995 WITH IT TOO!
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- AS101001 is south
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- AS101002 is north
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- AS101003 is south with samarium
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RTP180LVxxA
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PST360
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PST360G2-1A-C0000-ERA360-RE-K
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- 14mm rotor
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- simple analog
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- C0000
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- 360 deg rotational angle
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- 7-15V
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- 200Hz PWM
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PST360G2-1S-C0000-ERA360-05K
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- 14mm rotor
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- SPI
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- C0000
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- 360deg rotational angle
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- 5V
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https://www.newark.com/amphenol-piher-sensorscontrols/pst360g2-1s-c0000-era360-05k/magnetic-rotary-sensor-analog/dp/74AH3318?st=pst360g2
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Ideal: PST360G2-1A-C0000-ERA360-05K
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# 28MAR2024 - 1 hr
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It works! Current characteristics:
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- 15A inrush current
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- 6-8A on unworked ground
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- 5-6A on worked ground
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- 4A in air
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Motor characteristics
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- 7 A running
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- 12 VDC
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- 68 RPM
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- 50 IN-LBF
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# 29MAR2024 - 5 hr
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clock in 08:15
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clock out 09:45
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clock in 09:50
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clock out 11:18
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clock in 12:00
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clock out 14:00
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Let's say
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8A x 2 x 25 = 400 A
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400 A * 12V = 4800 W
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8A x 12V = 96W
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96W x 12s = 1152 J -> 16F capacitor
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15A x 12v x 0.01s = 1.8J -> 25 mF capacitor
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Hey... you know you were measuring the whole system current, not just the motor, right? Hmm.
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https://portal.agleader.com/community/s/article/2052?language=en_US
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https://portal.agleader.com/community/s/article/2420?language=en_US
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Oh man there's so much on agleader's site
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OK, but... an auxillary battery might be a better solution than a power unit. We are doing sporadic high current, not continuous lower current.
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400A * 12s * 50 times / (3600 h/s) = 66 Ah = a car battery
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Wire fusing currents (lol): https://www.powerstream.com/wire-fusing-currents.htm
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Wire size: https://www.powerstream.com/Wire_Size.htm
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Pre-made 2AWG leads: https://www.amazon.com/ABIGAIL-Battery-Inverter-Automotive-Motorcycle/dp/B0BVB29FKR
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2AWG running from the middle seems reasonable...
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northamerica@zf.com
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AN9 is same as AN8 but redundant output
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ANG-11HAW1
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BILLED
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## So many tasks!
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[ ] Get answers from ZF (worst case: we can't sell you that magnet, and there's nothing to be done about the other thingy... make one? eesh. 2x6mm magnets)
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[ ] Top sensor mount
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[ ] Lower sensor mount
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[ ] Cable routing
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[ ] Buy a bunch of electronics for prototyping
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[ ] Fix holes
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# 02APR2024 - 1hr
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clock in 1000
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clock out 1100
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# 03APR2024 - 2.5hr
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clock in 2100
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clock out 2330
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AutomationDirect
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12mm inductive sensors
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PBM6-CP-1A - flush 2mm / PNP NC
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PBM6-AP-1A - flush 2mm / PNP NO
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PBM6-AN-1A - flush 2mm / NPN NO (limited stock)
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PBM6-AP-2A - proud 4mm / PNP NO
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200mA
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lengths vary...
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for the IC side of things
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- LM2907 / LM2917 F->V converter
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- LM397 voltage comparator
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TONE DETECTION IS WHAT YOU ARE DOING!
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## LM567
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LM567CN is a DIP
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fo = 1 / (1.1 * R1 * C1)
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fo = 1 Hz ?
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R1 * C1 = 0.9
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w 0.1 uF cap = 9 Mohm
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fo = 5 Hz
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solve 5 = 1/(1.1 * x * 0.1e-6) for x
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-> R1 = 2Mohm
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100mA current sinking for output
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LM567CN + L7805CP + Or gate (drive signal at 12V)
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the 567 is high frequency = low
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low frequency = high
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so make the signal low frequency = high
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so OR gate (74LS32)
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# 04APR2024
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clock IN 0845
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clock OUT 1130
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clock IN 1400
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clock OUT 1600
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DTP10-4P
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DT15-4P
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DTP10-4P
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DTP15-4P
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AMPHENOL, YOOOO
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https://www.digikey.com/en/products/filter/rectangular-connectors/headers-male-pins/314?s=N4IgjCBcoBw1oDGUBmBDANgZwKYBoQB7KAbRACYAGAZjADYB2EAXQIAcAXKEAZQ4CcAlgDsA5iAC%2BBALQAWBCGSR02fCABuw1JlwFikMgxpgArC3ZdIISRIlA
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littelfuse 55505 and ZF GS101201/02 are interchangeable
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I kinda like their package better
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# 11APR2024
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clock IN 0830
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clock OUT 1100
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clock IN 0200
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clock OUT 0400
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got CAN working
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# 12APR2024
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clock IN 0700
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clock OUT 0800
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clock IN 1515
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clock OUT 1853
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clock IN 1949
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clock OUT 2049
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## Stalling C800 motor
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I get 300mV on my oscope at 10 mV/A -> 30A (multimeter seems to confirm this)
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Boy, it's a torquey motor!
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3in ^2 * pi/4 * 120 psi to lbf = 283 lbf
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airbag fully extended 7.75-8" long. pivot point distance 3.75".
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AN820032
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ANG-11HAW1
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55300-00-02-A !!!
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PS2P-ARC is cool
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PS2P-CON is usable
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PS2P-CON-CE-1A0-C0000-ERA360-05 is $50 and would just work
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https://us.rs-online.com/product/piher-amphenol/ps2p-con-ce-1a0-c0000-era360-05
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https://www.mouser.com/ProductDetail/Amphenol-Piher/PS2P-CON-CE-1A0-C0000-ERA360-05?qs=wnTfsH77Xs6wFhE4CvwJ8Q%3D%3D
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PIHER's PSCI series seems too good to be true (they are)
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AS5600... man... it's cheap and tiny. Is it robust?
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# 13APR2024
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clock IN 0800
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clock OUT 1050
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shear strength of grade 8 = 91ksi
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shear force for 5/16" bolt: 91000 psi * (0.3125in)^2 * pi/4 = 6980 lbf
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torque on shaft = 6980 lbf * 1.25 in = 8725 in-lbf
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pitch diameter of worm about 3.11 in
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force on worm = 5610 lbf
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pin diameter = .156 in = 292600 psi
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(91000 psi * (0.3125in)^2 * pi/4 * 1.25 in / (3.11 in /2)) / ((.15625in)^2*pi/4)
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# 14APR2024
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clock IN 1345
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clock OUT 1438
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LM567C is not the right path
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4*12 mph / (18*pi inches) to 1/s -> 15 Hz
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4*1 mph / (18*pi inches) to 1/s -> 1.25 Hz
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# 16APR2024
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clock IN 1230
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clock OUT 1630
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clock IN 2034
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clock OUT 2200
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tested CAN bus over 30 feet CAT5
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got LCDs working (you can do custom characters with them too)
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tested inductive prox over 30 feet CAT5
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continued developing messaging protocol
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got encoders working (with buttons... not as encoders. need to spec them)
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https://www.digikey.com/en/products/detail/pei-genesis/IPM12-A8F-PC-3/13143998
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https://www.digikey.com/en/products/detail/amphenol-ltw/M12A-08PFFS-SF8001/5253167
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ehhhh: https://www.amazon.com/Aviation-Connector-Lonlonty-Flange-Waterproof/dp/B0BBQN6NVR/ref=sr_1_4?crid=1RM3U3RJ342YG&dib=eyJ2IjoiMSJ9.bL04l_yAqfeArHfLlg9T5d5RPh52acgbzRwVCM8-fxsUksWOMbU8Gxn0KOUqjmJOjqCmgdsAOUl3yodYaxWHqw3ek3NAk0B4xYAcwzmHugxA3Gevigw_hjoXH8bgcT-ZmjiQhQy4_IkIEj5AzJZY55B4aQdJbO_sbNiGkLnrS0G7ITY4Or9OsrQZ0MgtwAEX6cZvOvkUeU7mNrrGzB2jXsS-DcmJUiF3Rs0-NCncIcw.EDwEZQ4hL5bwr5xqx8iOiIJiWp6Ss7g1c_4wkJBdQZA&dib_tag=se&keywords=m12+8+pin+bulkhead&qid=1713325429&sprefix=m12-8+bulkhead%2Caps%2C433&sr=8-4
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box: https://www.amazon.com/Otdorpatio-Waterproof-Electrical-Electronic-200x120x75/dp/B09B6QHQDQ
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https://www.digikey.com/en/products/detail/bud-industries/CU-3283/428968
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https://www.digikey.com/en/products/detail/bud-industries/PN-1324-DG/387043
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1092D1-12V-ND
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1092D5-12V-ND
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PEC11R-4220K-S0024
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adafruit 5529, 2056
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https://www.digikey.com/en/products/detail/bourns-inc/PEC11R-4220K-S0024/6164059
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https://www.digikey.com/en/products/detail/cliff-electronic-components-ltd/FC7252/21406836
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COM-10002 is best
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# 18APR2024
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clock IN downforce 1343
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clock OUT 1355
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clock IN RHP 1718
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clock OUT RHP 1932
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clock IN SSACT 2008
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clock OUT SSACT 2230
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IPM12-<coding><# contacts><Male or Female>-<SocketCup or PCb mount or FlyingLeads> (-3 for front mount)
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IPM12-A8M-SC-3 is for socket cup
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IPM12-A8M-PC-3 is for PCB mount
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********F is for female
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looks like flying leads aren't available lol
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# 19APR2024
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clock IN 1500
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clock OUT 1700
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clock IN 2030
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clock OUT 2400
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breakers
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relay: https://www.digikey.com/en/products/filter/power-relays-over-2-amps/188?s=N4IgjCBcoOwExVAYygMwIYBsDOBTANCAPZQDaIccAnGACwCsIhDMAHDAGxMW1X2uNCcXvy4BdQgAcALlBABlaQCcAlgDsA5iAC%2BhOgAYqiECkgYcBYmRC199KhyMSQMuYtWade2mH3HT5niEJJDkcPoABACC3ADMkTHOrpAgAKpqKtIA8qgAsrjo2ACuSrheIAC0CNAmUMpFliHkjGLabUA
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J107F1CS205VDC.45 should work: https://www.digikey.com/en/products/detail/cit-relay-and-switch/J107F1CS205VDC-45/14000915
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- 90mA coil current
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- 20A running current
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NOTE: AT15-<x>P-BM03 is the board mount you want, when you go to design a PCB
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https://www.digikey.com/en/products/detail/cit-relay-and-switch/A161CS12VDC-64/12503232 is also good
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# 09MAY2024
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clock IN 0800 (SS)
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clock OUT 1300 (SS)
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clock IN 1315 (RHP)
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clock OUT 1415 (RHP)
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clock IN 1415 (SS)
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Spider actuator works. Reasonably tuned. Here's a list of things that can/should be done:
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- Try the Piher sensor
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- Build a wiring harness
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- Mount sensors to cover
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- Space out the actuator
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- Put a USB port on the control box
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- Put SD card logging in the control box
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- Design mount for the center sensor
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- Put cigarette lighter adapter on M12 cable for RHP
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- Potentiometers for dimming
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#29MAY2024
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testing
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started
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kP 100
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kD 75
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sample len 25
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runs 1 & 2
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changed to
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kP 75
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kD 50
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sample len 18
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changed
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sample len 12
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kP 70
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kD 40
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len 15
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kP 80
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kD 50
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#31MAY2024
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refining CAD
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replaced THF-W210 with simply THF-2091
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modified
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THF-2091
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THF-2071
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THF-2045
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THF-2057
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THF-2079
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THF-2078
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THF-2061
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created
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THF-2091-GASKET
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CENTER PIVOT SENSOR BRACKET
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removed
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THF-W210 (replaced with THF-2091)
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# 01JUN2024
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what MCU to use?
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- R4 Minima
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- Mega Embed
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- Nano
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# 07SEP2024
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let center be positive cw, so it's positive when the rear is tilted left
|
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let angle be positive throwing in
|
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let front and rear be positive cw
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if (center > 0)
|
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front = + angle + center
|
|
rear = - angle - center
|
|
else
|
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front = - angle + center
|
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rear = + angle - center
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if (row == 0 and center > 0)
|
|
rear = - center
|
|
if (row == 0 and center <= 0)
|
|
front = + center
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if (row == LAST and center > 0)
|
|
front = + center
|
|
if (row == LAST and center <= 0)
|
|
rear = - center
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- OR -
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|
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if (center > 0)
|
|
front = + angle
|
|
rear = - angle
|
|
else
|
|
front = - angle
|
|
rear = + angle
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|
|
if (row == 0 and center > 0)
|
|
rear = 0
|
|
if (row == 0 and center <= 0)
|
|
front = 0
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|
|
if (row == LAST and center > 0)
|
|
front = 0
|
|
if (row == LAST and center <= 0)
|
|
rear = 0
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