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Post# 371623   8/12/2009 at 20:32 (5,370 days old) by supremewhirlpol ()        

!!!!The motor has arrived!!!!'

For the drive motor of this machine, I will use a 3HP 230V/460V 3PH 3520 RPM motor. It weighs in at 105LB. I've already tested it and it is one heck of a motor!!! I think 3HP is more than enough for a 22LB. machine.

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Post# 371626 , Reply# 1   8/12/2009 at 20:34 (5,370 days old) by supremewhirlpol ()        

close-up of the motor

Post# 371627 , Reply# 2   8/12/2009 at 20:35 (5,370 days old) by supremewhirlpol ()        

What do you guys and gals think?

Post# 371646 , Reply# 3   8/12/2009 at 21:30 (5,370 days old) by frigilux (The Minnesota Prairie)        

frigilux's profile picture
I think it's wonderful and frightening.

You boys just be careful not to create some monster that can think on its own. It would be an embarrassing way for future explorers to have to explain our demise!

Post# 371659 , Reply# 4   8/12/2009 at 22:55 (5,370 days old) by volvoguy87 (Cincinnati, OH)        
Great Scott!!!

 volvoguy87's profile picture
Only a 22 pound machine? I think you could wash 220 pounds with this monster.

Good luck and keep us posted,
DAve

Post# 371745 , Reply# 5   8/13/2009 at 09:46 (5,370 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Wow that is a motor, compared to my commuter motor, sort of makes it look small.

I’m currently working on a proper printed circuit board complete with new chip (PIC 16F77), with new programs and hopefully a time line to show progress of the wash cycle. Need to build a light box to photo develop circuit design onto copper clad board, I tried some iron on transfer sheets but have been unsuccessful. Also milling over a jog switch instead of push switches. If I can get the developing to working I will make one of each board which can be inter changed.

Post# 371746 , Reply# 6   8/13/2009 at 09:57 (5,370 days old) by hotpoint95622 (Powys)        
hotpoint 95622

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Hope some thing like this will be the end product

Post# 371902 , Reply# 7   8/13/2009 at 23:00 (5,369 days old) by supremewhirlpol ()        

Hotpoint 95622, your board layout looks very detailed. I ran across site with some info that may help you make your circuit board, when I find the site I will email it to you.

I chose a motor this big because I want to get the extract speed of the machine to at least 1000 rpm. The old motor was 3/4 hp with speeds of 330 rpm and 3350 rpm, also with 3in. diameter double pulley.This motor was also open at the ends, so if water leaked into it from sitting just below the drum gasket, you would be spending $1300 for a new one(happens very often in these machines). At 3350 rpm, the extraction speed was 525 rpm. What that means is that in order to get to 1000 rpm, I have to change the pulley ratio. The pulley on the cylinder shaft is proprietary, so it is easier to just use a bigger pulley on the motor. When a bigger pulley is used on the motor and the other pulley is the same, more strength is required to turn the cylinder, but the cylinder will turn faster. I was thinking that 3 HP at 3520 rpm will be more than enough and I will not have to overdrive the motor to get 1000 rpm. Also this motor is TEFC and rated for hazardous conditions, so water won"t be an issue as long as I use the right insulation and connectors from the junction box. The next steps are to find a big pulley(maybe 7" or 8" diameter) and a VFD to control the motor. But I have to say it again: "That's one heck of a motor!!!!".

Please keep your thoughts and suggestions coming.

Post# 371969 , Reply# 8   8/14/2009 at 03:11 (5,369 days old) by chestermikeuk (Rainhill *Home of the RailwayTrials* Merseyside,UK)        
wow

 chestermikeuk's profile picture
Monster washer indeed, Is this the washer in your profile pic?? will the bearings be able to cope with the extra speed & inertia without going into sub orbit??

am looking for an asko shell that I could do that with and put a clear perspex frame around it to observe the inner working etc.

Interesting projects guys!!

Mike

Post# 373281 , Reply# 9   8/19/2009 at 19:08 (5,363 days old) by supremewhirlpol ()        

************Update 8-19-09************

I have the pulley... it is 8"(outer diameter) 1 1/8" (inner diameter(shaft)).

Post# 373283 , Reply# 10   8/19/2009 at 19:15 (5,363 days old) by supremewhirlpol ()        

A quick check on parts:

I currently have the solid state relays(ssr), the motor, pulley, control box, user interface panel, SS disconnect.


Now I need to finish getting the cards for my PLC, the VFD, bus bars, and I need to design a mounting bracket for the motor. Then I can start putting more things together.

What do you guys and gals think?

Post# 373353 , Reply# 11   8/19/2009 at 23:59 (5,363 days old) by tolivac (greenville nc)        

There are some motors just like yours here at work-they are spinning blowers for the building HVAC system-3 and 5 hp-3Ph208V.

Post# 373359 , Reply# 12   8/20/2009 at 00:20 (5,363 days old) by volvoguy87 (Cincinnati, OH)        
Hmmmmm...

 volvoguy87's profile picture
I live only 45 minutes away from you. Please let me know when you run this thing so I can take shelter in my basement.

Seriously though, it is most interesting,
Dave

Post# 373435 , Reply# 13   8/20/2009 at 12:40 (5,363 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Good progress your making.

I have just spent more money I DON’T HAVE, what the hell, what do you have a master card for, now the owner of a UV photo light box so will try to process a PCB this weekend, fingers crossed it works for me.

Post# 373469 , Reply# 14   8/20/2009 at 16:06 (5,363 days old) by supremewhirlpol ()        

Hotpoint 95622,

Have you considered taking your PCB design to a company that custom makes boards? It may cost you a good amount of money to have it done. Have you tested your setup with the new chip and updated program?


Volvoguy87,
I think when I complete the programming structure for extraction on the PLC, I will put up a video of the machine spinning at full RPM's. But that may take a while. School starts Monday, so this project may be set a side until next summer.

Post# 373604 , Reply# 15   8/21/2009 at 12:11 (5,362 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Yes I have also had some costing for one-off production of a board; average of £70 so will persevere with making my own. I have 4 designs in my head at the moment and can’t decide which one to go with. I will take photos of the stages of production, even my many mistakes which will happen I am sure.

Post# 373629 , Reply# 16   8/21/2009 at 16:04 (5,362 days old) by supremewhirlpol ()        

hotpoint 95622...

Yes, I'd like to see the pictures. Good luck on your board designs. How much time have you dedicated to this project so far?

Post# 373768 , Reply# 17   8/22/2009 at 09:16 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
How long about 14 months, as I have had to learn all about electronic from books then read up about microcontrollers. How much have I spent, about £200 plus, most expensive part was the motor which was £90, cheapest the scrap machine £0.00.

Photo of first attempt with the transfer film.


Post# 373769 , Reply# 18   8/22/2009 at 09:17 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

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The used film.

Post# 373770 , Reply# 19   8/22/2009 at 09:18 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

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The best I have achieved with this method

Post# 373772 , Reply# 20   8/22/2009 at 09:25 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
First attempt at etching the best of the transfers. Some of the trace edges are a little off and some are missing.

Post# 373786 , Reply# 21   8/22/2009 at 11:09 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Some photos of the new UV light developing unit at work.

The UV unit.

Post# 373788 , Reply# 22   8/22/2009 at 11:10 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Art work from PCB wizard software on the PC.

Post# 373789 , Reply# 23   8/22/2009 at 11:12 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Art work printed onto transparency sheet.

Post# 373790 , Reply# 24   8/22/2009 at 11:13 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Cut and placed on UV unit.

Post# 373791 , Reply# 25   8/22/2009 at 11:15 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Photo copper clad board cut to just bigger than art work and placed photo side down on to transparency. Developed for 3 mins.

Post# 373792 , Reply# 26   8/22/2009 at 11:19 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Photo side after exposure to UV shows are work as yellow outline. Developer is applied and the art work is fully revealed.

Post# 373795 , Reply# 27   8/22/2009 at 11:25 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
Etched in ferric chloride until all the copper has gone.

Not bad for the first attempt with this method, right hand side not as good as the left. I think that is due to my printer, so will have to play with the settings to get the darkest print possible or try using the inkjet instead.

Post# 373797 , Reply# 28   8/22/2009 at 11:28 (5,361 days old) by hotpoint95622 (Powys)        
hotpoint 95622

 hotpoint95622's profile picture
So I'm very pleased with this first attempt and much happier to try agene.


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