VendArt at MakerFX

 

 

This effort aims to restore a National Vendors, Inc. Manual Cigarette Merchandiser Series 222, which was a classic mechanical cigarette vending machine that was popular between the 1960s and 1980s.  The machine that I’m helping restore is from 1975, as indicated by a stamp on the vending machine’s internal hardware. 

Date stamp found inside the merchandiser

 

Another MakerFX member owns this project, but I’m supporting the effort by restoring the mechanical vending mechanisms and integrating modern payment solutions while preserving the machine’s original and existing hardware.  When completed, this vending machine will sell local makers’ unique makes at various Central Florida maker events, like Maker Faire Orlando. 

The machine’s vending mechanisms are locked when idle, preventing the pull knobs from dispensing items from their respective magazines.  When payment is accepted, a solenoid engages the vending mechanisms to unlock the pull knobs and enable vending.  I was tasked with replacing the missing solenoid, designing and implementing a solenoid driver, and writing the code that drives the solenoid during a transaction.

 

 

Tech Stack

Mechanical

 

Left to Right: Internal vending unit front, merchandise magazines, internal vending unit side, vending lock mechanism detail

 

 

Solenoid 12V 10mm 5A Push Pull

 

Technical Specifications

 

 

XYZ Adjustable Solenoid Carriage (left) and Mount (right)

 

XYZ Adjustable Solenoid Carriage and Mount Assembly

 

 

·       Carriage and mount were designed in Fusion 360

·       Carriage and mount were 3D printed on the Bambu P1S

 

Detail of solenoid on XYZ carriage and mount, and fastened to existing machine bracket

 

 

Retrofitted XYZ Adjustable Solenoid Carriage and Mount Assembly on Existing Bracket

 

·       The solenoid carriage and mount are adjustable in the XYZ directions, so the solenoid can be precisely positioned to engage the vending lock mechanism

o   The solenoid fastens to the carriage

o   The carriage fastens to the mount

o   The mount fastens to the vending machine’s existing bracket

 

·       I designed this XYZ solenoid carriage and mount assembly to fit the existing bracket

·       This design makes it possible to position the solenoid plunger (piece that extends and retracts) with the vending machine’s mechanical lock mechanism

·       The XYZ carriage and mount positions are ‘locked’ with screws, washers, and nuts creating bolted joints

Bolted Joint

 

 

Solenoid Intermittent Duty Cycle Temperature Testing

·       The solenoid’s plunger extends by creating a magnetic field when current flows through the tightly wound coils surrounding the plunger

·       Continuous current flowing through the solenoid coils produces a lot of thermal energy (heat)

o   I reduced the solenoid’s input voltage from the rated 12V to 6V to reduce the heat produced when current is flowing through the coils

·       Since the solenoid is mounted to a carriage and mount that was 3D printed with PLA, I need to confirm that the heat produced by the solenoid does not exceed the melting point of PLA

 

·       I created a test bed to measure the temperature of the solenoid with an infrared thermometer

o   I attempted to keep the ambient temperature constant throughout each experiment run

§  No AC running, ambient temperature measured during the experiment

o   The infrared thermometer was mounted onto a tripod to secure its distance from the solenoid through the experiment

§  The infrared thermometer’s documentation recommends measuring a temperature from 14”, so I mounted the thermometer at 14” from the solenoid’s top surface where the temperature was measured

o   The solenoid was attached to the carriage mount to observe the solenoid’s temperature effect on the PLA

o   The carriage mount was securely taped to the test bed to reduce movement between engages and disengages

 

·       I wrote code to iterate through an engage and disengage procedure that parallels the use-case

o   This makes the experiment repeatable and the data more accurate

o   Code available on github

Solenoid Duty Cycle Testbed Setup

 

 

o   Manually pressing the trigger shakes the mounted infrared thermometer, which then shakes the laser and moves the point where the temperature is measured between readings

o   I eliminate the movement produced from physically pressing the thermometer trigger by clamping down the trigger, which puts the thermometer in an ‘always scanning’ mode

o   Eliminating human interaction with the testbed drastically reduces the risk of human error skewing the data

o   The thermometer can now consistently measure the temperature at precisely the same location on the solenoid between cycles

 

 

Clamped Trigger on Infrared Thermometer

 

 

·       Goal

o   Confirm that the solenoid operates as intended without compromising the integrity of the mechanical system

o   Confirm that the heat produced on the solenoid’s outer surfaces by coils does not exceed the melting temperature of the PLA carriage and mount

 

 

·       Procedure

o   Measure surface temperature at the designated location BEFORE starting engage-disengage cycles

§  This location is where the cycle temperatures will be measured for the entire experiment

o   For 130 duty cycles:

§  Solenoid engages for 15 seconds

§  Solenoid disengages and temperature is measured at the designated location

§  Solenoid remains disengaged for 10 seconds

 

o   This experiment iterated through an engage-disengage cycle for multiple duty cycles, and was repeated at various locations on the solenoid

o   NOTE: DO NOT touch the solenoid or move the infrared thermometer during the experiment

o   NOTE: Wait until the solenoid returns to ambient temperature before proceeding to the next experiment solenoid location

 

Locations on solenoid where temperatures were measured

 

 

 

·       Results

o   Duty Cycles 1-100: Capture the temperature rise toward a temperature steady-state

o   Duty Cycles 101-130: Measure steady temperature

 

Left: Solenoid Cycle Temperature Rise and Steady-State Data

Right: Solenoid Steady-State Temperature Data

 

o   Data Variability

 

§  Variance calculates the average of the squared distance from the mean, which measures the distribution of the data

·       Low variance is an indication of consistent measurements during data acquisition and high repeatability.  Conversely, high variance indicates unusual or inconsistent data

§  Standard Deviation measures the spread of a set of values around the average, where a low standard deviation indicates more values close to the average

§  Coefficient of Variability measures how far the standard deviation is from the data average

·       This value is used to determine a ‘low’ standard deviation, ideally within 10%

 

§  Variability in the data can be attributed to various factors, including but not limited to:

·       Human error

·       Environmental influences (temperature, humidity, sunlight, etc.)

·       Measurement device specifications, tolerances, error, etc.

·       Test procedures

·       Unexpected test anomalies (i.e. things that may happen during the experiment that are not directly related to the experiment)

 

§  The equations below are used to calculate the sample variance and standard deviation in the steady-state data acquisition

·       Sample variance subtracts 1 from the number of data points in the denominator (Bessel correction), which accounts for potential biases in the data acquisition. This increases the variance calculation as a ‘worst case’

 

 

 

 

 

o   This data shows low variance, which means that the data collected was relatively close to the average

o   Since the data has low variance, I can reliably use the steady-state data average temperatures to assess the active solenoid’s performance and effects on the mechanical system

§  This low variance metric can indicate that:

·       The thermometer was consistent with its measurements

·       Test procedures were consistent between iterations

 

Heat map of the solenoid steady-state temperature data measured under duty cycle load

 

o   The solenoid appears to have entered a steady-state temperature after about 80 engage-disengage duty cycles

o   Interestingly, the hottest point on the solenoid was at its steady-state during the engage-disengage duty cycling experiment was near the  leads

o   The coolest point on the solenoid at its steady-state during the engage-disengage cycling experiment was at the at the solenoid’s side opposite the  leads

§  This side of the solenoid is open, so the heat from the coils can dissipate more easily compared to points along the coil that are enclosed by the metal housing

 

·       Conclusion

o   The average solenoid steady-state temperature when cycling had a range of

o     PLA begins to soften at  and melts at

o   This cycle test was more aggressive than the cycles that the fielded solenoid will undergo and was still  under the PLA softening temperature

 

o   Given the experiment results, the heat produced from the active solenoid should not affect the PLA carriage mount

o   As an extra experiment, I allowed the solenoid to cycle through engage and disengage for 200 cycles with no impact to the solenoid’s performance or the PLA carriage mount

§  No data collected – Just observation for any impacts to the system at high cycle counts

 

·       How to Improve Future Experiment

o   Automate temperature readings with software instead of manually pressing the thermometer trigger

§  Reduces human error by with more consistent timing between measurements

§  Collect more frequent temperature data throughout the experiment to create a more complete temperature profile of the solenoid

o   Perform experiment in a more controlled environment

§  Thermal chamber to control the ambient temperature and reduce external influences (AC, sunlight, etc.)

§  Controlling ambient parameters would also normalize the data, ensuring that the temperature rise is comparable among all iterations

·       The data is reliable for my use-case, but a controlled environment could parameterize the solenoid more precisely

Electronics

Raspberry Pi Pico W

 

 

MP1584EN DC-DC Buck Converter (Step-Down Converter)

 

·       I wanted the solenoid and microcontroller to share one 12VDC power source, but both components have different electrical requirements:

o   Solenoid: 12VDC, 1.7A

o   Raspberry Pi Pico W: 5V, 95mA

·       A buck converter, AKA step-down converter, efficiently reduces a higher input DC voltage to a lower output DC voltage

o   This protects the lower-voltage components that are connected to a higher DC source voltage

·       An inductor stores and releases electromagnetic field and smooths the current by resisting rapid changes

·       A switch creates a duty cycle that outputs a desired voltage lower than the source

o   The lower the duty cycle, the lower the store in the inductor

o   Think Pulse Width Modulation (PWM)

o   The switch is usually a transistor (MOSFET)

·       A diode creates a path for the current when the switch is turned off

·       A capacitor smooths the voltage rippled

·       The buck converter unit uses a control (potentiometer) to control the output voltage

 

 

IRLZ44NPBF Logic Level MOSFET

IRLZ44N Logic-Level MOSFET

 

·       A MOSFET is an electronic switch that controls current flowing through a semiconductor channel using an electric field

o   MOSFET Terminals

§  Gate (G): Control Input

§  Drain (D): Where current flows out

§  Source (S): Where current flows in

 

o   N-Channel:

§  Turns on when the gate is more positive than the source

§  Current flows from drain to source

§  Efficient and low heat

§  Motor drivers, solenoids, power supplies, high-current applications

 

o   P-Channel

§  Turns on when the gate is more negative than the source

§  Current flows from source to drain

§  Simpler but less efficient at high currents (higher )

§  Battery-powered devices

 

·       The IRLZ44N is a logic-level N-channel MOSFET, which allows us to engage and disengage the solenoid by passing a boolean to the MOSFET gate with the solenoid driver code

·       2 main parameters for selecting the appropriate MOSFET: Voltage (V) and Current (I)

 

 

·       MOSFET Spec Sheet

o   Spec sheet assumes proper cooling, so operating the MOSFET at the rated specs without proper cooling (fans, heat sinks, etc.) can overheat or melt the unit

o   The Current spec only says that the MOSFET will not melt when operating at 47A when properly cooled

§  While the Current and Voltage are used to determine how a system will operate, the MOSFET’s internal resistance, , sets the threshold

·        tells how much power needs to dissipate from the MOSFET at a constant load

o   Constant Load: >10 seconds without a heat sink

IRLZ44N MOSFET Spec Sheet

·       Thermal Power Generated

o   Recall – the internal resistance, , is the spec that we will use to threshold our MOSFET selection calculations

o   Since there isn’t perfect control of the load on the MOSFET, we degrade the  by 20-30%

§       Increase  by 20%: 

 

o   Now calculate the thermal power generated, , by the system given the load’s specs

§  Since we are using the MOSFET to drive the solenoid, we are using the solenoid specs defined above as the load

 

 

·       Thermal Power Lost

o   These thermal losses need to somehow escape the MOSFET, and that can be determined with the thermal resistance,

§  This tells you how much the MOSFET will heat up for each watt of thermal loss,

 

o      Now that we’ve solved for , we can calculate the thermal losses to confirm that they are within the MOSFET’s specifications

§  The MOSFET spec sheet indicates that the Thermal Resistance, , for a MOSFET without a heatsink (Junction-to-Ambient) is

·       Use the heatsink spec sheet if a heatsink is screwed onto your MOSFET

·       We assume that ambient is  when unknown or unspecified

§  We calculate the thermal loss by multiplying the thermal power generated, , and the thermal resistance,

 

o   The calculated thermal loss can be compared to the Operating Junction  and Storage  Temperature Range indicated on the spec sheet:

 

o   Since the calculated temperature from thermal losses falls within this spec, we determine that the MOSFET can safely operate under the solenoid’s load

 

 

·       MOSFET Drive Levels

 

o   Since this MOSFET is a logic-level MOSFET, we need the voltage from the logic signal that the microcontroller produces

§  The solenoid will be driven by the Raspberry Pi Pico W microcontroller, which outputs 3.3V

o   The MOSFET spec to track here is the Static Drain-to-Source On-Resistance,

o   Notice that the resistance values on this spec are more in line with the resistance we calculated losses with at the 20% margin

§  Resistance goes up as the voltage goes down, which is the relationship indicated by

 

·       Confirm MOSFET selection

o   The spec sheet doesn’t indicate Static Drain-to-Source On-Resistance, , but I still want to confirm that my system won’t exceed the MOSFET’s thermal constraints

o      I’m using the indicated  for 5V and 4V to linearly extrapolate  for the microcontroller’s 3.3V

 

 

o      Now that  is calculated for my system, I can revisit the calculations and use my estimated  to more accurately determine the thermal effects on the MOSFET

 

 

 

o     At , I’m still well within the Operating Junction  and Storage  Temperature Range indicated on the spec sheet, so my solenoid driver will not thermally compromise the MOSFET

o   This MOSFET is excessive for my solenoid driver’s electrical parameters, but its large voltage and current margin will be reliable and usable

 

 

Solenoid Driver Wiring Schematic, designed and Simulated in TinkerCAD Electrical

 

 

Solenoid Driver Breadboard

Breadboard for solenoid driver development

 

 

Soldered Perfboards, Dev

Left to Right (per image): Solenoid, Solenoid Driver, Buck Converter, Raspberry Pi Pico Microcontroller (Dev), Redundancy Engage and Disengage Buttons

 

 

Solenoid Driver/Buck Converter Stack

Assembled solenoid driver unit on soldered perfboard, Dev

Software

Vending Flow of Execution

 

·       Point of Sale (POS) Solenoid Engage

o   The trigger that commands the solenoid to engage and unlock the vending lock mechanism is an initiated transaction

o   Once initiated, the solenoid will remain engaged until an item is dispensed or the defined engage time expires

§  Solenoids engage by running a continuous current, so they get very hot when engaged

§  A timed disengage is a safety parameter that protects the solenoid from overheating in its engaged state

o   The point of sale is performed via digital payment platform (DPP)

§  Square, Stripe, Venmo, Zelle, etc.

o   When a transaction is initiated, a webhook is posted to the defined endpoint from the DPS

o   Receipt of the webhook then commands the solenoid driver to engage and unlock the vending lock mechanism

 

 

·       Webhook Implementation

Production Webhook Implementation, Raspberry Pi Zero 2W

 

o   I decided to use a webhook instead of an API to keep the design efficient

§  API: System (client) pulls data or an event from another system (host) when the client system sends a request

·       Host: Data Source

·       Client: Data Requester/Recipient from an endpoint

§  Webhook: System (client) automatically pushes data to another system (host) when the client system detects an event

·       Host: Data Recipient

·       Client: Data Source that sends a POST to a URL endpoint

 

o   Instead of polling the endpoint with an API, a webhook is sent to a server when the endpoint detects an event

§  The host (receives the webhook) is ‘listening’ for a POST request from the client (sends the webhook)

§  The API for the service I’m using limits the number of calls to the host, but not webhooks as long as data receipt is confirmed

 

o   The server to which the webhook posts is hosted locally on the Raspberry Pi, but the server needs to be publicly accessible so that the external DPP can post the webhook

o   A secure tunnel creates an encrypted pathway for data to travel between two endpoints over HTTP protocol

o   The secure tunnel securely exposes the local server on the Raspberry Pi (host) to the internet, enabling the external DPP (client) to post to it

§  The Raspberry Pi (host) server ‘listens’ for a webhook post from the external client

§  When payment is accepted by the DPP, the DPP (client) sends a webhook to the server hosted on the Raspberry Pi (host) via a secure tunnel to inform of a received payment

§  The local host must send a receipt confirmation to the client when the webhook is received, typically within approximately10 seconds of receipt

·       Confirmation: 200 code

 

 

Dev Implementation

 

Development Webhook Implementation, Raspberry Pi Pico W

 

o   My dev environment uses a Raspberry Pi Pico W, which is a microcontroller, so it can’t run a secure tunnel

o   I’m using my laptop to create a local server and implement a secure tunnel that receives webhooks from the DPP endpoint

o   The laptop sends a Boolean to the Raspberry Pi Pico W’s IP on a common network when a webhook is received, commanding the solenoid driver to engage the solenoid in the vending lock mechanism

o   The deliverable will consolidate the Raspberry Pi Pico W and the laptop with a Raspberry Pi Zero 2W, which can host a local server and implement a secure tunnel, following the first diagram in this section

 

 

·       All code implemented in this notebook is publicly available on my github!

o   Solenoid Driver Demo

o   VendArt - RasPi Pico W

o   VendArt – RasPi Zero 2W

Helpful Links

·       Baomain BM-0530B Solenoid

·       MOSFET Explained - How MOSFET Works

·       MOSFET Selection Calculations

·       How to Use N-channel MOSFETs as Switches

·       Secure Tunnel Implementation with ngrok

·       Variance and Standard Deviation