1. EE Detailed Design Review

2. Wire Movement Team: Spooling Motors Specification Process

3. Take-up Spool Motor Selection Process: Solid Take-up
Inertia: kg-m2
Full Mass: 102 kg
Speed: 2390 rpm

4. Take-up Spool Motor Selection Process: 3 Supply Spool Take-up
Inertia: kg-m2
Full Mass: 157 kg
Speed: 1432 rpm

5. Take-up Spool Motor Selection Process: 2 Supply Spool Take-up
Inertia: kg-m2
Full Mass: 110 kg
Speed: 1432 rpm

6. Supply Spool Motor Selection Process
Inertia: kg-m2
Full Mass: 26.5 kg
Speed: 2450 rpm

7. Guide Roller Team: Roller Motors Specification Process

8. Guide Roller Team: Roller Motors Specification Process
Inertia: 1.03 kg-m2 (0.9 kg-m2)
Friction: 30N-m
Full Mass: 65 kg (55.9 kg)
Max Speed: 900 rpm
Nominal Speed: 716 rpm
Motor Price: $5280

9. Guide Roller Team: Roller Motors Specification Process With Gearbox
Inertia: 1.03 kg-m2 (0.9 kg-m2)
Friction: 30N-m
Full Mass: 65 kg (55.9 kg)
Max Speed: 3040 rpm (900 rpm)
Nominal Speed: 2149 rpm (716 rpm)
Motor Price: ~$ ~$1386 for gearbox
Backlash: arcminute ( degrees)

10. Work Piece Movement Team: Linear Actuator Specification Process

11. Work Piece Movement Team: Specification Process
Mass: kg
Force: N
Max Mass: kg
Max Force: 4356 N
Speed: 0.1 mm/min
Max Speed: 2mm/min
Applied Force (will vary): 200 N

12. Work Piece Movement Team: Specification Process

13. Options

14. Baldor EL1405T single phase 1 hp motor 1800 RPM
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 $ 2
PPA11-58B65-18EBXXX
Electrak PPA-AC Actuator Thomson /60Hz, 1ø Max Dynamic Load N (lbs): 6670 (1500) Max Static  Load N (lbs): (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 A $
TOTAL: $

15. 3-Phase AC Motor Details
AC Motors
Non-Inverter
Inverter Ready
Inverter Duty
VFD Compatible No
Yes
Cost
Low ( $)
Medium ($1000)
High ($ )
Speed Type
SIngle Speed
Single Speed
Variable Speed
Speed Variability
none
20:1 max
1000:1
Feedback Device
None
Encoder
Option
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 topic
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.

16. 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 $ 2
HVPMSMMTR
High Voltage Synchronous PM Machine (Brushless DC Motor)
$299.00
$598.00  3
 DRV M-KIT
Three Phase BLDC Motor Kit with DRV8312 and InstaSPIN-Enabled Piccolo TMS320F28069M MCU  4
AU-ZDH0100H
Shaft Encoder (for pulleys in wire movement fixture)
~≤ $379
~≤ $758
TOTAL: $
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)

17. Option 3 (Controller Only)
Item
Product
Description
Qty
List Price
Ext. Price 1
1769-PB4
Power Supply 24VDC Input 5VDC 24VDC
$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.
$4,770.00
TOTAL:
$5,265.00

18. 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 $ 2
25-ENC-2
Incremental Encoder Interface for PowerFlex 527
$70.00
$280.00 3
1769-PB4
Power Supply 24VDC Input 5VDC 24VDC
$495.00
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.
$4,770.00 5
IDM3667T
1.5HP, 1170 RPM, 3PH, 60HZ, 182TC, 0630M, TEBC $ $ 6
IDM3584T
1.5HP, 1760 RPM, 3PH, 60HZ, 145TC, 0530M, TEBC $ $ 7
ZUK2500H-ND
Digikey Red Lion Encoder with inch hollow diameter 2500 PPR
$472.31
$944.62 8
Hohner Corporation Encoder 7/8 inch diameter hollow shaft 2048 PPR
$480.00
$960.00
TOTAL:
$18,855.62

19. Option 5 (Rockwell-Ebay Option)
Item
Product
Description
Qty
List Price
Ext. Price 1
RDB-B B72AA
Bulletin 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
2090-CPWM7DF-16AA15
Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, Standard (Non-Flex), 16AWG, 15M
$99.00
$198.00 3
2090-XXNFMF-S09
Cable,Feedback,DIN Type 4 Connector,Non-Flex,Flying Lead,9M
$179.00
$358.00 4
2094-BC02-M02-M
Power Module, Integrated, 460V, 15kW Conv. 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module
$1,436.00
4.1
2094-EN02D-M01-S0
EtherNet/IP Safe Torque-Off Control Module
$603.00
4.2
2094-PRS8
Power Rail, Slim, 230V OR 460V, 8 Axis.
$290.00 5
2094-BM02-M
Power Module, Axis, 460V, 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module
$653.00
$1,959.00
5.1
$517.00
$1,551.00 6
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.
$2,895.00 7
1769-PB4
Power Supply 24VDC Input 5VDC 24VDC
$325.00 8
MPM-B2152F-SJ72AA
Bulletin 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)
$2,734.00
8.1
2090-CPWM7DF-08AA12
SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters
$245.00
8.2
2090-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
$67.00 9
MPM-B2153F-SJ72AA
$2,800.00
9.1
2090-CPWM7DF-08AA16
SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 16 Meters
9.2 10
2090-K6CK-D15M
Connector, Motor Feedback, D-Shell/Term Block, 15 Pin.
$39.00
$156.00 11
2090-K6CK-D44M
Connector Kit, 44 pin, K6200/K6500 I/O, Auxiliary feedback, and safety
$168.00
$672.00
TOTAL:
$27,161.00

20. Option 6 (Rockwell Solution)
Item
Product
Description
Qty
List Price
Ext. Price 1
RDB-B B72AA
Bulletin 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
2090-CPWM7DF-16AA09
Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, Standard (Non-Flex), 16AWG, 9M
$167.00
$334.00 3
2090-XXNFMF-S09
Cable,Feedback,DIN Type 4 Connector,Non-Flex,Flying Lead,9M
$323.00
$646.00 4
2094-BC02-M02-M
Power Module, Integrated, 460V, 15kW Conv. 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module
$2,650.00
4.1
2094-EN02D-M01-S0
EtherNet/IP Safe Torque-Off Control Module
$873.00
4.2
2094-PRS8
Power Rail, Slim, 230V OR 460V, 8 Axis.
$624.00 5
2094-BM02-M
Power Module, Axis, 460V, 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module
$1,180.00
$3,540.00
5.1
$2,619.00 6
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.
$4,770.00 7
1769-PB4
Power Supply 24VDC Input 5VDC 24VDC
$495.00 8
MPM-B2152F-SJ72AA
Bulletin 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)
$3,950.00
8.1
2090-CPWM7DF-08AA09
SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters
$425.00
8.2
2090-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
$170.00 9
MPM-B2153F-SJ72AA
$5,040.00
9.1
9.2 10
2090-K6CK-D15M
Connector, Motor Feedback, D-Shell/Term Block, 15 Pin.
$67.60
$270.40 11
2090-K6CK-D44M
Connector Kit, 44 pin, K6200/K6500 I/O, Auxiliary feedback, and safety
$188.00
$752.00
TOTAL:
$38,313.40

21. Deliverable
Ideal Option
Ebay Option
Minimalist
L36ERM Only
Compromise 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

22. 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 $ 2
25-ENC-2
Incremental Encoder Interface for PowerFlex 527
$70.00
$280.00 3
1769-PB4
Power Supply 24VDC Input 5VDC 24VDC
$495.00
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.
$4,770.00 5
IDNM3661T
3HP, 1755RPM, 3PH, 60HZ, 184TC, 0632M, TENV, F1 $ $ 6
IDM3764T
3HP, 1165RPM, 3PH, 60HZ, 215TC, 0737M, TEBC, F1 $ $ 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 $ $ 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
TOTAL:
$25,657.00

23. 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 $ $
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 $ 2
25-ENC-2
Incremental Encoder Interface for PowerFlex 527 4
$70.00
$280.00
1769-PB4
Power Supply 24VDC Input 5VDC 24VDC
$495.00
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.
$4,770.00 5
IDNM3770T
7.5HP, 1760RPM, 3PH, 60HZ, 213TC, 0748M, TENV $ 6
IDNM2238T
10HP, 1770RPM, 3PH, 60HZ, 256TC, 0948M, TENV $ $ 7
IDM2276T
7.5HP, 1180RPM, 3PH, 60HZ, 254TC, 0954M, TEBC $ $ 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 $ 9
H60064LT03CVV $ 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 $
TOTAL:
$40,924.00