1. EE Detailed Design Review

2. Wire Movement Team: Spooling Motors Specification Process

3. Take-up Spool Motor Selection Process: Solid Take-up Inertia: 0.4236 kg-m 2 Full Mass: 102 kg Speed: 2390 rpm

4. Take-up Spool Motor Selection Process: 3 Supply Spool Take-up Inertia: 1.6088 kg-m 2 Full Mass: 157 kg Speed: 1432 rpm

5. Take-up Spool Motor Selection Process: 2 Supply Spool Take-up Inertia: 1.1461 kg-m 2 Full Mass: 110 kg Speed: 1432 rpm

6. Supply Spool Motor Selection Process Inertia: 0.1273 kg-m 2 Full Mass: 26.5 kg Speed: 2450 rpm

7. Guide Roller Team: Roller Motors Specification Process

8. Inertia: 1.03 kg-m 2 (0.9 kg-m 2 ) 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-m 2 (0.9 kg-m 2 ) Friction: 30N-m Full Mass: 65 kg (55.9 kg) Max Speed: 3040 rpm (900 rpm) Nominal Speed: 2149 rpm (716 rpm) Motor Price: ~$4800 + ~$1386 for gearbox Backlash: 14-20 arcminute (0.23-0.33 degrees)

10. Work Piece Movement Team: Linear Actuator Specification Process

11. Work Piece Movement Team: Specification Process Mass: 317.5 kg Force: 3114.7 N Max Mass: 444.5 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. Option 1 (120 V option) ItemProductDescriptionQtyList PriceExt. Price 1EL1405TBaldor EL1405T single phase 1 hp motor 1800 RPM4$557.00$2228.00 2 PPA11-58B65- 18EBXXX Electrak PPA-AC Actuator Thomson 115 VAC @ 50/60Hz, 1 ø 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 A 1$1108.16 TOTAL:$3336.16

15. AC MotorsNon-InverterInverter ReadyInverter Duty VFD CompatibleNoYes CostLow (700-900$)Medium ($1000)High ($1700- 3600) Speed TypeSIngle SpeedSingle SpeedVariable Speed Speed Variabilitynone20:1 max1000:1 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 http://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

16. Options 2 (Microcontroller) ItemProductDescriptionQtyList PriceExt. Price 1TMDSHVMTRPFCKITHigh Voltage Motor Control and PFC Developer's Kit5$712.98$3564.90 2HVPMSMMTRHigh 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 4AU-ZDH0100HShaft 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)

17. Option 3 (Controller Only) ItemProductDescriptionQtyList PriceExt. Price 11769-PB4Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC1$495.00 21769-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 TOTAL:$5,265.00

18. Option 4 (120 V option realistic) ItemProductDescriptionQtyList PriceExt. Price 125B-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$3144.00 225-ENC-2Incremental Encoder Interface for PowerFlex 5274$70.00$280.00 31769-PB4Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC1$495.00 41769-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 5 IDM3667T 1.5HP, 1170 RPM, 3PH, 60HZ, 182TC, 0630M, TEBC2$2294.00$4588.00 6 IDM3584T 1.5HP, 1760 RPM, 3PH, 60HZ, 145TC, 0530M, TEBC2$1837.00$3674.00 7ZUK2500H-NDDigikey Red Lion Encoder with 1.125 inch hollow diameter 2500 PPR2$472.31$944.62 81427-0100-2048Hohner Corporation Encoder 7/8 inch diameter hollow shaft 2048 PPR2$480.00$960.00 TOTAL:$18,855.62

19. Option 5 (Rockwell-Ebay Option) ItemProductDescriptionQtyList PriceExt. Price 1RDB-B21529-3B72AA 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 Brake2$5,280.00$10,560.00 22090-CPWM7DF-16AA15Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, Standard (Non-Flex), 16AWG, 15M2$99.00$198.00 32090-XXNFMF-S09Cable,Feedback,DIN Type 4 Connector,Non-Flex,Flying Lead,9M2$179.00$358.00 42094-BC02-M02-MPower Module, Integrated, 460V, 15kW Conv. 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module1$1,436.00 4.12094-EN02D-M01-S0EtherNet/IP Safe Torque-Off Control Module1$603.00 4.22094-PRS8Power Rail, Slim, 230V OR 460V, 8 Axis.1$290.00 52094-BM02-MPower Module, Axis, 460V, 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module3$653.00$1,959.00 5.12094-EN02D-M01-S0EtherNet/IP Safe Torque-Off Control Module3$517.00$1,551.00 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$2,895.00 71769-PB4Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC1$325.00 8MPM-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)1$2,734.00 8.12090-CPWM7DF-08AA12SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters1$245.00 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 Meters1$67.00 9MPM-B2153F-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)1$2,800.00 9.12090-CPWM7DF-08AA16SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 16 Meters1$245.00 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 Meters1$67.00 102090-K6CK-D15MConnector, Motor Feedback, D-Shell/Term Block, 15 Pin.4$39.00$156.00 112090-K6CK-D44MConnector Kit, 44 pin, K6200/K6500 I/O, Auxiliary feedback, and safety4$168.00$672.00 TOTAL:$27,161.00

20. Option 6 (Rockwell Solution) ItemProductDescriptionQtyList PriceExt. Price 1RDB-B21529-3B72AA 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 Brake2$5,280.00$10,560.00 22090-CPWM7DF-16AA09Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, Standard (Non-Flex), 16AWG, 9M2$167.00$334.00 32090-XXNFMF-S09Cable,Feedback,DIN Type 4 Connector,Non-Flex,Flying Lead,9M2$323.00$646.00 42094-BC02-M02-MPower Module, Integrated, 460V, 15kW Conv. 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module1$2,650.00 4.12094-EN02D-M01-S0EtherNet/IP Safe Torque-Off Control Module1$873.00 4.22094-PRS8Power Rail, Slim, 230V OR 460V, 8 Axis.1$624.00 52094-BM02-MPower Module, Axis, 460V, 15A Inv., Kinetix 6500 EtherNet/IP Safe Torque-Off Control Module3$1,180.00$3,540.00 5.12094-EN02D-M01-S0EtherNet/IP Safe Torque-Off Control Module3$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 71769-PB4Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC1$495.00 8MPM-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)1$3,950.00 8.12090-CPWM7DF-08AA09SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters1$425.00 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 Meters1$170.00 9MPM-B2153F-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)1$5,040.00 9.12090-CPWM7DF-08AA09SpeedTEC Cable, Motor Power Only, SpeedTec DIN Connector, Drive-end, Flying-lead, 8 AWG, Standard (Non-Flex), 9 Meters1$425.00 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 Meters1$170.00 102090-K6CK-D15MConnector, Motor Feedback, D-Shell/Term Block, 15 Pin.4$67.60$270.40 112090-K6CK-D44MConnector Kit, 44 pin, K6200/K6500 I/O, Auxiliary feedback, and safety4$188.00$752.00 TOTAL:$38,313.40

21. Deliverable Ideal OptionEbay OptionMinimalistL36ERM Only Compromise Option Controller 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) ItemProductDescriptionQtyList PriceExt. Price 125B-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$3144.00 225-ENC-2Incremental Encoder Interface for PowerFlex 5274$70.00$280.00 31769-PB4Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC1$495.00 41769-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 5 IDNM3661T 3HP, 1755RPM, 3PH, 60HZ, 184TC, 0632M, TENV, F12$1986.00$3972.00 6 IDM3764T 3HP, 1165RPM, 3PH, 60HZ, 215TC, 0737M, TEBC, F12$3082.00$6164.00 7H62048LT01CVV 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 8H62048LT02CVV 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

23. Option Y (230 VAC Three-Phase) “most expensive” ItemProductDescriptionQtyList PriceExt. Price 125B-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 125B-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$1850.00 225-ENC-2Incremental Encoder Interface for PowerFlex 5274$70.00$280.00 31769-PB4Power Supply 24VDC Input 4A @ 5VDC 2A @ 24VDC1$495.00 41769-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 5IDNM3770T7.5HP, 1760RPM, 3PH, 60HZ, 213TC, 0748M, TENV1$2563.00 6IDNM2238T10HP, 1770RPM, 3PH, 60HZ, 256TC, 0948M, TENV1$3123.00$3213.00 7IDM2276T7.5HP, 1180RPM, 3PH, 60HZ, 254TC, 0954M, TEBC2$5423.00$10846.00 8H62048LT01CVV 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 9H60064LT03CVV 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 10H62048LT02CVV 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