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docs/electronics/End Stops.md deleted 100644 → 0
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# Home
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docs/electronics/Sensors.md
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# Home
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# Special Feature Of CNC Machines
## Introduction:
---
A process monitoring **Sensor** groups, expertise library, and neural network to automatically determine and correct process parameters such as cutting speed, depth and rate. Certainly, intelligent CNC machines also have motion control units that include **position sensors, rotary encoders, proximity switches, current sensors and pressure sensors** to work with process monitoring sensor group and achieve powerful function
## list of sensors and actuators can be used in a CNC machine:
---
### Proximity Sensor :
In the latest CNC machining centers, **Inductive sensors** are the components of choice for monitoring the motor spindle clamping process. Integrated into the spindle, they must be exceptionally small and offer high repeatability to ensure smooth tool changing at all times.
- One example is the inductive proximity sensor **IFRM 03** with a diameter of only 3 mm. It is available in various lengths starting at a mere 12 mm.
- another one is **TL-W3MB1** Inductive Proximity Sensor, TL-W Series, Flat, 3mm, PNP, 10 V to 30 V.
### Vibration Sensor:
A MEMS sensor has been installed on a CNC machine with *Fanuc controller* to measure vibrations for maintenance purposes. **PulseNG** is a permanently installed diagnostic tool. After the installation of the sensor, **it will be connected to the IBU-NG interface**, which is housing of the electronic board via cable that will later be connected to the PLC controller of the machine to work simultaneously.
- The piezo sensor **Maropass VA-3D** measures the accelerations of up to three axes.
### RTDs (Resistance Temperature Detectors):
Among different types of temparature sensors, RTDs detect temperature of the work-piece and cutting tools so as to realize thermal shielding in order to reduce thermal deformation.
### Angle Encoder:
Angle encoders measure the rotational relationship between two parts with extreme precision, typically of an accuracy better than ±10″ (arcseconds). These extreme levels of precision make angle encoders important in the development of multi-axis centers.
- **HEIDENHAIN** offers angle encoders with accuracy down to ± .04″ (arcseconds).
### Rotary Encoders :
While angle encoders excel at positioning, rotary encoders are often more suited for speed control. In the machine tool industry, this makes them ideal for monitoring spindle rotation per minute (RPM)
- **Mechanical rotary encoders** are common mainly because they are so **cheap and easy** to implement. However, the necessity of metal components coming into contact with each other at **rapid speeds will inevitably result in mechanical wear**.
- **optical rotary encoders** is that they are highly versatile and customizable However, the components of optical rotary encoders are a bit **fragile**, making them **unsuitable for highly rugged applications**
- **Magnetic encoders** are exceptionally suitable for tracking the speed of rotating shafts and disks. However, they cannot be used to generate data for absolute positioning. This severely limits the use cases for a magnetic encoder.
All of these cases, a rotary encoder is typically more suitable as a means for speed control. Control of spindle rotation plays many critical roles, such as in optimizing the machining process with due consideration of energy consumption and tool wear.
## Limitations:
In CNC machine monitoring case study, variety of conditions such as good/bad, wear or no wear, trend of wear of machine components, ball screws, linear guides, spindle, bearing etc. dedicated to the tool crashes.
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docs/electronics/Stepper Drivers.md
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# Stepper Motor Drivers
---
### What is a Stepper Motor Driver?
# Home
## Introduction
---
- A stepper driver is an electronic device which changes the current into the pulse.
- It actually does nothing on its own, it needs to be used with a controller.
- The basic function of a stepper driver is to drive the motor.
Stepper motor drivers are specifically designed to drive stepper motors, which are capable of continuous rotation with precise position control, even without a feedback system. The usual stepper motor drivers offer adjustable current control and multiple step resolutions, and they feature built-in translators that allow a stepper motor to be controlled with simple step and direction inputs. These modules are generally basic carrier boards for a variety of stepper motor driver ICs that offer low-level interfaces like inputs for directly initiating each step.
### Why a Stepper Motor Driver is needed?
## Types of Stepper Drivers
---
There are different types of stepper motor drivers. Here are the three main versions that you will come across-
- **L/R Stepper Motor Driver** : This type of stepper motor driver carried out rotations at a low to medium speed and this can result in fairly limited ranges of power output. They can still offer a full rotation but they don’t usually offer control in regards to variable current levels.
- **Chopper Stepper Motor Driver – Micro-step** : These types of stepper motor drivers are able to use a micro step mode. This means that it runs smoother and more efficiently as the current rate is regulated at all speeds. It works on a solitary supply of high voltage and has output transistors that have come on and off automatically.
- **Bi-level Stepper Motor Driver**:
The third type of stepper motor driver is the bi-level and this can use both high and low-level voltages. It works by powering up to a high rate of current and when it reaches the level that you need, the high voltage is turned off. The low voltage is then used to maintain this level of supply when it is in use.
- The voltage and the current required by the motor are not from the controller.
- The stepper driver could transform the movement instructions into the sequences.
- The sequences will be fed into the winding of unipolar step motor to make the motor run.
### Types of Stepper Motor Drivers:
### Specifying stepper drives :
---
### 1. Digital Stepper Driver:
- select a stepper with at least twice as much torque as required at the target operating speed, and use a motor rated at about ¼ supply voltage.
- The driver should output at least 1.4 times the motor's rated current. Choose a driver that has several step resolutions to test different microstepping settings to get the smoothest motion. Finally, make sure the driver can receive enough step pulses to rotate your motor at the desired speed. Sometimes drivers are limited to something small like 10 kHz. If you're hoping to microstep even at **8× with a 1.8° stepper**, your maximum revolutions per sec speed is **10,000/(8 × 200) = 6.25 rps**.
- To make a stepper motor run, we need to use possibly a A4988 or possibly a DRV8825 or possibly a Trinamic TMC2130.
### Best CNC Stepper Motor Drivers for Every CNC Application:
---
> These drivers are implemented using the most modern technology. They are easy to use and can be used for driving 2-phase or 4-phase motors. Some digital stepper drivers can work with a voltage of 24 - 70 V DC, and their maximum current can reach up to 10 A. And a DIP switch can be used to set the required current and micro-steps resolution.
Here are the best Stepper Drivers available today [2021] for CNC applications:
- **SongHe DRV8825 Stepper Motor Driver** **(Recommended)** : This CNC motor controller can run a 1.5 A NEMA 17 motor reasonably well and obviously any stepper motor that's smaller than that. While the A4988 can do up to 1/16 microstepping, the DRV8825 can do up to 1/32 microstepping, making the motor movement smoother. The Songhe DRV8825 ships with aluminium heat sinks included.
Adjusting the current from the driver in DRV8825 is very similar to that of the A4988, by doing a potentiometer adjustment.
- **StepperOnline DM542T Stepper Motor Driver** : This stepper driver can power almost any NEMA 17 and NEMA 23 motor, except probably the high torque NEMA 23 with 4.2A. the driver an excellent choice for almost any GRBL based DIY CNC project, including the large 8' x 4' frames. The heat sinking and cooling on this motor is excellent. It is a very silent driver and it doesn't sweat even when you hit 4A.
Some of the ímportant features of the digital stepper drivers are:
- Anti-resonance.
- The motor movement will become smooth.
- Low heat and noise.
- Support multi-axis control.
- The micro-step resolution is selectable.
- Support over-current protection and over-voltage protection.
- **GECKO G540 4-AXIS Stepper Motor Driver**: One important difference between the G540 and the other steppers is that it is run on Mach3/4 and LinuxCNC instead of GRBL and operates via a parallel port to connect to the CNC controller.
### Other Commercial Stepper Drivers
### 2. Analog Stepper Driver:
---
> These drivers may use THB7128 IC and can provide a micro-step resolution as much as 25,600 steps per rev.
one of these has the potentiality to suit our needs:
- **ULN2003 Driver Board** : a great choice for someone looking for a driver that is less phase specific.
- **DevMo Stepper Motor Driver** : a great choice for anyone concerned about the heat levels produced from their 3D printer. The driver operates at 4.75 Volts and 28 DC. The Devo model runs at a temperature of 70 degrees.
- **Bolsen Stepper Driver** : A Voltage of 35 with 2A output drive capacity, great choice for someone with a single-phase 3D printer.
- **ARCELI A4988 Compatible Stepper** : the best model to use if you’re looking to make your machine faster in speed. It is compatible with multiple 3D printer voltages, ranging from 6V to 36V 2.5A.
- **SMAKN TB6600 Upgraded Version** : A phase flow driver that is H-bridge bipolar constant. A maximum output current of 4.0A. The driver can be made to produce an output current of 8.0 A. The power supply chip version comes with a five-year warranty.
- **SparkFun EasyDriver** : you’re looking for a driver with many adjustabilities but no real mechanism for heat control.
- **Gikfun EasyDriver Shield Stepper Motor Driver for Arduino** : It is compatible with multiple stepper motors that come on a variety of voltage. Any four, six, and eight stepper motors should be able to use this driver. It is an A3967 micro-stepping driver
- **HobbyPower Stepstick 4-layer DRV8825** : the best choice for those looking for the **most micro-step resolutions** for their 3D printer.It is known for being well suited for those who like to build their 3D printers or have other do-it-yourself inclination.
Some of the ímportant features of the analog stepper drivers are:
- **DaFuRui 5-piece A4988 Stepstick Driver** : A translator is built into the complete micro-stepping motor driver frame that allows for the stepper motor’s easy operation. A great option if you want a driver that’ll fit in more than just your 3D printer.
- The output current is selectable.
- The micro-step resolution is selectable.
- H-bridge bipolar steady current driving.
- The signal input and output are isolated.
- The single pulse interface uses standard common anode.
- Off-line protection available.
- Semi-closed housing for the rough working condition.
- Automatic semi-flow lock available.
- **BIGTREETECH Direct TMC2209 UART driver** : a high tech motor drive that comes with a lot of extra mechanisms and most expensive one.
- **Tongbay TMC2208 V3.0 Stepper Motor Driver** : A single UART wire that is used for advanced configurations. It is a more high tech motor with lots of extra advancements.
docs/machines/3DPrinter/Step by Step Assembly.md
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......@@ -4,18 +4,8 @@ The build instructions below are divided into two parts, namely pre-assembly and
## Pre-Assembly
### 1. Frame Pre-assembly
Parts required:
1. Left Side Frame (1)
1. 500mm 3030 profile (2)
2. 340mm 3030 profile (3)
3. L bracket (6) with (2) set screws each
2. Right Side Frame (1)
1. 500mm 3030 profile (2)
2. 340mm 3030 profile (3)
3. L bracket (6) with (2) set screws each
### 2. Y-axis Left Pre-assembly (1)
### 1. Y-axis Left Pre-assembly (1)
Parts required:
1. XY Idler Assembly Left (1)
1. Printed XY Idler - Left (1)
......@@ -35,7 +25,7 @@ The build instructions below are divided into two parts, namely pre-assembly and
3. 10mm dia 340mm long Smooth Rod (1)
4. LMW10U Bearing (1)
#### 2.1 Subassembly - XY Idler Left
#### 1.1 Subassembly - XY Idler Left
Parts required:
1. XY Idler Assembly Left (1)
......@@ -114,7 +104,7 @@ The build instructions below are divided into two parts, namely pre-assembly and
| <img src="pictures/yaxis_l_xyidler_b006.jpg" width="350" /> | <img src="pictures/yaxis_l_xyidler_c011.PNG" width="320" /> |
---
#### 2.2 Subassembly - XY Stepper Motor Left
#### 1.2 Subassembly - XY Stepper Left
Parts required:
1. Printed Stepper Motor Bracket - Left (1)
......@@ -134,11 +124,12 @@ The build instructions below are divided into two parts, namely pre-assembly and
<img src="pictures/yaxis_l_xystepper_cev.PNG" />
### 2. Y-axis Right Pre-assembly (1)
Repeat the same process as in Y-axis pre-aassembly Left. The XY Idler Right and XY Stepper Right are mirrored versions of the XY Idler Left and XY Stepper Left.
----
1. Build Platform Pre-assembly
### 3. Build Platform Pre-assembly
1. 2020 Profile 335mm long (2)
2. 2020 Profile 140mm long (2)
3. Corner Brackets 2020 (4)
......@@ -161,33 +152,19 @@ The build instructions below are divided into two parts, namely pre-assembly and
4. M3 Hand Tightening Nuts (1)
2. Z axis bottom mount A (2)
1. M3x25 Bolts (1)
2. M3 Nut (1)
3. M5x10 Bolts (2)
4. M5 Hammernut (2)
3. Z axis bottom mount B (2)
1. M3x25mm Bolt (1)
2. M3 Nut (1)
3. M5x10 Bolts (2)
4. M5 Hammernut (2)
4. Z-axis top mount A (2)
1. M3x25mm bolt (1)
2. M3 Nut (1)
3. M5x10 Bolts (2)
4. M5 Hammernut (2)
5. Z-axis top mount B (2)
1. M3x25mm bolt (1)
2. M3 Nut (1)
3. M5x10 Bolts (2)
4. M5 Hammernut (2)
1. Z-axis lower mount (2)
1. M3x25 Bolts (2)
2. M3 Nut (2)
3. M5x10 Bolts (4)
4. M5 Hammernut (4)
2. Z-axis upper mount (2)
1. M3x25mm bolt (2)
2. M3 Nut (2)
3. M5x10 Bolts (4)
4. M5 Hammernut (4)
6. Y-Carriage Pre-assembly (2)
3. Y-Carriage Pre-assembly (2)
1. Y-Carriage Printed Part (1)
2. M3 Heatset Insert (4)
3. M3 Nut (4)
......@@ -196,25 +173,26 @@ The build instructions below are divided into two parts, namely pre-assembly and
6. GT2 20T Teethed 3mm Bore Smooth Idler Pulley (1)
7. X-End Stop Flag (1)
7. X-carriage Pre-assembly (1)
5. X-carriage Pre-assembly (1)
8. Printed X-Carriage (1)
9. M3 Heatset Insert (10)
10. M3x14mm Bolt (4)
11. 3mm dia 12mm long Dowel Pins (4)
12. LM8UU Bearing (3)
8. Extruder Mount Pre-Assembly (1)
6. Extruder Mount Pre-Assembly (1)
1. Printed Extruder Mount (1)
1. M3 Heatset insert (2)
2. M3 nut (2)
1. M3 nut (4)
1. Insert 2 nuts for extruder motor mount
2. Insert 2 nuts for retainer bracket mount
2. X-axis Endstop Assembly (1)
1. Printed X-endstop holder (1)
2. Mechanical Endstop (1)
3. 26G Wire 4cm long (2)
2. Mechanical micro-endstop switch (1)
3. 26G/24G Wire 4cm long (2)
4. 2pin JST-XT Female Connector (1)
3. M3x6mm bolt (1)
9. Exhaust Housing Preassembly (1)
7. Exhaust Housing Preassembly (1)
13. Exhaust Housing (1)
1. M3 Heatset insert (7)
2. PTFE Tube Through Connector (1)
......@@ -226,9 +204,9 @@ The build instructions below are divided into two parts, namely pre-assembly and
17. Filters (5)
18. Exhaust Rear Cover (1)
10. Dual Z Mount Pulley Pre-assembly
8. Dual Z Mount Pulley Pre-assembly
11. Power Supply Unit (PSU) Pre-Assembly (1)
9. Power Supply Unit (PSU) Pre-Assembly (1)
1. Meanwell 350W PSU (1)
2. PSU Back Cover (1)
3. PSU Front Cover (2)
......@@ -239,40 +217,49 @@ The build instructions below are divided into two parts, namely pre-assembly and
8. Power Switch (1)
9. M3x8mm bolt (2)
12. Electronics Assembly
1. Controller Board
10. Electronics Assembly
1. MKS Sbase v1.3 Controller Board
1. M3x10mm bolt (4)
2. 24-12V Step Down Converter
1. M3x6mm bolt (2)
3. LCD Controller
1. M3x8mm bolt (2)
13. Door Hinges (3)
11. Door Hinges (3)
1. Hinge Inner (1)
2. Hinge Outer (1)
3. M3 Nut (1)
4. M3x30mm Bolt (1)
14. Y-axis EndStop Assembly
12. Y-axis EndStop Assembly
1. Mechanical Endstop
2. Endstop holder
3. Endstop top cover
4. M3x8mm bolt (1)
15. X-Y Cable chain assembly
13. X-Y Cable chain assembly
16. LCD Display with casing assembly
1. RepRap Full Discount Display
14. LCD Display with casing assembly
1. MKS TFT32 Display
2. LCD Bottom Cover
3. LCD Top Cover
4. M3 bolts
5. 10Pin 50cm long flat ribbon cable (2)
5. 8Pin 50cm long flat ribbon cable (2)
----
## Final Assembly
1. Frame
1. Preasembled Left side frame
2. Preassembled Right side Frame
Parts required:
1. Left Side Frame (1)
1. 500mm 3030 profile (2)
2. 340mm 3030 profile (3)
3. L bracket (6) with (2) set screws each
2. Right Side Frame (1)
1. 500mm 3030 profile (2)
2. 340mm 3030 profile (3)
3. L bracket (6) with (2) set screws each
3. Left side to right side connection
1. 3030 profile 340mm (4)
2. L bracket (8) with (2) set screws each
......@@ -281,26 +268,23 @@ The build instructions below are divided into two parts, namely pre-assembly and
1. M6x10mm Bolt (2)
2. M6 Hammer nut (2)
2. Z-axis bottom mounts installation (4)
1. M5x10mm Bolt (2)
2. M5 Hammernut (2)
2. Z-axis upper mounts installation (2)
1. M5x10mm Bolt (4)
2. M5 Hammernut (4)
3. Z-axis top mounts installation (4)
1. M5x10mm bolt (2)
2. M5 Hammernut (2)
3. Z-axis lower mounts installation (2)
1. M5x10mm bolt (4)
2. M5 Hammernut (4)
4. 10mm rods insertion in Z axis lower mounts
1. 10mm smooth rod (4)
4. 8mm rods insertion in Z axis lower mounts
1. 8mm smooth rod (4)
5. Build Platform Installation (1)
1. Heatbed (1)
1. 3mm MK3 Heat Bed (1)
2. M3x40mm bolt (4)
3. M3 Knurled Nut (4)
4. Silicon Power Wires 1.5mm2 (2)
5. NTC Thermistor (1)
6. Kapton Tape
7. Insulation Layer (1)
8. 3mm Borosilicate Glass Plate (1)
9. Bulldog Clip (4)
......
docs/mechanics/Belts and Pulleys.md
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# Motion Systems
There are various mechanisms used for transmitting the motion on the X,Y and Z axes. Some of the most commonly used types are:
1) Rollers (Delrin wheels, metal rollers, bearings etc) rolling either on or within a straight or profiled extrusion (V-Rails)
a. Delrin wheels rolling within the V-slot grooves of a Aluminium V-slot extrusion profile. These are most commonly used in budget DIY 3D printers, since they are ideally suited for low load applications.
- Pros:
- Ease of build and assembly
- Robust and reliable
- Com
- Cons:
- Not as smooth as linear rails
- The Delrin coating on wheel wears away with time
1. Rollers (Delrin wheels, metal rollers, bearings etc) rolling either on or within a straight or profiled extrusion (V-Rails)
- Delrin wheels rolling within the V-slot grooves of a Aluminium V-slot extrusion profile. These are most commonly used in budget DIY 3D printers, since they are ideally suited for low load applications.
- Pros:
- Ease of build and assembly
- Robust and reliable
- Cons:
- Not as smooth as linear rails
- The Delrin coating on wheel wears away with time
2) Linear rods with linear bearings or simply bronze bushings
3) Timing Belts are toothed rubber belts reinforced with fibres within the matrix that provide the belts their strength and touchness. Timing belts require matching toothed and idler pulleys for motion.
4) A linear rail consists of a stiff, steel rail, along which a carriage slide. Most commonly, the carriage contains recirculating ball bearings that provide contact points between the carriage and the rail, as depicted above. This enables a smooth sliding motion as the balls roll between the surfaces. The shape of the shaft enables the carriage to stay locked on with tight tolerances, restricting the motion to strictly linear directions.
2. Linear rods with linear bearings or simply bronze bushings
3. Timing Belts are toothed rubber belts reinforced with fibres within the matrix that provide the belts their strength and touchness. Timing belts require matching toothed and idler pulleys for motion.
4. A linear rail consists of a stiff, steel rail, along which a carriage slide. Most commonly, the carriage contains recirculating ball bearings that provide contact points between the carriage and the rail, as depicted above. This enables a smooth sliding motion as the balls roll between the surfaces. The shape of the shaft enables the carriage to stay locked on with tight tolerances, restricting the motion to strictly linear directions.
https://i.all3dp.com/cdn-cgi/image/fit=cover,w=1000,gravity=0.5x0.5,format=auto/wp-content/uploads/2019/05/22192229/a-cut-away-depiction-of-a-linear-rail-and-its-rec-linear-motion-tips-190518_download.jpg
a. Pros:
i. High stiffness in all directions other than motion direction
ii. High precision > Reduced play and binding
iii. Easy Mounting
b. Cons:
i. Fragile i.e. dropping the carriage can result in loss of the recirculating balls causing damage – so must be handled with care
ii. 2 to 3 times more expensive than linear bearings solution
- Pros:
- High stiffness in all directions other than motion direction
- High precision > Reduced play and binding
- Easy Mounting
- Cons:
- Fragile i.e. dropping the carriage can result in loss of the recirculating balls causing damage – so must be handled with care
- 2 to 3 times more expensive than linear bearings solution
5) Acme Screw with nut block
6) Ball Screw with nut block
1. Acme Screw with nut block
2. Ball Screw with nut block
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