Technology improvement has been speedily sourced to add improvement in professional and making sector. This improvement means a lot to those big companies where improvement such as faster producing rate and lower operating cost means income and loss to the business.
Automations were being unveiled to the world to help improve the efficiency and earnings of new era factories. By using new technology, procedure cost of the commercial can be minimizing.
Automated machine have become a necessity in today world where the machines can operate themselves and produce product that are much appropriate and faster compare to a manual or side art product.
Milling machine is a machining tool that mill or change a solid stop material into components that are then fix into a prototype or something of machine. In the olden days and nights, milling machine are operate personally where there are crank to determine the position of the milling bit. Technology improvement brings integration of computer in to the milling machine in which a computer is linked to motors which controls the positioning of the mill pieces. These integrations of computers bring a new classification of milling machine call Computer numerical control (CNC) milling machine.
There are 2 basic type of milling machine, horizontal and vertical, which identifies the orientation of the main spindle. Unlike drill press which keeps the workpiece stationary as the drill goes axially to penetrate the material, milling machines also move the workpiece radially up against the revolving milling cutter which reduces on its factors as well as its suggestion. Workpiece and cutter movements are specifically controlled
Computer numerical control (CNC) milling machine is a common and far needed tool in commercial trade. These machines can operate themselves and produce a product regularly with almost perfect perfection, compare to olden days where parts are mill manually with bigger selection of problem. This machine can reduce the operator cost and improve efficiency and also reliability to product produce.
In today world once much expensive CNC milling are also becoming a much popular in hobbyist community. With technology improvement and wider knowledge of computing technology, CNC machine can be build with a much lower cost and by a wider range of people.
Objectives
The objective of the project is to make an affordable price table-top CNC vertical milling machine. Also to demonstrate the utilization of Cartesian XY robot movement control concept with stepper motors, threaded pole and nut to execute the machining operation.
Scope of Work
3D CAD software modeling.
CNC movement and device (kinematics calculation)
Fabrication of parts and set up of the mechanical body.
Problem Statement
Cost of the CNC machine components and controllers are costly. It includes hence improve the cost to create a CNC machine.
Normally the CNC controller that's available comes in package deal including controller, servo amplifier and electric motor, etc, and substitute of the parts by third party products (easily obtained on the market) is not possible due to the differences in design and specification.
Besides that, the replacement of the mentioned parts me is very expensive and sometime it is difficult to source.
Propose Solutions
Arduino microcontroller will be utilized in this job which it is inexpensive, light and simple to use. Arduino is rich in function libraries to perform certain action control however it could have slower velocity in execution in accordance with industrial CNC controller.
The parts (electronic, electro-mechanical, and mechanical) that are to be used in this prototype are from the shelf and easily obtain in the market.
The designed parts will be much easier to be fabricated and changed. Also, mechanical parts that are commonly used and sourced in the market will be utilized to lessen the maintenance cost and extra part inventories.
Open source code of the Arduino controller and common components or accessories of the device would be the essential parts of this prototype.
Chapter 2
What Is CNC?
CNC is brief form for Computer Numerical Control and CNC has been around since the early on 1970's. before this, it was called NC, for Numerical Control.
While people generally in most walks of life have never heard about this term, CNC is utilized in almost every form of production process in one way or another. If you ever join the creation sector, it's likely that you will be coping with CNC on a regular basis.
Before CNC
A drill press can of course be utilized to machine openings. A person can place a drill in the drill chuck that is secured in the spindle of the drill press. They are able to then manually choose the desired swiftness for rotation, and trigger the spindle. They manually draw on the quill lever to drive the drill in to the workpiece being machined.
There will be a lot of manual intervention required to use a drill press to drill slots. A person is required to take action nearly every step along the way. While this manual intervention may be appropriate for creation companies if but a small number of slots or workpieces must be machined, as amounts grow, so does the chance for fatigue due to the tediousness of the operation. And do note that we've used one of the simplest machining operations (drilling) for our example. You will find more difficult machining operations that would require a much higher level of skill (and raise the potential for flaws leading to scrap workpieces) of the individual running the conventional machine tool.
Machining center
By contrast, the CNC equal for a drill press can be designed to execute this operation in a more automatic fashion. Exactly what the drill press operator was doing physically will now be done by the CNC machine, including: putting the drill in the spindle, activating the spindle, placing the workpiece under the drill, machining the gap, and turning off the spindle.
How CNC works
As you may curently have guessed, everything that an operator would be required to do with regular machine tools is programmable with CNC machines. Once the machine is set up and running, a CNC machine is fairly simple to keep operating. Actually CNC operators tend to get quite bored during lengthy production runs because there is so little to do. With some CNC machines, even the workpiece loading process can be computerized.
Motion control
All CNC machine types talk about this commonality: They all have several programmable directions of motion called axes. An axis of action can be linear or rotary. One of the first requirements that implies a CNC machine's complexity is just how many axes they have. Generally speaking, the more axes, the more technical the device.
The axes of any CNC machine are necessary for the purpose of causing the movements necessary for the creation process. In the drilling example, these (3) axis would position the tool on the hole to be machined (in two axes) and machine the hole (with the third axis). Axes are called with characters. Common linear axis labels are X, Y, and Z. Common rotary axis brands are A, B, and C.
Programmable accessories
A CNC machine wouldn't be very useful if all it could only move the workpiece in several axes. Virtually all CNC machines are programmable in several other ways. The precise CNC machine type has a lot to do with its appropriate programmable accessories. Again, any required function will be programmable on full-blown CNC machine tools. Below are a few examples for just one machine type.
Machining centers
Automatic tool changer
Most machining centers can hold many tools in a tool publication. When required, the mandatory tool can be automatically located in the spindle for machining.
Spindle rate and activation
The spindle swiftness (in revolutions each and every minute) can be easily given and the spindle can be fired up in a ahead or reverse direction. It can also, of course, be turned off.
Coolant
Many machining operations require coolant for lubrication and cooling purposes. Coolant can be turned on and off from within the device cycle.
The CNC program
A CNC program is only a different type of instruction set. It's written in sentence-like format and the control will do it in sequential order, step by step.
A special group of CNC words are accustomed to communicate what the machine is supposed to do. CNC words commence with notice addresses (like F for feedrate, S for spindle speed, and X, Y & Z for axis motion). When placed together in a reasonable method, several CNC words make up a commandthat resemble a word.
For any given CNC machine type, there is only going to be about 40-50 words applied to a regular basis. So if you compare understanding how to write CNC programs to learning a foreign language having only 50 words, it shouldn't seem extremely difficult to learn CNC encoding.
The CNC control
The CNC control will interpret a CNC program and stimulate the group of orders in sequential order. Since it reads the program, the CNC control will switch on the appropriate machine functions, cause axis motion, and generally, follow the instructions given in this program.
Along with interpreting the CNC program, the CNC control has other purposes. All current model CNC adjustments allow programs to be changed if mistakes are found. The CNC control allows special confirmation functions to confirm the correctness of the CNC program. The CNC control allows certain important operator inputs to be specified separate from this program, like tool length values. In general, the CNC control allows all functions of the device to be manipulated.
Variant of Milling machine.
Bed mill This identifies any milling machine where in fact the spindle is on a pendant that steps up and down to go the cutter into the work, while the table sits on a stout bed that rests on the floor. These are typically more rigid than a knee mill. Gantry mills can be included in this bed mill category.
Box mill or column mill Very basic hobbyist bench-mounted milling machines that include a head riding up and down on a column or box way
C-Frame mill They are larger, industrial production mills. They feature a knee and set spindle mind that is only mobile vertically. They are typically much more powerful than a turret mill, having a separate hydraulic motor unit for integral hydraulic power feeds in all directions, and a twenty to fifty horse power engine. Backlash eliminators are nearly always standard equipment. They use large NMTB 40 or 50 tooling. The dining tables on C-frame mills are usually 18" by 68" or much larger, to allow multiple parts to be machined at exactly the same time.
Floor mill These have a row of rotary furniture, and a horizontal pendant spindle mounted on a couple of tracks that runs parallel to the table row. These mills have mostly been converted to CNC, however, many can still be found (if one can even find a used machine available) under manual control. The spindle carriage moves to every individual table, does the machining operations, and moves to the next table as the previous table is being create for another operation. Unlike other mills, floor mills have movable floor items. A crane drops massive rotary furniture, X-Y dining tables, etc. , into position for machining, allowing large and complicated custom milling functions.
Gantry mill The milling brain rides over two rails (often metallic pipes) which lie at each side of the task surface.
Horizontal boring mill Large, accurate bed horizontal mills that integrate many features from various machine tools. These are predominantly used to build large creation jigs, or to adjust large, high detail parts. They have a spindle heart stroke of several (usually between four and six) feet, and most are prepared with a tailstock to perform very long boring operations without losing exactness as the bore rises in depth. An average bed has X and Y travel, and it is between three and four feet square with a rotary desk or a more substantial rectangle with out a stand. The pendant usually provides between four and eight feet of vertical movements. Some mills have a large (30" or even more) essential facing head. Right position rotary tables and vertical milling attachments are for sale to further flexibility.
Jig borer Vertical mills that are built to bore holes, and very light slot machine or face milling. They are typically foundation mills with an extended spindle put. The beds will be more accurate, and the handwheels are graduated right down to. 0001" for specific hole placement.
Knee mill or knee-and-column mill identifies any milling machine whose x-y desk rides up and down the column on a vertically flexible knee. This consists of Bridgeports.
Planer-style mill Large mills built-in the same settings as planers except with a milling spindle rather than a planing mind. This term keeps growing dated as planers themselves are typically something of the past.
Ram-type mill This can make reference to any mill that has a cutting head installed on a sliding ram. The spindle can be oriented either vertically or horizontally. In practice most mills with rams also entail swiveling ability, if it is called "turret" mounting. The Bridgeport configuration can be categorized as a vertical-head ram-type mill. Van Norman customized in ram-type mills through almost all of the 20th century. Since the wide dissemination of CNC machines, ram-type mills remain made in the Bridgeport settings (with either manual or CNC control), but the less common variants (such as were built by Van Norman, Index, while others) have died out, their work being done now by either Bridgeport-form mills or machining centers.
Turret mill More commonly known as Bridgeport-type milling machines. The spindle can be aligned in a number of positions for an extremely versatile, if somewhat less rigid machine.
Usage of CNC machine
In the steel removal industry:
Machining processes which have customarily been done on standard machine tools are now possible with CNC. This include all kinds of milling face milling, contour milling, slot milling, drilling, tapping, reaming, boring, and counter boring.
In similar fashion, a myriad of turning operations like facing, boring, turning, grooving, knurling, and threading are done on CNC lathe.
Grinding operations of all kinds like outdoor diameter (OD) milling and interior diameter (ID) grinding are also being done on CNC grinders. CNC has even exposed a fresh technology as it pertains to milling. Contour milling (grinding a contour in an identical fashion to turning), that was previously infeasible credited to technology constraints is currently possible with CNC grinders.
In the steel fabrication industry:
In making terms, fabrication commonly refers to functions that are performed on relatively thin plates. Think about a metal processing cabinet. All of the primary components are constructed of steel sheets. These sheets are sheared to size, holes are punched in appropriate places, and the bedding are bent (formed) to their final designs. Again, operations commonly referred to as fabrication functions include shearing, fire or plasma slicing, punching, laser reducing, developing, and welding. Truly, CNC is heavily involved with almost every element of fabrication.
CNC back gages are generally used in combination with shearing machines to regulate the length of the plate being sheared. CNC lasers and CNC plasma cutters are also used to bring plates with their final figures. CNC turret punch presses can hold a variety of punch-and-die combinations and punch holes in every shapes and sizes through plates. CNC press brakes are used to bend the plates to their final designs.
In the electrical discharge machining industry:
Electrical release machining (EDM) is the process of removing metallic through the use of electro-mechanical sparks which burn away the metallic. CNC EDM will come in two forms, vertical EDM and Wire EDM. Vertical EDM requires the use of electrode (commonly machined on the CNC machining middle) that is of the condition of the cavity to be machined into the workpiece. Picture the condition of a vinyl bottle that must definitely be machined into a mold. Wire EDM is commonly used to make punch and perish combinations for dies pieces used in the fabrication industry. EDM is one of the less popular CNC operations since it is so meticulously related to making tooling used with other manufacturing operations.
In the woodworking industry
As in the steel removal industry, CNC machines are heavily found in woodworking shops. Functions include routing (comparable to milling) and drilling. Many woodworking machining centers are available that can take several tools and perform several businesses on the workpiece being machined.
CNC milling using commercial mills
Computer Numerical Control (CNC) Milling is the most common form of CNC. CNC mills is capable of doing the functions of drilling and frequently turning. CNC Mills are grouped based on the amount of axes that they have. Axes are called x and y for horizontal movements, and z for vertical activity, as shown in this view of a manual mill desk. A typical manual light-duty mill (such as a Bridgeport) is normally assumed to possess four axes:
Table x.
Table y.
Table z.
Milling Head z.
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Components of CNC machine
Linear movement
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Ball Bearing Slides
Also called "ball slides", ball bearing slides are the most common kind of linear glide. Ball bearing slides offer easy precision movement along a single-axis linear design, aided by ball bearings housed in the linear platform, with self-lubrication properties that increase dependability. Ball bearing glide applications include delicate instrumentation, robotic set up, cabinetry, high-end devices and clean room conditions, which primarily serve the developing industry but also the furniture, electronics and engineering industries. For instance, a widely used ball bearing glide in the furniture industry is a ball bearing drawer glide.
Commonly made of materials such as light weight aluminum, hardened frigid rolled metal and galvanized metal, ball bearing slides contain two linear rows of ball bearings covered by four rods and located on differing factors of the base, which support the carriage for simple linear movement along the ball bearings. This low-friction linear movement can be power by the drive mechanism, inertia or yourself. Ball bearing slides tend to have a lower load convenience of their size in comparison to other linear slides because the balls are less protected to wear and abrasions. In addition, ball bearing slides are limited by the need to fit into property or drive systems.
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Roller Slides
Also known as crossed roller slides, roller slides are non-motorized linear slides offering low-friction linear movement for equipment power by inertia or by hand. Roller slides are based on linear roller bearings, which are frequently criss-crossed to provide heavier fill capabilities and better movements control. Serving companies such as processing, photonics, medical and telecommunications, roller slides are functional and can be changed to meet numerous applications which typically include clean rooms, vacuum surroundings, materials handling and automation machinery.
Consisting of your stationary linear basic and a moving carriage, roller slides work similarly to ball bearing slides, except that the bearings housed within the carriage are cylinder-shaped instead of ball formed. The rollers crisscross each other at a 90 position and move between your four semi-flat and parallel rods that encompass the rollers. The rollers are between "V" grooved bearing races, one being on the top carriage and the other on the bottom. The travel of the carriage ends when it meets the finish cap, a limiting part. Typically, carriages are made of aluminium and the rods and rollers are made of steel, as the end caps are made of stainless steel.
Although roller slides are not self-cleaning, they are really suitable for conditions with low degrees of airborne impurities such as dirt and dust. As one of the more expensive types of linear slides, roller slides are capable of providing linear movement on several axis through stackable slides and dual carriages. Roller slides offers lines contact versus point contact much like ball bearings, developing a broader contact surface due to the reliability of contact between the carriage and the bottom and resulting in less erosion.
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Plain bearings
Plain bearings are incredibly similar in design to rolling-element bearings, except they glide without the utilization of ball bearings.
Plain bearings can run on hardened metallic or stainless steel shafting (raceways), or can be operate on hard-anodized light weight aluminum or soft steel or aluminum. The precise kind of polymer/fluoro-polymer will determine what hardness is allowed.
Plain bearings are less rigid than rolling-element bearings.
Plain bearings handle contamination well and frequently do not need seals/scrapers.
Plain bearings generally deal with a wider temp range than rolling-element bearings
Plain bearings (plastic material variants) do not require oil or lubrication (often it can be used to increase performance characteristics)
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Dovetail slides
Dovetail slides, or dovetail way slides are typically constructed from cast iron, but can be made of hard-coat aluminum, acetal or stainless. Like any bearing, a dovetail slip is composed of a stationary linear bottom and a moving carriage. a Dovetail carriage has a v-shaped, or dovetail-shaped protruding channel which locks into the linear base's correspondingly shaped groove. Once the dovetail carriage is fixed into its base's channel, the carriage is locked in to the channel's linear axis and allows free linear motion. When a system is attached to the carriage of a dovetail slide, a dovetail desk is established, offering extended insert carrying capacities.
Since dovetail slides have such a big surface contact area, a larger force is required to move the saddle than other linear slides, which results in slower acceleration rates. On top of that, dovetail slides have difficulties with high-friction but are beneficial as it pertains to insert capacity, affordability and longevity. Capable of long travel, dovetail slides are definitely more resistant to surprise than other bearings, and they're mostly immune system to chemical, particles and dirt contaminants. Dovetail slides can be mechanized, mechanical or electromechanical. Electric dovetail slides are influenced by lots of different devices, such as ball screws, belts and cords, which are driven by efficient motors such as stepper motors, linear motors and handwheels. Dovetail slides are immediate contact systems, making them appropriate for heavy weight applications including CNC machines, shuttle devices, special machines and work having devices. Mainly utilized in the making and laboratory knowledge companies, dovetail slides are not well suited for high-precision applications.
Homemade linear slide
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Assembled sliding component Sliding component - bearings and Teflon
http://oneoceankayaks. com/madvac/cnc_images/machine/x_slip_asbly1lg. jpg http://www. cnczone. com/forums/attachment. php?attachmentid=19501&d=1151930380
Stepper motors:
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A stepper motor's shaft has permanet magnets mounted on it. Around your body of the electric motor is some coils that create a magnetic field that interacts with the permanet magnets. When these coils are turned on and from the magnetic field triggers the rotor to go. As the coils are fired up and off in collection the motor unit will rotate forward or invert. This sequence is named the phase structure and there are several types of patterns that may cause the motor to carefully turn. Common types are full-double period, full-single stage, and half step.
To make a stepper motor unit rotate, you must constantly turn on and from the coils. In the event that you simply energize one coil the engine will just hop to that position and stay there resisting change. This energized coil pulls full current even although motor is not turning. The stepper engine will generate a lot of warmth at standstill. The capability to stay put at one position rigidly is often an advantage of stepper motors. The torque at standstill is named the positioning torque.
Because steppers can be manipulated by turning coils on / off, these are easy to regulate using digital circuitry and microcontroller potato chips. The controller simply energizes the coils in a certain routine and the motor will move accordingly. At any given time the computer will know the position of the engine since the quantity of steps given can be tracked. That is true only when some outside push of greater power than the engine hasn't interfered with the motion.
An optical encoder could be mounted on the motor unit to validate its position but steppers are usually used open-loop (without reviews). Most stepper electric motor control systems will have a home switch associated with each motor that will allow the software to look for the starting or reference "home" position.
Servo motors:
There are various kinds servo motors but I'll just offer with a straightforward DC type here. Invest the a standard DC motor that can be bought at Radio Shack it offers one coil (2 cables). If you attach a electric battery to those wires the electric motor will spin. See, very different from a stepper already!. Reversing the polarity will invert the route. Attach that engine to the steering wheel of the robot and watch the robot move noting the rate. Now put in a bulkier payload to the robot, what happens? The robot will slow down because of the increased weight. The computer inside of the robot wouldn't normally know this happened unless there is an encoder on the electric motor keeping track of its position.
So, in a DC electric motor, the speed and current sketch is a influenced by the strain. For applications that the exact position of the motor must be known, a feedback device as an encoder Can be used (not optional such as a stepper).
The control circuitry to execute good servoing of any DC motor is MUCH more technical than the circuitry that control buttons a stepper electric motor.
Comparison between stepper motor and servo motor
Characteristics
Servo Electric motor (DC Brushed
Stepper (Hybrid)
Cost
The cost for a servo motor and servo motor system is greater than that of a stepper electric motor system with identical power score.
This feature would need to go to stepper motors. Steppers are usually cheaper than servo motors that have the same power rating.
Versatility
Servo motors are extremely functional in their use for automation and CNC applications.
Stepper motors are also very functional in their use for automation and CNC applications. For their convenience stepper motors may be found on anything from printers to clocks.
Reliability
it is determined by the environment and how well the electric motor is secured.
The stepper will take this category only since it does not require an encoder which may fail.
Frame Sizes
Servo motors are availible in a multitude of body sizes, from small to large motors capable of jogging huge machines. Lots of the motors come in NEMA standard measured.
Stepper motors do not have as much size selections as servo motors in the large sizes. However stepper motors may be found in a variety of NEMA shape sizes.
Setup Complexity
Servo motors require tuning of the (PID) closed down loop varying circuit to obtain correct motor unit function.
Stepper motors are almost plug-and-play. They require only the motor cables to be wired to the stepper motor driver.
Motor Life
The brushes on servo motors must be replaced every 2000 time of procedure. Also encoders may need replacing.
The bearing on stepper motors will be the only putting on parts. That provides stepper motors hook advantage on life.
Low Rate High Torque
Servo motors will do fine with low rate applications given low friction and the correct gear ratio
Stepper motors provide most torque at low swiftness (RPM).
High acceleration High Torque
Servo motors maintain their graded torque to about 90% of the no fill RPM.
Stepper motors lose up to 80% of the maximum torque at 90% of these maximum RPM.
Repeatability
Servo motors can have very good repeatability if installation appropriately. The encoder quality can also play into repeatability.
Because of the way stepper motors are constructed and operate they may have very good repeatability with little if any tuning required.
Overload Safety
Servo motors may malfunction if overloaded mechanically.
Stepper motors are unlikely to be injuries by mechanised overload.
Power to Weight/Size ratio
Servo motors have a great power to weight proportion given their efficiency.
Stepper motors are less reliable than servo motors which usually means an inferior power to weight/size ratio.
Efficiency
Servo motors are extremely successful. Yielding 80-90% efficiency given light tons.
Stepper motors consume a lot of power given their productivity, much of which is converted to warmth. Stepper motors are usually about 70% reliable but this has some regarding the stepper drivers.
Flexibility in engine resolution
Since the encoder on a servo motor decides the motor quality servos have a wide range of resolutions available.
Stepper motors usually have 1. 8 or 0. 9 degree resolution. However thanks to micro-stepping steppers can obtain higher resolutions. That is up to the driver rather than the motor unit.
Torque to Inertia Ratio
Servo motors are very capable of accelerating loads.
Stepper motors are also with the capacity of accelerating loads however, not as well as servo motors. Stepper motors may stall and skip steps if the motor unit is not powerful enough.
Least Temperature production
Since the current draw of an servo motor unit is proportional to the strain applied, heat development is suprisingly low.
Stepper motors bring excess current no matter load. The excess vitality is dissipated as heat.
Reserve Electric power and Torque
A servo electric motor can supply about 200% of the constant power for brief periods.
Stepper motors do not have reserve electric power. However stepper motors can braking system perfectly.
Noise
Servo motors produce very little noise.
Stepper motors create a slight hum because of the control process. However a high quality driver will decrease the sound level.
Resonance and Vibration
Servo motors do not vibrate or have resonance issues.
Stepper motors vibrate somewhat and have some resonance issues because of the way the stepper motor operates.
Availability
Servo motors are not as readily available to the masses as are stepper motors.
Stepper motors are far easier to find than quality servo motors.
Motor Simplicity
Servo motors are usually more mechanically complex due to their inside parts and the exterior encoders.
Stepper motors are incredibly simple in design with no designed consumable parts.
Direct Drive Capability
Servo motors usually require more gearing ratios due to their high RPM. It's very rare to see a immediate drive servo motor unit setup.
Stepper motors will work fine in immediate drive function. Many people simple use a motor couple and connect the motor shaft directly to the leadscrew or ballscrew.
Power Range
Because servo motors are available in DC and AC servo motors employ a wide power availableness range.
The power supply range for stepper motors is not that of servo motors.
Arduino
Arduino is a popular open-source single-board microcontroller, descendant of the open-source Wiring system, designed to make the procedure of using electronics in multidisciplinary projects more accessible. The hardware contains a simple wide open hardware design for the Arduino plank with an Atmel AVR cpu and on-board input/output support. The software consists of a typical program writing language compiler and the boot loader that runs on the board.
Arduino hardware is programmed utilizing a Wiring-based language (syntax and libraries), similar to C++ with some small simplifications and improvements, and a Processing-based built-in development environment.
Power supply unit
A power source is a tool that supplies electric ability to an electric powered load. The word is most commonly applied to devices that convert one form of electricity to another, though it may also make reference to devices that convert another form of energy (mechanical, chemical substance, solar) to electricity. A regulated ability resource is one that controls the productivity voltage or current to a specific value; the controlled value is organised nearly frequent despite versions in either load current or the voltage supplied by the power supply's power source.
Power items for gadgets can be broadly split into line-frequency (or "conventional") and moving over power equipment. The line-frequency supply is usually a not at all hard design, but it becomes increasingly cumbersome and heavy for high-current equipment because of the need for large mains-frequency transformers and heat-sinked digital regulation circuitry. Regular line-frequency power products are occasionally called "linear, " but that is clearly a misnomer because the transformation from AC voltage to DC is inherently non-linear when the rectifiers feed into capacitive reservoirs. Linear voltage regulators produce governed output voltage by means of an active voltage divider that consumes energy, thus making efficiency low. A switched-mode way to obtain the same rating as a line-frequency resource will be smaller, is usually more efficient, but could be more complex.
A test in 2005 revealed computer power supplies are generally about 70-80% efficient. For just a 75% efficient power to produce 75 W of DC end result it could require 100 W of AC insight and dissipate the rest of the 25 W in high temperature. Higher-quality power items can be over 80% efficient; energy efficient PSU's waste products less energy in temperature, and requires less air flow to cool, and consequently will be quieter.
Converting a ATX power supply
Computer power materials are usually cost cheaper than professional power. ATX power products that may be found accessible at computer store at great deal price, with this we can get a phenomenal lab power supply with huge current outputs, brief circuit protection, and very tight voltage rules.
http://reprap. org/mediawiki/images/thumb/1/10/FAQ-ATX-to-Lab-PSU-1. jpg/180px-FAQ-ATX-to-Lab-PSU-1. jpg
Steps
Unplug the energy cord from the trunk of the computer. "Harvest" a power from your personal computer by checking the truth of the computer, locating the gray box that is the power supply unit, tracing the wires from the energy source to the boards and devices and disconnecting all the cables by unplugging them.
Remove the screws (typically 4) that connect the power source to the computer case and remove the power supply.
Cut off of the connectors (leave a few inches wide of wire on the connectors so as to use them down the road for other projects).
Discharge the energy supply by stripping the insulation of the ends of the dark-colored and a red line and connecting them mutually.
Get all the parts that you'll require together, like the pursuing: binding posts (terminals), a LED with an ongoing limiting resistor, a transition, a vitality resistor (10 ohm, 10W or increased wattage), and high temperature shrink tubes.
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Open up the power supply unit by removing the screws connecting the top and underneath of the PSU circumstance.
Bundle cables of the same colors collectively. IMPORTANT: Make sure that the lone brownish sense cable is bundled with the orange line. If the brownish wire is tied to 3. 3V, the energy resource will produce an output.
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The color code for the wires is: Red = +5V, Black color = 0V, Yellow = +12V, Blue = -12V, Brown = Sense (tie to 3. 3V), Orange = +3. 3V, Crimson = +5V Standby (not used), Gray = electricity is on, and Green = Convert DC on.
Drill holes in a free of charge area of the power supply case by marking the guts of the holes with a nail and a touch from the hammer. Work with a dremel to drill the starting holes accompanied by a hands reamer to enlarge the openings till they will be the right size by test fitted the binding content. Also drill openings for the power ON LED and a On / off switch.
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Screw the binding articles into their corresponding holes and attach the nut on the back.
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Connect all the pieces together.
Connect one of the red wire connections to the power resistor, all the remaining red wires to the red binding content;
connect one of the dark-colored wire connections to the other end of the energy resistor, one black cable to a resistor (330 ohm) attached anode of the LED, one black line to the DC-On transition, all the remaining black wiring to the dark binding post;
connect the white to the -5V binding post, yellow to the +12V binding post, the blue to the -12V binding post, the grey to the cathode of the LED;
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connect the renewable line to the other terminal on the change; and attach the orange wiring with the dark brown.
Make sure that the soldered ends are insulated in heatshrink tubing.
Organize the wires with a whole lot of electrical power tape.
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Make sure all the relationships look good. Put a drop of superglue to keep the Resulted in its hole. Position the cover on.
Plug in the IEC cord into the back again and into an AC socket. Switch on the main activate the PSU. Check to see if the LED light comes on. If it hasn't, then switch on by flipping the swap that you had placed on the front. Plug in a 12V bulb into different sockets to see if the PSU functioned, also check with an electronic voltmeter. It should look good and work like a dream!
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Things that are needed
An obsolete computer with an ATX 250W, 300W or 400W power.
Wire cutters, needle nose pliers, drill, reamer, soldering cable, soldering iron, electric tape, warmth shrink tubing
Binding content for result terminals, LED, current limiting resistor for the LED, electric power resistor to load the power supply, a minimal wattage turn.
o prevent the inevitable trip over loose wiring, it's a good idea to make your wiring more everlasting after you have confirmed the power resource (PSU) to work. That is one way of doing so.
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Design features.
A big remove switch for quick access.
The fan upon this 250w PSU is very peaceful, so a LED was added to show electric power on.
Unused wires are spared and stored in a box privately, if they're to be utilized later. In the event that you know you don't want them, you can slice them off to make it even neater, remember to insulate the ends to avoid short circuits.
Easy link with the reprap by the initial molex connector.
A cable tie supports the molex connector to avoid ripping wires when unplugging.
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Wiring
Power to ground transforms the PSU on, and off.
The slice to the 12v series will turn the power off a few insignificant milliseconds faster as some demand is performed in the capacitors of the PSU. But if you don't have a dual / surface switch you really want to work with, you can equally well leave the 12v brand be.
female molex connector on the PSU can be used immediately for easy interconnection on / off.
Add a vacation safe wire connector, so if you do trip you will not destroy the consumer electronics.
Make several switches and connectors which means you can connect more machines to 1 PSU.
Chapter 3
Research
Research is an essential process it must be achieved before we can check out the next process. In this technique, what I will do is, I'll execute a research on the part and material that had a need to complete this task and list down all the possible things I needed such as, motors, linear drive, linear motion axis, bearing materials used. I tried to do as much research on the topic as I could so within the next step so that I could choose what I must say i needed to do.
Literature Review
In this section I will do a further research and also the books review on every materials and parts, and list down advantages and disadvantages. By that I am going to understand all the characteristic of the materials and parts, therefore i can choose the the most suitable materials and parts for my task, this will help me reduce the cost of the job and create a good project. Besides that process did help me design the prototype effectively and making the right decision. Doing so it help me gain some knowledge on other field that normally lecturer cannot show in school such as, electric and electric, PLC control and machining parts.
Planning
Planning is a very important process; planning means time management, with a great time management only we can complete the project promptly. After get all the information and reviews now we can make a plan that are able to complete the job by given time period. Once selected the machine and program, must plan forward such as, time had a need to review and understand the system and program.
Conceptual design
After all the process of planning, now is the time to execute a conceptual design, this is a sketch and idea of a prototype that sketch by not using professional software. The sketch must be get prior to the real design of the prototype; this is to reduce failure probability. This only required a draft sketch of the fundamental shape. Though it is just a sketch but the scale of all the desired parts must be accurate, all the parts must maintain appropriate position and it must be clear and easy to understand. When come to you see, the design, conceptual designs help a great deal, It provide a guide steps to make a good genuine design, so the design will not be out of condition. There are many types of tools that can draw a much better design, AutoCad software and Solidwork. . The benefits of using that software are the design may easily adjust, it can test the materials stress and strain. This is a major issue on planning. After all of the parts are set up in the software it is clearer and better understands the prototype. In the look the sizing of the prototype must be evidently stated and all the parts must be signed up with accordingly.
Material selection
Material selection is important when come to fabricating the prototype, in order to get a high reliability of the merchandise the correct materials selection is a must. Alternatively choosing the incorrect material it'll lead to failing of the product. Some materials will flex when are scheduled to stress. The materials choose have to be low cost and dosage not burden us. Therefore a further research and get information on material selection before check out the fabrication process. Material properties and characteristic must also be looked at before choosing it.
Fabrication
Once the material selection is performed, it come to the fabrication process, this is actually the most time consuming process, it require us to visit workshop to do all the machining to all the material we've bought such as, milling, turning, drilling, slicing and grinding. A proper planning must be made before we can fabricate our materials, without it we will finish up failure, once failed, we need to redo the workpiece and it cost money. It also require some routine knowledge of machining. There should be safeness precaution when doing this technique such as, using a goggle during handling the workpiece.
Assembly
After all the parts are fabricated and check the parts proportions. It finally come to the previous process which is assemblage, in this technique we become a member of all the parts along by using bolt and nut, screw, welding and so on. The circuit panel is located on the right location and all the wiring is connected. All the pneumatic valves can be found accordingly to the genuine designs that recently draw on the program. Lastly check all the component locate on the right location and hook up all the parts along and make sure the power supply connected to the prototype.
Testing
Ensure all the parts are linked accordingly; the test run must be made for few times. In case the prototype does not encounter any problems or problems the task is accomplished. Once it encounters any mistake or malfunctions troubleshooting are needed.
Troubleshooting
If the evaluation shows errors or a negative result that's not our desire results, troubleshooting must be produced in order to solve the problems. Troubleshooting method such as checking out the bond or wiring if they're fully linked, all the parts are positioned on the location accordingly to the look, and lastly check this program if there are any problems. After the checking, the prototype is run again and observe if the results is desire they project is known as completed.
