CNC Torch Table 2/Research Development: Difference between revisions

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=Prototype 2=


=Progress / To Do=
==Videos==
This link goes to a youtube playlist on the OSE CNC Torch Table:
http://www.youtube.com/watch?v=LbqqGMtm6BY&list=PL2C1A547A8A20653F


My (Dan Benamy's) understanding as of Oct 2013 is that there were various [[Stepper Motor Driver]]s being considered. We have an (inactive) project to develop an OSE driver called [[CoolRAMPS]]. The fallback was to use the [[Steppernug]] open source stepper motor driver. The folks behind it are amazing and we love open source. It's not clear to me (Dan), if the [[Steppernug]] is quite ready. For the short term I'd like to try to get the version 2 table up and running with the [[RAMPS]] system so we can get something working and build momentum. Then we can quickly iterate to version 3 where we switch to the [[Steppernug]] which will allow us to cut faster.
This link goes to videos on the assembly instructions (in progress)
http://www.youtube.com/watch?v=VzjvJEHHRcI&list=PLCBC578BE5586F1D1


Lots of info on the control systems at [[CNC Torch Table 2/Control Overview]].
==Frame and Mechanical Assembly==
[http://opensourceecology.org/w/images/7/79/CNC_Torch_Table_-_Sketchup_Model.zip Sketchup model]
[http://opensourceecology.org/w/images/d/d1/Creation_Flame_CNC_Torch_Table_Drawings.zip Dxf files (incomplete)]
[solidworks assembly]


My (Dan's) plan/suggestion as of Oct 2013 would be to try getting the torch table 2 up and running with librecad, dxf2gocde, unknown [[GcodeCommunications | software to send gcode to the]] grbl firmware running on an arduino with RAMPS 1.4 (including pololo). I'd do it all open loop (no sensors) for starters.
==Electronics==


I'd do it something like this:
===Arduino instructions===
* Order and add a few missing springs and screw to the FeF torch table and mount all the motors.
[http://arduino.cc/en/Main/ArduinoBoardLeonardo Arduino Leonardo]
* Put some wd-40 or other oil in the moving parts so it slides easily.
[http://arduino.cc/en/Main/ArduinoBoardUno Arduino Uno]
* Wire up the motors to the arduino/RAMPS board we have and run the test ramps code to ensure it's all wired up right.
* Attach a sharpie to the tool head and put poster board or similar on the bed for initial testing.
* Load grbl onto the arduino and do any needed configuration.
* Draw a rectangle in librecad, run it through [[DXF to G-code Conversion Tutorial | dxf2gcode]] and use a TBD tool to stream it to grbl. Get the table to draw the rectangle.


Then I'd do incremental improvements, keeping the table working after each step so if I had to leave or something didn't work, it'd be easy to revert to the most recent working stuff:
===Stepper Motors===
* Add a circle to the dxf that's not touching the rectangle. Re-run and make sure the head lifts up between the shapes.
Power supply: Maybe one or two recycled computer supplies can be used drive it. If 24V is needed, connect output in serial. On some PSU
* Add [[DXF_to_G-code_Conversion_Tutorial#Piercing | gcode postprocessing]] if still needed for piercing and torch width. The "torch" should move back and forth while making an initial "pierce". For the circle, I think it should make the pieces inside the circle. I'm not sure if it should pierce the rectangle inside or on one edge. We want it to make the pierce in a part of the metal we won't use. I wonder how the piercing code knows what that is... There's a conversation [https://groups.google.com/forum/#!msg/dxf2gcode-dev/6ZnNcX3O5i4/d-3NeBfHpbUJ here] about integrating this functionality into dxf2gcode which would be great for ease of use and gives us a gui where maybe we could click where we want the pierce to be.
it is easy to adjust output voltage a bit. --[[User:Jth|Jth]] 19:07, 25 July 2012 (CEST)
* Try it with the real torch!!! For future steps, I'd switch back to the sharpie for testing and only use the torch once things look good.
* Computer control of the torch since the ratio of fuel to oxygen should change for piercing vs cutting.
* Endstops.
* More powerful [[stepper drivers]] to allow faster movement (and use more open hardware).
* Height sensing to automatically deal with different thickness material and maybe uneven material.
* Rebuild the table using as many [[Warehouse]] parts as possible.
* There was a comment that said "[[Height Controller]] for oxyacetylene and plasma torches". I don't know what that means.


==Developement Board==
<gallery perrow=6>
<html><iframe width=80% height='500' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0Av4ZjQn4DHJHdDBNVmlFTmZ5S3YxckY3ZkxZc01ISHc&output=html&widget=true'></iframe></html>
 
File: steppernug1labeled.svg|Steppernug v1.1
File: voltreg.png|12V and 5V Voltage Regulator
File: cnctorchtable.svg|CNC 3-Stepper Electronics
 
</gallery>
 
The CNC Torch Table uses the heavy duty [[Electronics Case]] with the reliable [[Arduino Uno]] microcontroller that controls open-source stepper drivers called [[Steppernug]]s
 
External wiring is easy with the use of [[Terminal Block]]s
 
Fans can be powered with the voltage regulator.
 
 
 
==Mechanical==
 
[[CNC Table Z Axis]]
[[CNC Table Y Axis]]
[[CNC Table X Axis]]
[[CNC Table Base Frame]] (including legs and holding flats)
 
Fasteners from [[BoltDepot]]
Metric hex nuts, Stainless steel 18-8, 5mm x 0.8mm --- x12
Metric socket cap, Stainless steel 18-8, 5mm x 0.8mm x 10mm --- x4 z-axis motor mounting
Metric socket cap, Stainless steel 18-8, 5mm x 0.8mm x 16mm --- x12 x and y-axis motor mounting
 
==See Also==
Dave (not part of OSE) built a nice cnc torch table which he showed off at NYC Maker Faire 2013. Partial plans are available at https://solar1.net/drupal/plasma_cnc and Dave offered to answer any questions we have.
 
=End Effector=
This is the plasma cutter that the CNC Torch Table will be designed to work with. In the event that this cutter is no longer available here are the important specifications:
Adjustable Post Flow (power plasma only) control up to 60 seconds to improve consumable and torch life. Front air pressure adjustment makes adjusting pressure easy and painless. (PowerPlasma only)
Front air pressure gauge allows quick verification of air pressure. Over Current and Air Pressure light indicators keep you updated on your units operating condition. Suitable for use with 11,000 W "clean power" generators
60AMP 120/220Volt 50/60HZ Plasma Cutter. Cuts 3/8-Inch to 1-1/4-Inch
<gallery perrow=6>
 
File: everpplasma60.jpg|[http://www.amazon.com/Everlast-PowerPlasma-Plasma-Cutter-Cutting/dp/B0081BEWUY/ Everlast PowerPlasma 60 from Amazon]
 
</gallery>
 
=Status=
 
==CNC Torch Table Prototype II'''==
 
Design is finished. Stepper motor controller is under way.
*[http://opensourceecology.org/w/images/7/79/CNC_Torch_Table_-_Sketchup_Model.zip Sketchup Model]
*[http://opensourceecology.org/w/images/3/31/Torch_Table_Solidworks_2010.zip Solidworks model - In progress]
*First Run of Prototype II:
 
<html><iframe width="300" height="169" src="https://www.youtube.com/embed//uvXkV08EutI?list=PL203534A13731D4FF&amp;hl=en_US" frameborder="0" allowfullscreen></iframe></html>
 
The first cut was done by "jogging" a single axis. This essentially verified the ability to control the torch (end effector) with a computer interface.
*need to test jogging on both the Y and X axis, Z is low priority for now because we can manually adjust the Z height for each cut.
*need to make a strait cut without Jogging, this would demonstrait an ability to control the end effector with more automation.
*need a more simplified list of instructions for software installation.
I would like to begin a '''manufacturing procedure''' for the Torch Table. This should utilize parralel fabrication, and have a complete list of skills needed.
*To fully complete Prototype II I would like to see the following
**manufacturing instructions
**parts list
**software tutorials
**user manual
***how to cut a strait line using the arduino.
***how to cut a X inch diameter circle.
***how to cut an arc.
If we can finalize a Prototype that can do these 3 things we will have both '''another useful machine at Factor e Farm''' and '''somthing people will want to replicate and improve'''. Then we can start working on other vital machines, and after people have had time to replicate the torch table and generate feedback, we can start prototype III.
*Results: the mechanical structure is robust and lends itself to torch and CNC wood milling operations. Gantry design by [[Ben Horton]]. The innovation here is the Arduino-based stepper motor controller, [[Steppernug]] - which can be milled on a CNC circuit mill. This system is a replacement for a proprietary version equivalent to the Gecko G540 in terms of current-handling ability.
*[[CNC_Torch Table Control Overview|Computer Control Overview]]
 
[[File:SteppernugInterfaceImage.png|300px|border]] [[File:DriverBoard.jpg|300px|border]]
 
[[File:SteppernugAssy.jpg|300px|border]]
 
=Cutting Torch=
[http://www.fabricatingandmetalworking.com/2012/07/complementary-cutting-evaluating-automated-plasma-oxy-fuel-processes/ plasma vs oxyfuel comparison]
* Oxyacetylene, oxypropane, oxy-biogas. Oxygen: commercial bottled gas or on-site oxygen generator (purchase [http://www.sundanceglass.com/oxygen-concentrator.htm],[http://www.oxygenplusmedical.com/industrial_oxygen_concentrators.htm]) (build [http://cr4.globalspec.com/blogentry/20384/To-Build-an-Oxygen-Concentrator-or-Not]). Steel only. Best on thick (1 inch +) steel.
* [[Plasma_Cutter|Plasma torch]]. Cuts aluminum, stainless, others in addition to steel. PP60 [[Everlast_Plasma_Cutter]] (alternate [[Everlast_PowerPro_256]]). Plasma gas: [http://www.centricut.com/New_Lessons/lessons_9.html air or oxygen]. Starting method: [http://www.pirate4x4.com/forum/shop-tools/955085-how-important-pilot-arc-new-plasma-user.html#post12505736 pilot arc (HF, blowback), scratch start]
 
 
=Developement Board=
<html><iframe width=80% height='400' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0Av4ZjQn4DHJHdDBNVmlFTmZ5S3YxckY3ZkxZc01ISHc&output=html&widget=true'></iframe></html>


[https://docs.google.com/spreadsheet/ccc?key=0Av4ZjQn4DHJHdDBNVmlFTmZ5S3YxckY3ZkxZc01ISHc#gid=2 edit]
[https://docs.google.com/spreadsheet/ccc?key=0Av4ZjQn4DHJHdDBNVmlFTmZ5S3YxckY3ZkxZc01ISHc#gid=2 edit]
=Resources=
* Issue Tracker- https://github.com/OSE/CNC-Torch-Table-OSE/issues
* 3d models
** Github (solidworks 3d models and issues) - https://github.com/OSE/CNC-Torch-Table-OSE. '''Use this for new development'''
** This was originally developed at an [https://github.com/Fractal618/CNC-Torch-Table-OSE old repo] and we forked it into the OSE org. '''Do not use the old repo.'''
** [http://opensourceecology.org/w/images/7/79/CNC_Torch_Table_-_Sketchup_Model.zip] - Sketchup files - I don't know if there are conversions of the solidworks files in github or something else.
* 2d drawings- [http://opensourceecology.org/w/images/d/d1/Creation_Flame_CNC_Torch_Table_Drawings.zip] - DXFs of motor mounts


=Design=
=Design=
[[Image:Table_Frame.JPG|none|360px|Torch Table Prototype II Design.]]
[[Image:Table_Frame.JPG|none|360px|Torch Table Prototype II Design.]]


More information about the control system in [[CNC Torch Table 2/Control Overview]].
Lots of information about the control system in [[CNC Torch Table 2/Control Overview]].


Additional discussion at [[TorchTableModularTooling]]
Additional discussion at [[TorchTableModularTooling]]
==Files==
Github, mostly solidworks - [https://github.com/Fractal618/CNC-Torch-Table-OSE].
[http://opensourceecology.org/w/images/d/d1/Creation_Flame_CNC_Torch_Table_Drawings.zip - DXFs of motor mounts]. [http://opensourceecology.org/w/images/7/79/CNC_Torch_Table_-_Sketchup_Model.zip - Sketchup files]


=Additional Notes=
=Additional Notes=
*As a large x-y-z coordinate table, the Torch Table has potential applications with other tooling besides a cutting torch. One limitation is that the drive system is not powerful enough or stiff enough to support heavy cutting-tool forces.
*As a large x-y-z coordinate table, the Torch Table has potential applications with other tooling besides a cutting torch. One limitation is that the drive system is not powerful enough or stiff enough to support heavy cutting-tool forces.
*A modular tool mounting (possibly dual mounting, so two tools could be available simultanously) would facilitate tool changeover.

Latest revision as of 03:06, 5 December 2013


CNC Torch Table 2
   Home  |  Research & Development  |  Bill of Materials  |  Manufacturing Instructions  |  User's Manual  |  User Reviews    CNC Torch Table 2.png

Prototype 2

Videos

This link goes to a youtube playlist on the OSE CNC Torch Table: http://www.youtube.com/watch?v=LbqqGMtm6BY&list=PL2C1A547A8A20653F

This link goes to videos on the assembly instructions (in progress) http://www.youtube.com/watch?v=VzjvJEHHRcI&list=PLCBC578BE5586F1D1

Frame and Mechanical Assembly

Sketchup model Dxf files (incomplete) [solidworks assembly]

Electronics

Arduino instructions

Arduino Leonardo Arduino Uno

Stepper Motors

Power supply: Maybe one or two recycled computer supplies can be used drive it. If 24V is needed, connect output in serial. On some PSU it is easy to adjust output voltage a bit. --Jth 19:07, 25 July 2012 (CEST)

  • Steppernug v1.1

    Steppernug v1.1

  • 12V and 5V Voltage Regulator

    12V and 5V Voltage Regulator

  • Cnctorchtable.svg

    CNC 3-Stepper Electronics

The CNC Torch Table uses the heavy duty Electronics Case with the reliable Arduino Uno microcontroller that controls open-source stepper drivers called Steppernugs

External wiring is easy with the use of Terminal Blocks

Fans can be powered with the voltage regulator.


Mechanical

CNC Table Z Axis CNC Table Y Axis CNC Table X Axis CNC Table Base Frame (including legs and holding flats)

Fasteners from BoltDepot Metric hex nuts, Stainless steel 18-8, 5mm x 0.8mm --- x12 Metric socket cap, Stainless steel 18-8, 5mm x 0.8mm x 10mm --- x4 z-axis motor mounting Metric socket cap, Stainless steel 18-8, 5mm x 0.8mm x 16mm --- x12 x and y-axis motor mounting

See Also

Dave (not part of OSE) built a nice cnc torch table which he showed off at NYC Maker Faire 2013. Partial plans are available at https://solar1.net/drupal/plasma_cnc and Dave offered to answer any questions we have.

End Effector

This is the plasma cutter that the CNC Torch Table will be designed to work with. In the event that this cutter is no longer available here are the important specifications: Adjustable Post Flow (power plasma only) control up to 60 seconds to improve consumable and torch life. Front air pressure adjustment makes adjusting pressure easy and painless. (PowerPlasma only) Front air pressure gauge allows quick verification of air pressure. Over Current and Air Pressure light indicators keep you updated on your units operating condition. Suitable for use with 11,000 W "clean power" generators 60AMP 120/220Volt 50/60HZ Plasma Cutter. Cuts 3/8-Inch to 1-1/4-Inch

Status

CNC Torch Table Prototype II

Design is finished. Stepper motor controller is under way.

The first cut was done by "jogging" a single axis. This essentially verified the ability to control the torch (end effector) with a computer interface.

  • need to test jogging on both the Y and X axis, Z is low priority for now because we can manually adjust the Z height for each cut.
  • need to make a strait cut without Jogging, this would demonstrait an ability to control the end effector with more automation.
  • need a more simplified list of instructions for software installation.

I would like to begin a manufacturing procedure for the Torch Table. This should utilize parralel fabrication, and have a complete list of skills needed.

  • To fully complete Prototype II I would like to see the following
    • manufacturing instructions
    • parts list
    • software tutorials
    • user manual
      • how to cut a strait line using the arduino.
      • how to cut a X inch diameter circle.
      • how to cut an arc.

If we can finalize a Prototype that can do these 3 things we will have both another useful machine at Factor e Farm and somthing people will want to replicate and improve. Then we can start working on other vital machines, and after people have had time to replicate the torch table and generate feedback, we can start prototype III.

  • Results: the mechanical structure is robust and lends itself to torch and CNC wood milling operations. Gantry design by Ben Horton. The innovation here is the Arduino-based stepper motor controller, Steppernug - which can be milled on a CNC circuit mill. This system is a replacement for a proprietary version equivalent to the Gecko G540 in terms of current-handling ability.
  • Computer Control Overview

SteppernugInterfaceImage.png DriverBoard.jpg

SteppernugAssy.jpg

Cutting Torch

plasma vs oxyfuel comparison


Developement Board

edit

Resources

Design

Torch Table Prototype II Design.

Lots of information about the control system in CNC Torch Table 2/Control Overview.

Additional discussion at TorchTableModularTooling

Additional Notes

  • As a large x-y-z coordinate table, the Torch Table has potential applications with other tooling besides a cutting torch. One limitation is that the drive system is not powerful enough or stiff enough to support heavy cutting-tool forces.
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