CNC Torch Table 2/Research Development: Difference between revisions

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{{GVCS Header}}
{{GVCS Header}}
=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==
[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]
==Electronics==
===Arduino instructions===
[http://arduino.cc/en/Main/ArduinoBoardLeonardo Arduino Leonardo]
[http://arduino.cc/en/Main/ArduinoBoardUno 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.  --[[User:Jth|Jth]] 19:07, 25 July 2012 (CEST)
<gallery perrow=6>
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=
=Status=


This is my (Dan Benamy's) understanding as of Oct 2013:
==CNC Torch Table Prototype II'''==
 
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.


Generally, my strategy is to '''make lots of quick iterations with self-contained improvements''' so we almost always have a working table and project handoff is simpler. I'm also focusing on '''getting something working''' at FeF that we can use to cut parts we need for other machines, '''rather than something that's easily reproducible or perfectly documented'''. Being able to cut [[Warehouse]] parts will save lots of time and money on all other development. It will also be a waste of effort to carefully document stuff that turns out not to work well. Once we get to the point where we can cut useful stuff, I (or you!) will need to make any changes needed for ease of reproduction, and create awesome manufacturing guides so others can copy it.
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:


There's a torch table base in the shop at FeF which needs just a little more work to be usable. I mounted the motors, although we didn't have quite enough of some of the proper screws with springs, but what I've got on there may be good enough for now. TODO link to issue to fix this
<html><iframe width="300" height="169" src="https://www.youtube.com/embed//uvXkV08EutI?list=PL203534A13731D4FF&amp;hl=en_US" frameborder="0" allowfullscreen></iframe></html>


I ran wires from the long and short axis motors up to a mount in the ceiling and over to the table with the RAMPS electronics and laptop. TODO pic
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]]


Lots of info on the control systems at [[CNC Torch Table 2/Control Overview]]. That page predates me (Dan) so may have outdated info.
[[File:SteppernugInterfaceImage.png|300px|border]] [[File:DriverBoard.jpg|300px|border]]


=Next Steps=
[[File:SteppernugAssy.jpg|300px|border]]


* Finish fixing/replacing the RAMPS hardware that I burned. Make sure each motor moved properly when using the RAMPS test code.
=Cutting Torch=
* Order a new "RAM" board in case this one is damaged or becomes damaged.
[http://www.fabricatingandmetalworking.com/2012/07/complementary-cutting-evaluating-automated-plasma-oxy-fuel-processes/ plasma vs oxyfuel comparison]
* Find a power supply for the arduino so it can be run without being connected to a computer to prevent a short from frying the computer.
* 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.
* Attach a sharpie to the tool head and put poster board or similar on the bed for initial testing.
* [[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]
* Load [http://reprap.org/wiki/Marlin the Marlin firmware] onto the arduino and do any needed configuration. Grbl looks sweet but doesn't support RAMPS out of the box and we're going for simple here for the moment.
* The standard RAMPS setup for 2 motors on one axis is to run them in parallel off one driver. Since our motors draw a fair amount of current, try to use a separate driver for each motor and [http://shapeoko.com/forum/viewtopic.php?f=4&t=1095 modify marlin] to drive those two drivers identically.
* Run a simple test gcode program- https://github.com/grbl/grbl/wiki/G-Code-Examples.
* Draw a rectangle in librecad, run it through [[DXF to G-code Conversion Tutorial | dxf2gcode]] and use [[http://reprap.org/wiki/Pronterface Printrun]] to stream it to the arduino. 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:
* Add a circle to the dxf that's not touching the rectangle. Re-run and make sure the head lifts up between the shapes.
* 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.
* 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.
* Order proper screws to replace to replace what I used for the 2 long axis motor mount.


=Developement Board=
=Developement Board=
<html><iframe width=80% height='500' frameborder='0' src='https://docs.google.com/spreadsheet/pub?key=0Av4ZjQn4DHJHdDBNVmlFTmZ5S3YxckY3ZkxZc01ISHc&output=html&widget=true'></iframe></html>
<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=
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Additional discussion at [[TorchTableModularTooling]]
Additional discussion at [[TorchTableModularTooling]]
==Files==
* 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.
* [http://opensourceecology.org/w/images/d/d1/Creation_Flame_CNC_Torch_Table_Drawings.zip] - DXFs of motor mounts.


=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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