Universal Controller: Difference between revisions
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{{Hint|The Universal Controller is a LCD-screen equipped controller that is capable of controlling 3D printers, CNC machines, welders, filament makers, automated machines, or any other applications where a microcontroller runs different actuators, sensors, or power elements. It is a platform consisting of RAMPS, LCD screen, power supply, power outlet, and power handling SSRs, and can be connected to external stepper drivers, solenoid valves, or other power elements. Equipped with an Arduino Mega, it can be used to control just about anything that requires a 100 kHz or lower control signal. See 2019 work on this at [[OSE Design Manual - Universal Machine Controller]]}} | |||
=About the Universal Controller - Design and Uses= | |||
The Universal Controller consists of a 3D printed mounting panel, which holds all the components. This panel is printed with a 90 degree bend, and is straightened with a heat gun as shown in [[4D Printing]]. The main components for the D3D Pro 3D printer are 5: | |||
#GFCI - safety device, which shuts off the circuit if any short is detected. | |||
#24V power supply - provides power to stepper motors and electronics | |||
#RAMPS control board - the brain of the controller | |||
#LCD display - allows for controlling the machine with an SD card, without using a wire computer connection | |||
#Solid State Relay - switches power to the heatbed. | |||
Then, a 5V wall wort powers the RAMPS control board. A plug connected to the GFCI feeds the heat bed and power supply. | |||
See below for all the connection details, observing that the earliest Universal Controller was built in 2019, and the current version has only a small change. We replaced the small 5v regulator circuit with a 5V wall wort to allow for a simpler build - where a standard USB cable is used to feed power into the Arduino Mega board of the RAMPS controller. Note also that the controller runs at 24V - so a small modification on the RAMPS board must be made as shown at [[RAMPS on 24V]]. | |||
[https://docs.google.com/presentation/d/ | The controller is ''Universal'' because it can control a stepper motor of any size - by using external stepper drivers instead of the on-board RAMPS drivers. To use external drivers, remove the on-baord drivers, and connect the Step, Direction, and Enable signals (3 wires) to the external drivers. This allows for a simple, robust solution for motor drive with a controller that is deployed using common, off-the-shelf parts - at the lowest cost possible. Because the Universal Controller has all components accessible - it can be serviced in minutes by diagnosing and replacing parts as needed. This allows for lifetime design, with minimal down time. | ||
=Build Video= | |||
From Irvin Inzurriaga. Note that this uses the [[Titan Aero]] extruder. Since this 2020 build, we have upgraded to the OSE [[Universal Gearless Extruder]] and began shipping all OSE printers with the Universal Gearless Extruder starting in the second half of 2020. | |||
<html><iframe width="560" height="315" src="https://www.youtube.com/embed/hWzM90JEi8Q" title="YouTube video player" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe></html> | |||
=Development= | |||
{| class="wikitable" | |||
|+ Development Template | |||
! | |||
! Description | |||
! Link to Work Product | |||
! % | |||
|- | |||
! scope=row | | |||
| '''DESIGN''' || || | |||
|- | |||
! scope=row | 1 | |||
| [[Requirements + Value Proposition]] || [[Universal Controller Requirements + Value Proposition]] || 0 | |||
|- | |||
! scope=row | 2 | |||
| [[Industry_Standards]] || [[Universal Controller Industry Standards]] || 0 | |||
|- | |||
! scope=row | 3 | |||
| [[Conceptual Design]] || [[Universal Controller Conceptual Design]] || 0 | |||
|- | |||
! scope=row | 4 | |||
| [[Module Breakdown]] || [[Universal Controller Module Breakdown]] || 0 | |||
|- | |||
! scope=row | 5 | |||
| [[Design Guide]] || [[Universal Controller Design Guide]] || 0 | |||
|- | |||
! scope=row | | |||
| '''TECHNICAL DESIGN''' || || | |||
|- | |||
! scope=row | 6 | |||
| [[3D CAD]] || [[Universal Controller 3D CAD]] || 0 | |||
|- | |||
! scope=row | 7 | |||
| [[Basic Calculations|Calculations]] || [[Universal Controller Calculations]] || 0 | |||
|- | |||
! scope=row | 8 | |||
| [[Electronics Design]] || [[Universal Controller Electronics Design]] || 0 | |||
|- | |||
! scope=row | 9 | |||
| [[Wiring and Plumbing]] || [[Universal Controller Wiring and Plumbing]] || 0 | |||
|- | |||
! scope=row | 10 | |||
| [[Software]] || [[Universal Controller Software]] || 0 | |||
|- | |||
! scope=row | | |||
| '''BILL OF MATERIALS || || | |||
|- | |||
! scope=row | 11 | |||
| [[Proper BOM|BOM]] || [[Universal Controller BOM]] || 0 | |||
|- | |||
! scope=row | 12 | |||
| [[vBOM]] || [[Universal Controller vBOM]] || 0 | |||
|- | |||
! scope=row | 13 | |||
| [[CAM Files]] || [[Universal Controller CAM Files]] || 0 | |||
|- | |||
! scope=row | 14 | |||
| [[Cut List]] || [[Universal Controller Cut List]] || 0 | |||
|- | |||
! scope=row | | |||
| '''BUILD''' || || | |||
|- | |||
! scope=row | 15 | |||
| [[Build Instructions]] || [[Universal Controller Build Instructions]] || 0 | |||
|- | |||
! scope=row | 16 | |||
| [[Fabrication Drawings]] || [[Universal Controller Fabrication Drawings]] || 0 | |||
|- | |||
! scope=row | 17 | |||
| [[Exploded Part Diagram]] || [[Universal Controller Exploded Part Diagram]] || 0 | |||
|- | |||
! scope=row | 18 | |||
| [[Production Engineering]] || [[Universal Controller Production Engineering]] || 0 | |||
|- | |||
! scope=row | | |||
| '''LIFECYCLE DESIGN''' || || | |||
|- | |||
! scope=row | 19 | |||
| [[Build Pictures and Video]] || [[Universal Controller Build Pictures and Video]] || 0 | |||
|- | |||
! scope=row | 20 | |||
| [[Data Collection]] || [[Universal Controller Data Collection]] || 0 | |||
|- | |||
! scope=row | 21 | |||
| [[Future Work]] || [[Universal Controller Future Work]] || 0 | |||
|- | |||
! scope=row | 22 | |||
| [[Troubleshooting and Repair]] || [[Universal Controller Troubleshooting and Repair]] || 0 | |||
|} | |||
=With External Stepper Drivers= | |||
[[File:uc.jpg|300px]] | |||
As used in the [[CNC Torch Table v19.10]]: | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fphoto.php%3Ffbid%3D10217912083610884%26set%3Da.2106813187074%26type%3D3&width=500" width="500" height="286" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
=Used in OSE Machines= | |||
*[[D3D_v20.04.27]] and older printer models | |||
*[[CNC Torch Table v19.10]] | |||
*Intended for use in the [[CEB Press]], with weatherproof enclosure. | |||
*[[D3D CNC Circuit Mill]] | |||
*Variant is currently used in [[D3D Universal 2]] | |||
*[[D3D Pro 2]] | |||
*[[D3D Pro 3]] | |||
=Working Doc= | |||
<html><iframe src="https://docs.google.com/presentation/d/e/2PACX-1vRUjPtSIStGUt4-SFQreMWmfKU8-_hjrOlRHJLMuxwihRyKVPIXAatiBMdlvkD81dTIIufFTdnOtbwN/embed?start=false&loop=false&delayms=3000#2" frameborder="0" width="480" height="375" allowfullscreen="true" mozallowfullscreen="true" webkitallowfullscreen="true"></iframe></html> | |||
[https://docs.google.com/presentation/d/16I2jMREySnsTjOTz8ABAvylG7d5vs_cHHJHL6qs2T5U/edit#slide=id.g5c3be0cf03_0_0 edit] | |||
=CAD= | |||
See [[D3D v19.06]] for complete machine. | |||
See more at [[3D Printer Control Panel]] | |||
[[File:framev1902.png|100px]][[File:powersupply_v1904.png|100px]][[File:RAMPS14_v1904.png|100px]][[File:stepperdriver_v1904.png|100px]][[File:ssr_v1904.png|100px]][[File:smartcontroller_v1904.png|100px]][[File:gfci_v1904.png|100px]][[File:controlpanel_v1904.png|100px]][[File:controlpanel+frame_v1904.png|100px]][[File:controlpanel+panel_v1904.png|100px]][[File:controlpanelproper_v1904.png|100px]][[File:controlpanelwithmounts_v1904.png|100px]][[File:wirecover_v1904.png|100px]][[File:panelonly_v1904.png|100px]][[File:bentpanel_v1904.png|100px]][[File:Heatbed_wirelock.png|100px]][[File:finalcontrolpanel.png|100px]][[File:ontrolpanelseated.png|100px]] | |||
[[File:D3DPlugInner.png|100px]] | |||
[[File:D3DPlugCover.png|100px]] | |||
<gallery perrow=6> | |||
File:controlpanelwithmounts_v1904.png|'''Control Panel''' - FreeCAD -[[File:controlpanel_v1904.fcstd]]. Bent panel STL - [[File:Bentpanel_v1904.stl]] | |||
File:powersupply_v1904.png|'''D3D v19.04 Power Supply''' - FreeCAD -[[File:powersupply_v1904.fcstd]] | |||
File:RAMPS14_v1904.png|'''RAMPS 1.4''' - FreeCAD -[[File:RAMPS14_v1904.fcstd]]. Full detailed file - 4MB - [https://github.com/OpenSourceEcology/RAMPS_1.4/blob/master/RAMPS.fcstd] | |||
File:stepperdriver_v1904.png|'''Stepper driver''' - FreeCAD -[[File:stepperdriver_v1904.fcstd]]. File for detailed LCD controller and endstop can be found at [https://grabcad.com/library/gadgets3d-starter-pack-ramps-1-4-elettronics-for-3d-printers-1] | |||
File:ssr_v1904.png|'''Solid state relay''' - FreeCAD -[[File:ssr_v1904.fcstd]]. Source: [https://grabcad.com/library/ssr-40-da-1]. See [[Fotek SSR]]. Dimensions verified with Amazon source. | |||
File:smartcontroller_v1904.png|'''Reprap Discount Smart Controller''' - FreeCAD -[[File:smartcontroller_v1904.fcstd]]. Source: [https://grabcad.com/library/full-graphic-smart-controller-1]. | |||
File:gfci_v1904.png|'''Ground Fault Connection Interrupt (GFCI) outlet''' - FreeCAD -[[File:gfci_v1904.fcstd]]. CAD source at McMaster Carr: [https://www.mcmaster.com/gfcis]. May not represent actual GFCI. | |||
File:wirecover_v1904.png|'''Wire box cover.''' - FreeCAD -[[File:wireboxcover_v1904.fcstd]]. | |||
File:Heatbed_wirelock.png|'''Power cord wire clamp''' - FreeCAD -[[File:Heatbed wirelock.fcstd]]. | |||
File:D3DPlugInner.png|'''Inner part of D3D Electric Plug''' - FreeCAD [[File:D3DPlugInner.fcstd]]. STL - [[File:D3DPlugInner.stl]] | |||
File:D3DPlugCover.png|'''Outer cover of D3D Electric Plug''' - FreeCAD [[File:D3DPlugCover.fcstd]]. STL file is scaled to 105% already - [[File:D3DPlugCover.stl]] | |||
</gallery> | |||
=BOM= | |||
<html><iframe src="https://docs.google.com/spreadsheets/d/e/2PACX-1vTKYLRjFxGMSRE7wuQD0reu-WQMopqddoVdlgS3QNoEfYiVEmVVdOhTjFTRT0jBtHBLZk__GJnBYF7B/pubhtml?widget=true&headers=false" height=500 width=900></iframe></html> | |||
[https://docs.google.com/spreadsheets/d/1Cd9IFWemcdsGVF-ZjUjlGAutV-hHVUxjSCZadBiUJp0/edit#gid=0 edit] | |||
=Video - from June 2019 STEAM Camp= | |||
*Connect Power Cord to the GFCI on the Control Panel - [https://drive.google.com/drive/folders/1ZRZDaOsyJex-eOKjf2QqtyDj6Gbs97yg] | |||
<html><iframe width="280" height="200" src="https://www.youtube.com/embed/_sJFUxSjDJ8" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe></html> | |||
==Converting RAMPS to 24V== | |||
<html><iframe width="280" height="200" src="https://www.youtube.com/embed/XPv0Sl-MG8E" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe></html> | |||
=Detailed Wiring Pictures= | |||
See Google Photos [https://photos.google.com/share/AF1QipMDeSR0Ok68l3x-JdNt0MgsE1zqXcrg2B3B4_jqHjz4SXyxeoanohJDksOoTMdBYw?key=RU13empkSVlHSG94MDFQb2l5d1B4WEZsTERuMThB] for basic controller with small drivers. | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10221848289733577&width=500&show_text=true&height=486&appId" width="500" height="486" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowfullscreen="true" allow="autoplay; clipboard-write; encrypted-media; picture-in-picture; web-share"></iframe></html> | |||
=Build= | |||
See [[4D Printing]]: | |||
<html><iframe width="560" height="315" src="https://www.youtube.com/embed/UcqkHa4DVMs" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe> | |||
</html> | |||
==From 2019 STEAM Camp - Video by Adrian Sinclair== | |||
https://drive.google.com/drive/folders/1ZRZDaOsyJex-eOKjf2QqtyDj6Gbs97yg?usp=sharing | |||
==October 2019== | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10217369190838904&width=500" width="500" height="670" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
==July 2019== | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10216748084471633&width=500" width="500" height="708" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe> | |||
</html> | |||
==June 2019== | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10216339473616617&width=500" width="500" height="708" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10216339515817672&width=500" width="500" height="708" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
=Build= | |||
See [[4D Printing]]: | |||
<html><iframe width="560" height="315" src="https://www.youtube.com/embed/UcqkHa4DVMs" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe> | |||
</html> | |||
==From 2019 STEAM Camp - Video by Adrian Sinclair== | |||
https://drive.google.com/drive/folders/1ZRZDaOsyJex-eOKjf2QqtyDj6Gbs97yg?usp=sharing | |||
==October 2019== | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10217369190838904&width=500" width="500" height="670" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
==July 2019== | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10216748084471633&width=500" width="500" height="708" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe> | |||
</html> | |||
==June 2019== | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10216339473616617&width=500" width="500" height="708" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
<html><iframe src="https://www.facebook.com/plugins/post.php?href=https%3A%2F%2Fwww.facebook.com%2Fmarcin.jakubowski.378%2Fposts%2F10216339515817672&width=500" width="500" height="708" style="border:none;overflow:hidden" scrolling="no" frameborder="0" allowTransparency="true" allow="encrypted-media"></iframe></html> | |||
=Links= | =Links= | ||
*[[Universal Controller | *[[Arduino]] | ||
*[[Arduino Environment]] | |||
*[[ArduinoIDE]] | |||
*[[Arduino Beginner Resources]] | |||
*[[Arduino Tutorial]] | |||
*[[RAMPS on 24V]] | |||
*2019 work - [[OSE_Design_Manual_-_Universal_Machine_Controller]]. See also [[STEAM Camp Recordings]]. | |||
*Old work - [[Universal Controller 2017]] | |||
[[Category: Universal Controller]] [[Category: 3D Printing]] |
Latest revision as of 00:21, 23 January 2022
About the Universal Controller - Design and Uses
The Universal Controller consists of a 3D printed mounting panel, which holds all the components. This panel is printed with a 90 degree bend, and is straightened with a heat gun as shown in 4D Printing. The main components for the D3D Pro 3D printer are 5:
- GFCI - safety device, which shuts off the circuit if any short is detected.
- 24V power supply - provides power to stepper motors and electronics
- RAMPS control board - the brain of the controller
- LCD display - allows for controlling the machine with an SD card, without using a wire computer connection
- Solid State Relay - switches power to the heatbed.
Then, a 5V wall wort powers the RAMPS control board. A plug connected to the GFCI feeds the heat bed and power supply.
See below for all the connection details, observing that the earliest Universal Controller was built in 2019, and the current version has only a small change. We replaced the small 5v regulator circuit with a 5V wall wort to allow for a simpler build - where a standard USB cable is used to feed power into the Arduino Mega board of the RAMPS controller. Note also that the controller runs at 24V - so a small modification on the RAMPS board must be made as shown at RAMPS on 24V.
The controller is Universal because it can control a stepper motor of any size - by using external stepper drivers instead of the on-board RAMPS drivers. To use external drivers, remove the on-baord drivers, and connect the Step, Direction, and Enable signals (3 wires) to the external drivers. This allows for a simple, robust solution for motor drive with a controller that is deployed using common, off-the-shelf parts - at the lowest cost possible. Because the Universal Controller has all components accessible - it can be serviced in minutes by diagnosing and replacing parts as needed. This allows for lifetime design, with minimal down time.
Build Video
From Irvin Inzurriaga. Note that this uses the Titan Aero extruder. Since this 2020 build, we have upgraded to the OSE Universal Gearless Extruder and began shipping all OSE printers with the Universal Gearless Extruder starting in the second half of 2020.
Development
With External Stepper Drivers
As used in the CNC Torch Table v19.10:
Used in OSE Machines
- D3D_v20.04.27 and older printer models
- CNC Torch Table v19.10
- Intended for use in the CEB Press, with weatherproof enclosure.
- D3D CNC Circuit Mill
- Variant is currently used in D3D Universal 2
- D3D Pro 2
- D3D Pro 3
Working Doc
CAD
See D3D v19.06 for complete machine.
See more at 3D Printer Control Panel
- Error creating thumbnail: File missing
Control Panel - FreeCAD -File:Controlpanel v1904.fcstd. Bent panel STL - File:Bentpanel v1904.stl
- Error creating thumbnail: File missing
D3D v19.04 Power Supply - FreeCAD -File:Powersupply v1904.fcstd
- Error creating thumbnail: File missing
RAMPS 1.4 - FreeCAD -File:RAMPS14 v1904.fcstd. Full detailed file - 4MB - [1]
- Error creating thumbnail: File missing
Stepper driver - FreeCAD -File:Stepperdriver v1904.fcstd. File for detailed LCD controller and endstop can be found at [2]
- Error creating thumbnail: File missing
Solid state relay - FreeCAD -File:Ssr v1904.fcstd. Source: [3]. See Fotek SSR. Dimensions verified with Amazon source.
- Error creating thumbnail: File missing
Reprap Discount Smart Controller - FreeCAD -File:Smartcontroller v1904.fcstd. Source: [4].
- Error creating thumbnail: File missing
Ground Fault Connection Interrupt (GFCI) outlet - FreeCAD -File:Gfci v1904.fcstd. CAD source at McMaster Carr: [5]. May not represent actual GFCI.
- Error creating thumbnail: File missing
Wire box cover. - FreeCAD -File:Wireboxcover v1904.fcstd.
- Error creating thumbnail: File missing
Power cord wire clamp - FreeCAD -File:Heatbed wirelock.fcstd.
- Error creating thumbnail: File missing
Inner part of D3D Electric Plug - FreeCAD File:D3DPlugInner.fcstd. STL - File:D3DPlugInner.stl
- Error creating thumbnail: File missing
Outer cover of D3D Electric Plug - FreeCAD File:D3DPlugCover.fcstd. STL file is scaled to 105% already - File:D3DPlugCover.stl
BOM
Video - from June 2019 STEAM Camp
- Connect Power Cord to the GFCI on the Control Panel - [6]
Converting RAMPS to 24V
Detailed Wiring Pictures
See Google Photos [7] for basic controller with small drivers.
Build
See 4D Printing:
From 2019 STEAM Camp - Video by Adrian Sinclair
https://drive.google.com/drive/folders/1ZRZDaOsyJex-eOKjf2QqtyDj6Gbs97yg?usp=sharing
October 2019
July 2019
June 2019
Build
See 4D Printing:
From 2019 STEAM Camp - Video by Adrian Sinclair
https://drive.google.com/drive/folders/1ZRZDaOsyJex-eOKjf2QqtyDj6Gbs97yg?usp=sharing
October 2019
July 2019
June 2019