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.

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

Development Template
	Description	Link to Work Product	%
	DESIGN
1	Requirements + Value Proposition	Universal Controller Requirements + Value Proposition	0
2	Industry_Standards	Universal Controller Industry Standards	0
3	Conceptual Design	Universal Controller Conceptual Design	0
4	Module Breakdown	Universal Controller Module Breakdown	0
5	Design Guide	Universal Controller Design Guide	0
	TECHNICAL DESIGN
6	3D CAD	Universal Controller 3D CAD	0
7	Calculations	Universal Controller Calculations	0
8	Electronics Design	Universal Controller Electronics Design	0
9	Wiring and Plumbing	Universal Controller Wiring and Plumbing	0
10	Software	Universal Controller Software	0
	BILL OF MATERIALS
11	BOM	Universal Controller BOM	0
12	vBOM	Universal Controller vBOM	0
13	CAM Files	Universal Controller CAM Files	0
14	Cut List	Universal Controller Cut List	0
	BUILD
15	Build Instructions	Universal Controller Build Instructions	0
16	Fabrication Drawings	Universal Controller Fabrication Drawings	0
17	Exploded Part Diagram	Universal Controller Exploded Part Diagram	0
18	Production Engineering	Universal Controller Production Engineering	0
	LIFECYCLE DESIGN
19	Build Pictures and Video	Universal Controller Build Pictures and Video	0
20	Data Collection	Universal Controller Data Collection	0
21	Future Work	Universal Controller Future Work	0
22	Troubleshooting and Repair	Universal Controller Troubleshooting and Repair	0

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

edit

CAD

See D3D v19.06 for complete machine.

See more at 3D Printer Control Panel

Control Panel - FreeCAD -File:Controlpanel v1904.fcstd. Bent panel STL - File:Bentpanel v1904.stl
D3D v19.04 Power Supply - FreeCAD -File:Powersupply v1904.fcstd
RAMPS 1.4 - FreeCAD -File:RAMPS14 v1904.fcstd. Full detailed file - 4MB - [1]
Stepper driver - FreeCAD -File:Stepperdriver v1904.fcstd. File for detailed LCD controller and endstop can be found at [2]
Solid state relay - FreeCAD -File:Ssr v1904.fcstd. Source: [3]. See Fotek SSR. Dimensions verified with Amazon source.
Reprap Discount Smart Controller - FreeCAD -File:Smartcontroller v1904.fcstd. Source: [4].
Ground Fault Connection Interrupt (GFCI) outlet - FreeCAD -File:Gfci v1904.fcstd. CAD source at McMaster Carr: [5]. May not represent actual GFCI.
Wire box cover. - FreeCAD -File:Wireboxcover v1904.fcstd.
Power cord wire clamp - FreeCAD -File:Heatbed wirelock.fcstd.
Inner part of D3D Electric Plug - FreeCAD File:D3DPlugInner.fcstd. STL - File:D3DPlugInner.stl
Outer cover of D3D Electric Plug - FreeCAD File:D3DPlugCover.fcstd. STL file is scaled to 105% already - File:D3DPlugCover.stl