161 lines
9.0 KiB
Markdown
161 lines
9.0 KiB
Markdown
# Robot driven print systems
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***brief*** this is part of our work of PP OpenSource contributions, please check our [library](https://library.precious-plastic.org/) or our [main page](https://plastic-hub.com/products/) for more.
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The print head is a modification of [Lydia-v4](https://plastic-hub.com/products/lydia-v4.html) and aims at a generic solution for most of it´s components.
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**Status** : Confirmed & in progress, ETA Mid. of October
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## Todos
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* [x] Motor selection
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* [ ] Firmware updates
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+ [x] Check TCP stack memory/CPU footprint on the ControllinoMega
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* [x] Sensors / Audio, LED feedback (status, etc... )
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* [ ] Support [RAPID - ABB robots, but uses customer spec](https://library.e.abb.com/public/688894b98123f87bc1257cc50044e809/Technical%20reference%20manual_RAPID_3HAC16581-1_revJ_en.pdf)
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### Todos Frederike@3dtreehouse
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monday memo:
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* [ ] Gantry mount plate, we need the size and locations of the mount holes. We'd need a test rig here.
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* [ ] Location and size of the cabinet, what on the control panel (controls & plugs) ?
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* [x] We have to know how we share power source & ground among all digital circuits. Currently we're mostly at 24V and we need another source for 12V (fans, etc...)
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* [ ] Clarify RAPID ethernet connectivity
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- [ ] local setup / updates ?
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- [ ] screw tip / max. barrel length / screw mod
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- [ ] Fan control
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## Components
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* [x] [OMRON MX2 VFD](https://industrial.omron.es/es/products/3G3MX2-A2022-E) [BOM](https://es.wiautomation.com/omron/variadores-motores-proteccion-de-circuitos/3G3MX2A2022E?SubmitCurrency=1&id_currency=1&gclid=Cj0KCQjwy8f6BRC7ARIsAPIXOjgnGbRSd_DaX-o59wjtIBqI2mGllXWWOvjhSC1sPQgOTmGMvc7toncaAqejEALw_wcB)
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* [ ] [3G3MX2-A2015-E](https://es.wiautomation.com/omron/variadores-motores-proteccion-de-circuitos/3G3MX2A2015E?utm_source=shopping_free&utm_medium=organic&utm_content=ES105728&gclid=Cj0KCQjwgYSTBhDKARIsAB8KuksIYzB6ATQnPv1r7SiF5Z1-2ySXLYHNzPDPoK95TaC2jr17-ueXM_8aAtZiEALw_wcB)
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* [x] Controllino - Mega as already mentioned a few times, adds 280 Euro
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* [x] a better motor and gearbox - MotoVario
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* [ ] custom firmware development
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* [x] ModBus capable PID controllers (3x) : [Omron - E5DC-B](https://industrial.omron.eu/en/products/E5DC-QX2ASM-002) - Din - Rail Module [BOM](https://es.wiautomation.com/omron/productos-generales/E5DCCX2ASM000?gclid=CjwKCAjw_YShBhAiEiwAMomsEI9iqltgV3_5qpTXhLZG9uFn4RjY-j0ZLPj0MnmkBxz1Z3phzK6WnxoC1HgQAvD_BwE)
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* [Hopper - Linear Solenoid](https://uk.farnell.com/guardian-electric/t12x19-c-24d/solenoid-pull-operation-24vdc/dp/1608128?gclid=EAIaIQobChMIn4Xa8LPz6wIVEuntCh2SvwcDEAkYASABEgK3uvD_BwE&gross_price=true&mckv=s7TWt3nIG_dc%7Cpcrid%7C459864482330%7Cplid%7C%7Ckword%7C%7Cmatch%7C%7Cslid%7C%7Cproduct%7C1608128%7Cpgrid%7C114464711464%7Cptaid%7Cpla-323868377918%7C&CMP=KNC-GUK-SHOPPING-SMEC-Whoops-Newstructure-31Aug2020)
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* [ ] Motor [Cidepa](https://www.cidepa-sincron.com/en/25/cfm-parallel-shafts-gearboxes) - CFM-37.3 1/35 1 | 750W | 1.2SF
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### Noah OS Variant
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* [x] [PLC/Proxy for Aux, Sensors, Relays, etc... - CP1L-EM40DT1-D](http://www.ia.omron.com/products/family/1916/lineup.html), works well with [Omron NB NB3Q-TW01B](https://es.wiautomation.com/omron/hmi-pc-industriales/NB3QTW01B?SubmitCurrency=1&id_currency=1&gclid=CjwKCAjwh7H7BRBBEiwAPXjadt5G-53T-xJ8v5VmzdF5wUu8uHT1us-fzXU5913IwC3Kbz4cDg3jnBoC7g0QAvD_BwE)
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### Specs
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- Voltage : 220V|380V
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- [ ] Max. 120Kg, first rev. might be around 60KG
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- [ ] Controller cable length around 20 meter
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- [ ] PID : +/- 5 degc tolerance, alarm/cooling outputs
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### Gantry Mount
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- [ ] : run static tests
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* the tool flange is on p30, ([see also ATI Toolchanger - YuTu](https://www.youtube.com/watch?v=kDP-oofDn4w&feature=youtu.be))
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* [Why ATI Manual Tool Changers?](https://www.youtube.com/watch?v=N2Pr0tAsYkU&ab_channel=ATIIndustrialAutomation)
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* [x] we need a laser cut barrel shield which holds the insulation material
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* [x] on the barrel tip, we need some mounting possibilties for fans which are a little heavy as well
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- [ ] ATI mount ([see ATI Tool changers @ 3dcentral](https://www.3dcontentcentral.com/syndication/supplier/ATI%20Industrial%20Automation/147.aspx))
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### Firmware
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(https://www.controllino.biz/product/controllino-mega/) which gives us Ethernet and RS485. The board has been proven reliable and robust (ideal for prototyping).
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- [-] VFD and PID control is mapped to Serial communication which might accept G-Code
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- [x] VFD will be Omron-M2X series since we can use existing code. The VFD also supports Modbus (rather difficult)
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- [x] Internal registers/coils (custom PlasticHub Firmware) to Modbus rep
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**[Diagram source](https://app.diagrams.net/#G1L7Prviy9U-2gpcZHm8Z5dj39gxDHd_V_)**
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### PID Controller
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* [x] We should go for [Omron E5-C](https://assets.omron.com/m/6f7cd0d93654a7a4/original/E5_C-Temperature-Controller-to-NB-Screen-Template-Tech-Guide.pdf) series which come with Modbus (consider EMI and cable length to the main controller)
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* [x] Each PID will be exposed on the internal ModBus mapping
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* There is currently a [custom PID controller](https://gitlab.com/plastichub/pid-controller) in development but as mentioned, it's unlikely that it sees the light before November. However, I can imagine we use sub-routines as they're avaiable
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* [-] We should create logging module as well a an API to set temperature profiles for different materials. The logging module will help analyzing different PID settings as well experimenting with barrel cooling (when overshooting becomes an issue).
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* [-] Additional, we forward alarms for overshooting on the internal bus
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* **Changes** : Turns out that the [E5DC / E5DC-B](http://www.ia.omron.com/products/family/3242/) family is better choice.
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### Barrel
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- [-] OD should be standard to EU heatbands
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- [ ] Between Nozzel and barrel we might have some adaptery to exchange different screw tips, up to 10 cm
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- [x] should have a mount near the nozzle
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- [x] Barrel - motor flange should have some redunancy to enable different barrels
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- [ ] [Taper bearing](https://www.123rodamiento.es/rodamiento-325207) - 52OD - 30ID | 17H
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----
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### Hopper interface and Hopper
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* [x] should have a thread interface
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* [x] integrate loader system
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## Todos
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* [x] Investigate Omron - PID feedback to enable more control via M/G codes (purge, ...)
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* [x] Investigate GCode to ROS mapping
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* [x] Investigate screw tip machining, if lucky we get away with 4 axis
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* [-] Test different VFD/PID checksum/parity settings with larger EMI around
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# References
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## ROS (cancelled)
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* [ROS - Github](https://github.com/ros-industrial)
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* [ROS - GBRL - Github](https://github.com/openautomation/ROS-GRBL/wiki/GRBLtron)
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* [ROS - Matlab|SimuLnk](https://www.mathworks.com/help/ros/ug/get-started-with-ros-in-simulink.html)
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* [ROS Modbus - Wiki](http://wiki.ros.org/modbus)
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* [ROS Modbus - PLC - Github](https://github.com/sonyccd/ros_plc_modbus)
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## ProfiBus
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* [Instructables Arduino](https://www.instructables.com/Profibus-DP-Communication-Between-Arduino-and-PLC/)
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* [Arduino Forum](https://forum.arduino.cc/index.php?topic=458492.0)
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- [Specs - PDF](https://forum.arduino.cc/index.php?topic=458492.0)
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## Related Projects
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* [Project Noah](https://gitlab.com/plastichub/noah)
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### Cable robotics
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- [The Cable-robot Analysis and Simulation Platform for Research (CASPR)](https://github.com/darwinlau/CASPR)
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- [CUHK C3 Robotics Laboratory - Youtube](https://www.youtube.com/channel/UCxadDa3g1fUarP4ldAECtLQ)
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### Rapid - ABB
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* [Language specs and docs](./vendor/abb/2CSG445026D0201-ANR-LAN-Modbus-TCP-Protocol.pdf)
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* [ABB - AC_800M - Protocols](./vendor/abb/3BSE035982-511_en_AC_800M_5.1_Feature_Pack_Communication_Protocols.pdf)
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### ABB 6600
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<img src="./vendor/abb/abb-irb-6600.jpg" style="width:50%"></img>
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- [ABB - IRC - 5 - Controller](https://new.abb.com/products/robotics/controllers/irc5)
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- [ABB - IRC - 5 Manuals](./vendor/abb/IRC5_Operating manual_Trouble shooting_3HAC020738-001_revK_en.pdf)
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- [ABB - IRC - Datasheet](./vendor/abb/IRC5-Industrial-Robot-Controller-data sheet.PDF)
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- [ABB irb 6600 175-2.8](https://library.e.abb.com/public/560fa420555c2d8ac1257b4b0052112c/3HAC023933-001_rev1_en.pdf)
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- [ABB irb 6600 175 - 2.8 - Local](./vendor/abb/IRB_6600_R_US 02_05.pdf)
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- [ABB 660 - Specs](./vendor/abb/ABB-IR-6600-3HAC14064-1_revH_en_library.pdf)
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- [ABB Robotstudio Downloads](https://new.abb.com/products/robotics/robotstudio/downloads)
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## Project links
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* [Project Slack channel](https://pporgworkspace.slack.com/archives/C01A8G36MRP)
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* [Firmware](https://gitlab.com/plastichub/medusa/firmware)
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## Follow ups
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- [ ] calc. energy overhead, per printed kg of plastic
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- [ ] calc. min. invest to print obvious products
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- [ ] investigate possible OS verticals
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- [ ] develop generic system & functional design for v2.0 candidats, for 6D robots but also cable driven 3D systems
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- [ ] check displacement options for segmented prints, (cheap floor track system?)
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- [ ] check material remove options (see ATIish tool changers [YT](https://www.youtube.com/watch?v=EvsgCZyQuq0&ab_channel=ATIIndustrialAutomation))
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