Designing a Delta Tripod Robot Based Fused Deposition Modelling 3 Dimensional Printer Using an Open-Source Arduino Development Platform

* Co esponding au ho : zsol .molna [email protected] Designing a del a ipod obo based used deposi ion modelling 3 dimensional p in e using an open-sou ce A duino de elopmen pla o m Tamás Templom1, Timo ei Is án E dei1, Zsol Molná 1,*, Edwin Shaw2 and Géza Husi1 1Uni e si y o Deb ecen, Mecha onics Depa men , 4028 Ó eme ő s ee 2., Deb ecen, Hunga y 2London Sou h Bank Uni e si y, School o Law and Social Sciences, London, Uni ed Kingdom Abs ac . The pinnacle o 3D p in ing is i s e ec on he ield o apid p o o yping. The majo ad an age comes om he ac ha designe s can quickly ma e ialize a pa o objec , which hen could be es ed in p ac ice, and can be e o lessly modi ied i needed. This ob iously cu s he de elopmen expenses and ime by a signi ican pe cen . Mo eo e , i ’s possible o c ea e complex and p ecise shapes wi h he echnology, which would be much mo e ime and esou ce in ensi e i done by olde me hods, o example manual o au oma ic machining. 1 In oduc ion The Uni e si y o Deb ecen’s Building Au oma ion Resea ch Facul y houses nume ous p ojec s o he Facul y o Enginee ing [1]. These p ojec s always inspi e us o u he esea ch, like ou IoT (In e ne o Things) enabled FDM (Fused Deposi ion Modeling) 3D p in e [2]. Du ing my s udies, smalle p ojec s always equi ed a modes amoun o mechanical pa s, which we e o en needed o be special sized, o ha d o manu ac u e, and would cos an unp opo ional amoun o money. En e in: apid p o o yping. The explosion o CAD (Compu e -Aided Design) sys ems in 1980 d as ically changed he ield o enginee ing, and enabled us o quickly c ea e and manu ac u e pa s a a negligible cos and ime. This whole p inciple made us conside he p ojec . In compa ison o he “classical” Ca esian 3D p in e s, I’ e decided o use a less common, Del a mechanism, as an essen ial challenge. The p oblem comes om he much mo e complex kinema ical and calib a ion issues o said pa allel del a sys ems. The p ojec s a ed in 2016/2017/2 semes e , and wi h he aid o Uni e si y o Deb ecen’s P og am o Gi ed S uden s (DETEP). 2 Design poin s One o he mos c ucial design poin was cos e iciency, ha ’s why I’ e chosen an Open-Sou ce A duino pla o m. [3]. Fo he Con ol So wa e, I’ e picked he A duino i mwa e Ma lin, which is specially designed o Del a 3D p in e s [4] The o he con ol and slicing so wa e communica es ia USB (Uni e sal Se ial Bus) on he se ial bus. Del a obo s can ha e wo ypes o mo emen , linea and adial, and I’ e decided in a ou o he linea . Fu he mo e, he aim was o c ea e a wo kspace capable o manu ac u ing pa s o s anda d sizes, and gene al uses, no only p oo o concep smalle ones. Del a ipods consis o h ee e ical axes, each o a ed om 60 [°] om one ano he . By compa ing di e en p esen designs, We’ e chosen oo hed bel as a me hod o mo ing he sys em, as i ’s as , and p ecise enough o ou demands [5]. The d i e consis s o a oo hed bel o 2 [mm] pi ched, GT2 bel and a gea wi h 20 ee h d i en by hyb id s eppe mo o s. We’ e picked a Nema 17 ype bipola s eppe mo o , wi h he dimensions o 42,3 x 42,3 x 34 [mm] [6]. The sled s uc u e consis s o 2-2 pieces o ∅8 [mm] diame e ci cula s eel pieces connec ed wi h linea bea ings. To each he en i e wo king a ea wi h he ho end, 5 pa ame e s needed adjus men s: heigh o axis(H), adius o del a (DR), consis ing o he ci cle included by he 3 axis, leng h o push od (L), ha connec s he sled and he e ec o , o se o he e ec o (EO), and he o se o he sled (SZO). The sled s uc u e is downloaded om an Open- Sou ce STL (s e eoli hog aphy) ile sha ing si e, p in ed om ABS (Ac yloni ile Bu adiene S y ene), and designed o LM8UU ype bea ings and GT2 oo hed bel [7]. The push od is made ou o ca bon ib e, and has ball join s on each end. The hea ing solu ion o he ho end is a E3D V6 ype elemen . To connec he push ods o he ho end, we need an adap e , a so-called e ec o , his connec s he 6 push ods o he ho end. As we choose he MK2Y ype, d = 220 [mm] diame e hea ed bed, we de ined ou p in ing wo k a ea as well. On he Z axis, we aimed o 110 [mm] maximum heigh . ANNALS OF THE UNIVERSITY OF ORADEA Fascicle o Managemen and Technological Enginee ing ISSUE #2, AUGUST 2018, h p://www.im uo adea. o/auo. m e/ 89 Fig 1. shows ou 3 a iables (H, DR, L) a e hea ily dependen on each o he . The la ge he del a, he longe push ods we need o each he co ec a ea on he X-Y plane. bu his b ings he need o leng hen he axis as well, o keep he mo emen ange on he Z axis as well. The push ods’ angle wi h he bed a he obo ’s HOME posi ion is: α. Howe e , du ing mo emen s push od’s angle wi h he bed canno go unde 20°, so he angle in he endpoin is: γ.  SZOz = 20 [mm]  HEOz = 60 [mm] (1) (2) (3) Table 1. Speci ied physical pa ame e s Componen Speci ied size Push od leng h [mm] 336 Radius o Del a [mm] 260,75 Heigh o Axis [mm] 460 A e we laid down ou design poin s, we used he ee Au odesk In en o o c ea e he 3D model o ou sys em [8], which was necessa y o u he planning. The 3D model enables us o check he i ing and usabili y o any pa ha will be added o he sys em la e . I ’s also bene icial ha we can check he possible collisions in a simula ion, p e en ing eal acciden s. Fig. 1. The model 3D ende ed in Au odesk In en o Componen s on Fig 1.: 1. Bo om T ay 2. Top T ay 3. Bo om Axis Suppo 4. Top Axis Suppo 5. Hea ed Bed 6. Round Ba 7. Push od 8. Ho end 9. E ec o 10. Sled 11. S eppe Mo o 12. Ex ude mo o 13. Pulley 14. Con ol Ci cui 15. Hollow Sec ion Legs We’ e used a Bowden solu ion o he eede uni , which means ha he ex ude mo o is no di ec ly abo e he ho end, bu connec ed o he op ay, and connec ed ia a Te lon ube, which guides he he moplas ic ma e ial [9]. On he plus side, he o al mo ed weigh is less, Howe e , i equi es a mo o wi h highe o que, some le o e ilamen will emain in he pipe, and I ’s no sui able o eeding lexible ma e ials. Du ing he assembly, we used ensione s o as en he oo hed bel s, and I is also ad an ageous o use some kind o elas ic connec ing elemen in be ween he push od pai s. 3 The comple ed ci cui Ou nex job was o ins all he elec onic componen s. The se o d i e s, and he o he necessa y componen s we e connec ed o ou A duino Mega wi h a Ramps 1.4 as a shield, which is a specialized ins umen o 3D p in e s. The shield un on 12 [V] DC (Di ec Cu en ), p o ided by a 280 [W] ATX PSU (Powe SUpply). I possesses wo 5 [A] ou pu s, one o he ho end, which is in cha ge o hea ing he he moplas ic ma e ial, and one o he an, o cool down he al eady ex uded laye s. Addi ionally, i includes an 11 [A] ou pu , which p o ides he equi ed powe o he hea ed bed. We can connec up o 3 he mis o s o i , in ou case, we used 100 [kΩ] esis ance ones. Mo eo e , we added 6 limi swi ches, which o 3 used as he op endpoin s, as basic mechanical NO (No mally Open) swi ches. Ramps 1.4 can suppo up o i e s eppe d i e s, cu en ly we use 3 o mo emen , and 1 o he ex ude , so in he u u e we could add an ex a ex ude o a second ho end. Ou chosen s eppe mo o s’ echnical da a: 1,3 [A], 0,22 [Nm] o que, oll pe each s ep is 1,8°. We used DRV825 (Pololu) d i e s o con ol he mo o s [10]. This IC (In eg a ed Ci cui ) also houses he necessa y esis o s and po en iome e s o ope a e he mo o s. Fig. 2. Pololu DRV8825 module [10] ANNALS OF THE UNIVERSITY OF ORADEA Fascicle o Managemen and Technological Enginee ing ISSUE #2, AUGUST 2018, h p://www.im uo adea. o/auo. m e/ 90 One o he g ea es bene i o he IC is he so-called mic os ep unc ion, which enables us o spli he s eps o he mo o o e en mo e s eps. In mic os ep, we dis inguish 1/2, 1/4, 1/8, 1/16, 1/32 s ep angles, depending on he se ing o he ci cui . We can se he co ec mic os ep on he jumpe on he d i e . Because DRV8825 is capable o 1/32 mic os eping, we choose ha . The maximum ampe age and ol age is 2,2 [A], and 8-45 [V] o e he mo o s in he case o Pololu. We used he ollowing o mulas o calcula e he mo emen esolu ion: [11]: (4) (5) 4 Calib a ion Du ing calib a ion, we di e en ia e be ween So wa e and Ha dwa e calib a ion. Du ing he So wa e calib a ion, we se ou A duino p og am, and he slicing so wa e o he co ec con igu a ion. In he i mwa e Ma lin, we ha e o submi he physical pa ame e s o he p in e , he da a o he d i e , limi swi ches, and empe a u e da a, and also he pinou s. The ee slicing so wa e Ul imake Cu a e en possesses an o icial manual, o se he co ec wo k a ea, co ec communica ion, and he diame e o he nozzle [12]. We also se he pa ame e s o he cu en p in he e as well, o example: ill ac o , p in speed, and he ilamen ’s speci ied hea alues. Be o e he physical calib a ion o he p in e , we ha e o calib a e some indi idual pa s as well. Such pa s a e like he limi swi ches, ha needs an indi idual check-up o each componen . Mo eo e , i ’s impo an o se he cu en limi o he s eppe mo o s, hus o achie e he highes o que, we ha e o use a d i e wi h highe cu en low han he maximum cu en on he s eppe . Bu we don’ wan o o e powe ou mo o s, he maximum se cu en should be he highes possible powe d aw o he mo o . The co ec calib a ions esul in coole mo o s, and no loss o s eps. A e we co ec ly se he pa ame e s, we can connec he uni s o he sys em. Fo he co ec se ings, we need o measu e he e e ence ol age o he ins umen . The DRV8825 his me hod ollows he equa ion: (6) Because ou chosen mo o s’ maximum cu en pe phase is 1,3 [A], he o mula no. 6. le ’s us calcula e he e e ence ol age: U e = 650 [mV]. The i s s ep o calib a ing a Del a-T ipod ype p in e is o se he P(0,0,0) mechanical null poin in ad ance, manually. The obo se in he HOME posi ion will be mo ed along he Z axis in he nega i e di ec ion (down) un il he ho end eaches ou glass plane co e ed wi h a shee o o dina y pape , bu i shouldn’ p ess i on o he glass. Because a shee o pape usually has abou ≈0,1 [mm] hickness, we can en e he co ec pa ame e s in o he A duino p og am om he o al dis ance co ec ed wi h he gi h o he shee . This is he so-called pape es [13]. These co ec ions a e ollowed by e ining he limi swi ches. This is done by p in ing a one laye , bu hick es p op, o measu e he di e ence be ween he hickness o he laye app oaching o he axes om he cen e. I he measu ed alues do no co espond o he p e-se hickness o he laye , we can use he di e ence o co ec ion pu poses again. Ou la es ask is o se he dimensions. This can be done wi h wo me hods. In he i s one we use an equila e al iangle based p ism. By measu ing he heigh o he objec on di e en edges and sides, I can come o he conclusion o some e o s, such as loose bel s. On he o he hand, we can use a cube as ou es p in as well, bu all in all, he main goal is o measu e he dimensions, co ec he e oneous calib a ions, hen p in once mo e, and measu e once mo e as well, epea edly, un il we ge he same alues on he physical mani es a ion ha we ga e o he p og am. 5 Re e ence p in s Wi h he calib a ion p in s, we came o he conclusion o :  X and Z axes had ma ginal di e ences, bu on he Y axis a 20 [mm] had -0,1 [mm] di e ence.  A 80 [mm/s] p in speed, we can s ill able o use ea - ee ill ac o s. A e accomplishing he co ec p in condi ions, we implemen ed a nozzle o cool down he ex uded ma e ial, o u he inc ease he p in quali y. We also ab ica ed ensione s o he bel s, and a ilamen d um holde wi h bea ings, o ease he eeding p ocess. I’ e had he oppo uni y o p in ou a h ee inge g ipping ool designed by Vik o Va ga, one o my unde g adua e colleagues, o he KUKA KR5, loca ed a he Mecha onical Facul y o he Enginee ing Depa men , Uni e si y o Deb ecen. I’ e used 1,75 [mm] diame e PLA (Polylac ic Acid) ilamen , wi h i s co ec hea alues isible in he able bellow The p in consis ed o he h ee inge s, and he push ods and o a y elemen s as well. Addi ionally, We’ e p in ed a holde o he ool, o kep secu e when no in use. All pa s ha e been made wi h 0,2 [mm] laye hickness, 30 [%] ill ac o and 50 [mm/s] p in speed. ANNALS OF THE UNIVERSITY OF ORADEA Fascicle o Managemen and Technological Enginee ing ISSUE #2, AUGUST 2018, h p://www.im uo adea. o/auo. m e/ 91 Fig. 3. Push ods and o a y elemen The Push ods’ p in ime was: 3 minu es pe piece, and he o a y elemen ook 10 minu es o al. The o al p in ime pe inge was: 85 minu es, and equi ed suppo ing ma e ial, he addi ional holde ook ano he 163 minu es. The o al p in ime did no go o e 8 hou s and hei o al weigh is only 52,2 [g]. Fig. 4. The inished g iping ool on he holde 6 Conclusion A e ca e ully planning ou he mechanical ame, I’ e p oceeded o ins all he elec onic componen s as well. A e I’ e se up he chose p og ams, I’ e s a ed o o e come my g ea es challenge o con igu ing, calib a ing, and co ec ing he obo in e e y aspec . In addi ion o my heo e ical knowledge o he ield, I’ e acqui ed p ac ical expe ience in he ield o FDM 3D echnology. My inal ask o p in ing he a o emen ioned 3- inge g ipping ool, I’ e been able o p esen my abili y o quickly and e icien ly use he p in e o apid p o o yping. Fo u u e de elopmen I wan o emo e mysel as a cons an wa chman o he p in ing p ocess, I’d like o implemen and Open-Sou ce Linux-based emo e su eillance sys em accessible ia In e ne , enabling me o p in o ge eal- ime oo age o he p in ing p ocess ongoing om anywhe e. Fig. 5. The inished 3D P in e Acknowledgmen The publica ion was suppo ed by he p ojec EFOP- 3.6.1-16-2016-00022. This p ojec was co- unded by he Eu opean Union, om he Eu opean Social Fund. Re e ences 1. 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