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3D Printer Simple Extruder Wiring Requirement

24V system

15 wire requirement

2 of 8 pin MTA-100

Connectors

With 22 ga Cat6

Print Head

Plug 1

Stepper Plug

Heater Block

Thermistor

Height Sensor

Fan

Print Cooling Fan

Plug 2

Number of wires involved

Requirements:

MTA 100 quick connector plugs
For scalability and good fit, we make our own wire harnesses to length

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Circuit Plotter Wiring Requirement

3 wires

Mill Wiring Requirement

5 wires

Pen Toolhead

8mm Height Sensor

Plug 2

Mill Toolhead

5A @ 24V

8mm Height Sensor

Plug 2

Plug into the speed controller

Requirements:

5A power source is a PWM speed control circuit etched in the Camp, plugged into the GFCI of the Universal Controller

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Plotter Quick Connect Toolhead Modules

Pen

Pen Holder with Spring

Quick-Connect Mount

Quick-Connect Plug

Universal Axis Carriage

Vinyl Cutter

Requirements:

Pen holder must fit a thin plotting pen for drawing pictures and creating artwork
Pen holder must fit a marker for masking copper-clad boards for 3D printing
Pen adapter must be capable of holding just about any pen or marking device
Device adapter allows for retrofit of vinyl cutter into the system
System has one MTA-100 8-pin quick connect plug for connecting to other uniform plugs.
Plug is compatible with universal wiring system for the 3 different tool heads
Workpiece holding system must be included, and allow for holding the substrate that is being drawn upon.

Pen

Adapter

Device

Adapter

Workpiece holding system

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Toolhead Quick Attach Mount Geometry

Carriage

Horizontal Orient.

Carriage CAD full clamshell Rough Detail.

Full Detail CAD of Carriage half clamshell. See source.

It has 5 holes.

Requirements:

Pay attention to tip of working tool reaching under the carriage
Must attach quickly

At most 2 plugs for electrical
One screw-down bolt with thumb screw, without using any tools

Must attach strongly
May attach below or above a horizontal carriage
Each toolhead type has an integrated mount
Mounts may be different for different tool heads
Bare carriage without magnets is the default attachment interface
Can use any of the 5 holes, which are 6 mm
May use magnetic mount, as long as EMF doesn’t interfere with fans or other components
When tool is disconnected, no nuts fall out; any nuts are captive
Carriage must have integrated height sensor, which is required by all the toolheads.
See ideas on next page

Universal Axis Exploded 3D

(may need to wait a little to load)

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Toolhead Quick Attach Mount Concepts

Eccentric Lever Design

Eccentric Lever

No bolts are used to hold to Carriage

Bolt with wings

Nut Catcher

Bolted Clamp

Note that bolt is not through middle of carriage because toolhead is there (not shown).

Nut Catcher

Ideas

Clamped design - most secure
Non-clamped - simpler
Purely magnetic - inadequate for contact machining
Bolted - require unscrewing, not as quick as a quick-attach level
Lever with eccentric lock

Carriage Side View

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Looking for possibilities to use generic off the shelf parts for kinematic coupling.

An interesting option might be if the existing bolt holes could be used.

Round head bolts might have some consistent precision, but I don’t see a good V groove solution in slot bolts.

Facing together an oversized 10mm slotted bolt and a 3mm round head just doesn’t make sense.

I’m slightly surprised I can not find kinematic mount parts on mcmaster carr.

https://www.mcmaster.com/tool-mounts

https://www.amazon.com/Treal-Steering-Ball-Head-Screws-10pcs-Pack/dp/B07L3D6X9X/ref=sr_1_3?keywords=ball+head+screw&qid=1570310103&sr=8-3

Part Sourcing is probably why the cylinder groove is used.

https://reprap.org/forum/search.php?2,search=kinematic,author=,page=1,match_type=ALL,match_dates=365,match_forum=ALL,match_threads=0

https://3ddistributed.com/e3d-tool-changer-cad-files/ There are some reverse engineering designs of the e3d printer. However, this one is licensed NC.

https://hackaday.com/2019/07/04/e3ds-love-letter-to-toolchanging-3d-printers/

https://github.com/e3donline/ToolChanger

https://www.thingiverse.com/thing:3365456 This is open, but uses an extra motor for

latching, which I think is unnecessary. That isn’t important immediately though. It uses

Balls from another machine, but surely round screw heads would be good enough,

considering it is 3d printed plastic and not precision milled Al.

https://www.mcmaster.com/catalog/125/3190 The shoulder bolts could be

more generic too?

Downside it all adds metal mass and complexity. Although, round head bolts could be added into the carriage, but they need to not be recessed. Add washers?

To test a 3D printed kinematic mount the bolt through the middle clamp might be adaptable to something like this: https://hackaday.com/2018/11/19/a-3d-printed-kinematic-camera-mount/

It could also be printed as a single piece without kinematic mount points, but then it would rotate slightly about the single clamp bolt making it less precise. PLA would be less accurate than metal, but probably add some precision relative to the current simple printers.

Nope, the clamp is not kinematic to the carriage so when the single bolt is undone it can move.

Conclusion: for the immediate simple versions CAD the clamp with the end bolt and merge it with an existing motor angle bracket.

https://docs.google.com/presentation/d/1xuGsPGhbtTUaespbW9WlWgM1uy4IAv6TmEuJy8VVH-c/edit#slide=id.g62e9827f2c_0_27

NEMA Motor Mounts

In single piece angle bracket with V grooves

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Wiring to Controller - Printer

Number of wires

Need 2 Cat 5 cables

Z axis

Requirements

Uses 8 strand cat 22 bundles which lends itself to MTA-100 quick connectors
Easiest wiring is without cable chain, but with spiral wire wrap
6-wire bundles are easiest with off-the-shelf stepper and
Use easiest wire strategy that allows for the quick-connect MTA-100 plug

X axis

Y axis

Quick-Connect Tool

Universal Controller

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PWM Electric Motor Power Supply

Aka noisy Universal DC Power Supply for Welders, Motors, etc.

Requirements

Uses full wave rectifier for 120 DC
Target voltage is 24VDC
Arduino code for Atmel 328 microcontroller is required
From there, uses PWM driven by Atmel 328 microcontroller etched on previous day
Uses MOSFETs or IGBTs for the PWM.
Use power elements that don’t require drivers for circuit simplicity
Circuit design for power stage is required in KiCad
Integration into an enclosure is required for safety
PWM-controlled power is fed to the motor ESC (See next page)
Power supply must be compatible with the ESC

Power supply provides voltage control
ESC provides commutation

Same power stage can be used with Welder Power Supply
Input voltage to Power Stage can be 2-fold:

120AC rectified - for 24V DC motor
24VDC battery bank (from Day 4) - for welder power supply

Power input is scalable to 6kW (~250A at 24V)
Experimental power supply without proper heat sinking - just very small duty cycle for testing the power of power electronics

15A 800V rectifier $1 or this

Power Supply Rectifier:

ESC Components

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Motor ESC - After Power Supply, this controls speed.

We can already use voltage control, and possibly get good results - but phase control via ESC can be used to time the power to the coils to get more efficient operation at as high a voltage as possible. Power=IV=I²R. The higher the voltage, the smaller the fraction of resistive loss?

Building the ESC: how it works - from AmazingDIYProjects

How it works on the high power side:

The high power side turns the batteries DC into AC in crude and simple mechanically-

electronic manner. Start out with a HexFet power transistor named: IRFP3703 (12-18V) or

IRFP3710/IR (up to 48V).

The IR-diodes sends out a light beam which can only reach the photodiodes when the ignition

hole on the rotor is in the right position. Once the IR-light reaches the photodiode the first half

of the high power circuit is activated. When the IR-light reaches the photodiode a small

current passes trough the photodiode, which triggers the transistor.

As soon as the IR-light is turned off by the rotation motion of the rotor, the transistor is turned

off. The residual electricity in the Gate-connection is drained away trough the 1k Ohm resistor.

The cycle repeats when the rotor hole lets the IR-light through to the next photo diode which

activates the other half of the high power circuit. The only difference is that the outgoing

cables from the power circuits are “swapped”; negative out circuit1 connects to positive out

circuit2 and positive out circuit 1 is connected to negative circuit2. .The result of the rotors

ignition hole passing the two photo diodes result in an alternating current, AC.

When the power is on, all the 20 electromagnets get activated and attracts/repels all 40

permanent rotor magnets at once. The next part of the cycle is started when the ignition hole

in the rotor lets the light beam from the second IR-diode pass trough to meet the second

photodiode. The whole cycle repeats with one important difference. The current runs the other

way trough the electromagnets causing them to repel the magnets that were attracted and vice

versa.

This is effective but has two major flaws:

1. It does not self-start at times

2. You can not throttle the motor, there is only on and off. And this brutal way of starting the

motor often burns the power transistors at voltages over18 volts.

There is again an effective solution. By building a pulse width modulator, PWM, you can

easily adjust the power level. Notice that it is not the main power source we pulse directly.

Instead it is the IR-diodes that are pulsed! Since all the electronics of the high power side of

the motor is so fast, switching this setup works great without any lagging or other

complications up to at least 10kHz.

Picture shows the components necessary to complete the electrical system of the motor.

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Arduino Uno Design Requirements

Requirements

Start with Atmel 328 chip
Etched ug thesin circuit plotter mask
Use USB to serial converter for practical programming
5V power enters via USB or 5V header
5V is tapped from Universal Controller via Dupont or MTA-100 connectors. MTA-100 preferred for flexibility
Make it look like an Arduino Uno - interchangeable with Arduino Uno.
Etch OSE logo
Use dupont pin headers, such that Arduino Uno shields fit on this board.
Incx10 clude green LED power indicator light
Use entire 7m board to avoid necessity of cutting the board
Produce replicable sourcing of the Arduino to make a kit
Source file must be in KiCad, intermediate in FlatCAM, and CAM file in gcode for use wite D3D Universal Plotter

USB to serial converter $1

MTA-100 2 connection

Atmel 328

USB A to A female

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CNC Plotter Etching Requirement

Etchant bath agitation by gentle back-forth motion of Universal Axis bed

Etchant Bath

Copper Board

Container

Container is attached to the Bed so it doesn’t fall off

Etchant Container top view

Attachment can be a magnetic holder (same as circuit board holder) - just 4 magnets

Requirements

Bath is cupric chloride
Specify the preparation and concentration testing of the etchant solution
Masking pen specification is critical; along with any post-processing of sketch on the PCB
Works with Plotter Software Toolchain
Specify the copper plating weight for replicable etching.
Shaking is done in a bath using the bed axis of the D3D Unviersal CNC machine
Timing of the bath is set in software for the ideal time
Bath container is attached in a way that can be removed readily from the bed
Works with 7x10 cm copper boards, so the container is 5”x5” in size
Container attachment is done using 12x3 mm Nd 52 magnets

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Commutation Logic Requirement

LED is on only for a short time when LED is over the hole (⅛ duty cycle?)

-J -J

J xB

Functioning Mechanism:

Coil power turns on for a short time (⅛ duty cycle) when magnet is over edge of coil, top view:

The magnet at that time is closest to J for highest force F=JxB, side view:

The -J commutates to +J once it goes to the maget because second LED activates opposite current

coil

magnet

Opposite coil

magnet

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Back of Envelope Efficiency Calculations

Only vertical component of this current contributes to JxB

Vertical

magnet

Functioning Mechanism:

Using magnets and coils with minimum separation, where coil has magnets on both sides:

It appears the efficiency is affected negligibly by the coil resistance (P_J_xB>>P_{coil resistance}), but will be affected by the geometrical overlap.
Assume 1% loss for bearing efficiency

coil

magnet

coil

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Back of Envelope Efficiency Calculations

Only vertical component of this current section contributes to JxB.

Yellow part does not waste much energy because it doesn’t interact with much magnetic field. Thus for practical purposes: efficiency is defined as the fraction of black vector that is vertical compared to overall black vector?

Vertical

magnet

Functioning Mechanism:

Using magnets and coils with minimum separation, where coil has magnets on both sides:

It appears the efficiency is affected negligibly by the coil resistance (P_JxB>>P_{coil resistance}), but will be affected by the geometrical overlap.
Assume 1% loss for bearing efficiency

coil

magnet

coil

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Back of the Envelope Efficiency

A=r Sin 60 = 0.87 r

B = 2 pi r / 6

= R pi/3

Efficiency =A/B

=83% upper magnetic efficiency limit

Requirements

fdga

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Summary of Commutation

Front Bearing Mount Plate

Stator

Rotor 1

Rotor 2

(underside)

Requirements

2 LEDs are lit inside stator pointing outwards
Holes in rotor turn on transistors when magnet is over the edge of the magnetic coil (see next page)
There are 2 LEDs that reverse polarity, and therefore only half as many (10) light holes as magnets (20)

Coils Alternate in polarity:

Control Photodiodes are outside on bearing mount

Control LEDs are inside stator pointing out

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Universal Controller Light Dimmer + Welder Power Supply 1

Topology sample (except work here should be on a 3D printed panel)

Requirements

Uses Universal Controller for the controller part
Uses an external power stage
Power stage contains a 120V full bridge rectifier + transistor to handle up to 2.4 kW of power
Specify components such that 120V AC or 240V AC can be used as the input.
First use case implemented is a 120V AC light dimmer for incandescent lights.
Transistor uses a heat sink
Power stage is on a 3D Printed board with all mounting holes 3D printed for convenience, and with 3D printed terminal blocks

This includes input power + output power for a 100A welder

Control board is 3D printed for hanging all components. Terminal blocks as integrated into the 3D printed board, so that part cound is minimized.
Design of Circuit Board 3D print is in FreeCAD. See more here.
Input to power stage is is a 120V power cord from the GFCI of the Universal Controller.
3D Printed Terminal Block design features 6 mm bolts with self-tapping hole through the plastic

Used for power and signal wires
Signal wires are the 22 Ga Cat 6 stranded

Design is such that the single Universal Controller can run 2 or more power stages as above

Either via the same pin
Or by using multiple pins
Scalability can be demonstrated up to any number of power stages, for example for a 400A welder power supply (10kW)

Arduino Mega code is required as part of this project for the 120AC light dimmer and welder power supply
Control is done via the knob of the LCD screen. LCD shows the duty cycle and voltage calculated from the duty cycle.
Power circuit has no feedback at this point.
The welder power supply is an AC-input, DC welder power supply controllable for 100A from each power stage, stackable to any amperage.
Use a DIY welding electrode holder - and produce a replicable BOM for it.
Both design and a tested system are required.

3D Printed terminal block with 6 mm self-tapping bolt

15A 800V rectifier $1 or this

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Ingition Holes

Stator

Rotor

Ignition holes about 2-3 mm diameter. Distance between them is about 14 mm. Each hole is lit twice (about 5 mm of light out fo 14 mm so about ⅓ duty cycle). Note that the shorter the duty cycle, the more efficient the motor (to an extent).

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Cordless Welder Requirement 1

AC in

DC in

DC out

Signal Input

Transistors

Cordless Welder Power Board

Requirements - Power Supply -

Uses Universal Controller for the controller part
Same hardware as AC welder power supply
Power hardware circuit has terminals for connecting AC or DC power as the input

DC is from battery pack (no rectifier needed)
AC is from wall outlet (rectifier is needed)

Stackability and power input flexibility are included
Circuit design required in KiCad. Design includes the RAMPS board connection

Cooling Fans if required

Arduino

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Cordless Welder Requirement 2

DC out

Requirements - Stackability

The Arduino on the Universal Controller can trigger multiple power boards
Multiple power boards can be plugged into multiple power outlets or a larger power outlet.
Output DC terminals must be large enough to fit multiple wires as needed

Arduino

Power Board

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Scalable Battery Pack Requirement

Basic Unit is a 6s cell (6 cells) in-line pack
Uses a 3D printed battery holder

6s cell form is used as a battery pack for a cordless drill
Holder allows the battery string to slide in
Holder is designed for 1, 2, or more Basic Units

Basic Unit has 6 mm threads sticking out for connecting via metal bus bars, which are CNC cut
Basic unit makes contacts through metal strip and spring or press fit
Standard 6 mm socket head screw is used for the terminals

3D printed holder must accommodate this while maintaining good connection
Design must be editable in FreeCAD

Cordless Welder

- + - + -

Series stacking 6-holder as a power tool battery pack

Various Concepts:

- + - + -

- + - + -

Basic unit of 6s connected cells

M6 thread

‘24’ v pack

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Scalable Battery Pack Requirement 2

Bus bar of any lenght can connect any number of Basic Units
2-basic unit holders bind adjacent Basic Units, so that the number of Basic Units can scale to any number

12 of these provide 20A each x12 for a max of 240 Amps at 22V
Bus bar design assumes mild steel cut with CNC or drilled out for the 6 mm bolts
Standard 6 mm bolts are used as the ones in the Universal Axis - see bolts at McMaster

Bus bar

Basic Unit

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Modules

3D Printer

Circuit Plotter

Commitments:

Motor + CNC Mill

Cordless Welder

Arduino

Universal Axis Build

Simple Extruder

Universal Controller

Extruder Head w/ Quick Mount+Plug

Wiring Harness

Circuit Plotter Quick Attach for Tool Head

CNC Mill Quick Attach Tool Head

3D Printed Motor

Cordless Welder Battery Stack

Scalable Battery Pack

Arduino Uno Etched Board

DC Power Source

Cordless Welder Power Controller Board

Cordless Welder Software with LCD

Cordless Welder Welding Clamps + Welding Rods

3D Printed Motor Control Software

Etching System

Circuit Plotter Pen Tool

Marlin Plotter Software

Inkscape to Gcode (Drawing)

Uno Displaying Hello World w/ Smart Controller

FlatCAM File Generation

KiCad DIY Arduino Uno Part Library

Importing KiCad into FreeCAD

RAMPS + LCD Temperature Logger

2.4 kW Scalable AC Light Dimmer w/ Uni Controller

2.4 kW DC Noisy Power Supply w/ Uni Controller

D3D Simple Universal

3D Printed Hacksaw

FreeCAD Axial Motor Designer Spreadsheet

Motor Controller

Coil Winding Jig

Motor Disk CAM File

Build Instructions

Axis Build Instructions

Build Instructions

Circuit Milling Software Instructions

Circuit Milling Marlin Software

Workpiece Holder

Charge Indicator Light

RAMPS-based 18650 Scalable Charger Circuit

Arduino Charger Software

Reprapdiscount Graphics Programming

Wireless RAMPS in OSE Linux

Michel

Marcin

Vasco

Kevin Corbett Ferdi

Chris, Abe, William

Matt Maier

Flatcam to Gcode

Biz Dev

Mini Drill

Ritwik - Raspberry Pi Tablet?

Cindy

Emmanuel

Emmanuel?

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Day 1

Universal Controller + Universal Axis = 3D Printer
All products in Camp are made with this printer for bootstrapping education and cost reduction

Wiring harness connects electronics + toolhead

Universal Controller Build Instructions

3D Printed Hacksaw

Marcin

Chris Caswell

D3D Simple Build Instructions

Universal Axis Build Instructions

Simple Extruder Build Instructions

Wiring Harness Build Instructions

Quick Connect Wiring Plug

Quick Connect Tool Mount

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Day 1 Summary

Universal Controller

Universal Axis

3D Printer

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Day 1 Blender Animation

3 axes make the D3D Simple

14 Common off-the-shelf parts make up the Universal Axis

6 Common off-the-shelf parts make up the Universal Controller

Script: (This moves up to the 9 days. First paragraph only covers Day 1.

On Day one, we build a 3D printer from scratch. We take 14 common off the shelf parts and 3D printed pieces to build the Universal Axis motion system. We take 6 common off the shelf electronics components and mount them on a 3D printed base to make the Universal Controller. We combine the Universal Controller with 3 Universal Axes to make a 3D printer. We use a quick connect tool head, so we can mount a circuit plotter or a milling head to make a 3-in-1 universal machine. Our first print - is a 3D printed hacksaw.

The machine is then used to make an Arduino from scratch, a power controller, an electric motor, and a battery pack. These components are then used to make a CNC router, and a cordless welder.

Thus we have bootstrapped to a powerful basic toolset that can be scaled up to make larger machines, and to prototype and build other products. In the STEAM Camps, we have a choice to build a Raspberry Pi tablet, an aerial drone, or a vacuum robot.

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Day 1 To Do

Add 5V power supply
Change main power supply
Adjust locations for new power supply
Needs a hole for cable management and screwing down GFCI wire
Build Instructions
BOM - broken by main components + vitamins
Set up production line
Set up wiring harness for TB6600 with MTA-100 connectors

Fix the idler and motor piece for belt through-hole
3D Printer Construction Set in FreeCAD. Develop v1.0 for axes + frame.

Simple Extruder Design
Quick-connect mount
Quick-connect wiring
Performance data - 50-200 mm/sec for Universal Axis parts
BOM
Rework D3D Simple to fit Titan Aero

Full CAD D3D Simple
Full build of D3D Simple
BOM of D3D Simple
Full Kits of D3D Simple posted on website for the workshop

Universal Controller Build Instructions

Universal Axis Build Instructions

3D Printer

Simple Extruder

All products are shipped to OSE for quality control.

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Simple Mill that is Strong. Reconfigurable.

Use Z servo, 11lb force. Not.
Use Z axis
8 mm rods
4”x4” work area/ 2” Z travel

Stepper: $8

Pulley - $1.5

Belt - $0.7

Linear Bearings - $6

Pulley bearing - $1.4

Rod - $2.5/ft - 1.3ft - $3.2

Bolts - $3

Wiring - $1.8

$25 Cost Per Axis

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