Plc 3d printer

Reddit - Dive into anything

https://www.youtube.com/watch?v=zTz4KF9EIWI&feature=youtu.be

Just came across this subreddit, and thought I'd share a pretty awesome university project I got to do as part of the course I finished last year since there isn't that many people who would appreciate it. Apart from the gantry frame, the entire project was made in 4 weeks so please excuse the many rough edges. Excuse the long post...

Initially we had four groups which had to make four different final projects, however myself and another group leader decided to merge them into one project, we felt that fulfilled the aim of our course a little more (collect data on everything... including different systems).

Essentially our project was made out of 4 stations

Production. Repetier-Server was used to monitor and control 2 Creality Ender 3 Printers. Node-Red Industrial PC talked via Websocket to Repetier, and managed queueing and monitoring prints. When a print was done, Node-Red via Modbus TCP would move the print of via the Universal Robot if the next station was ready. This was co-ordinated by presenting an OPC-UA server for SCADA
Quality Assurance: Using an IFM PLC via Codesys also co-ordinated by OPC-UA, if a part was ready to inspect a RFID product ID was generated and written to the 'pallet' and it was moved a location where it was inspected by a camera hooked up to a PC. This used OpenCV + Python + OPC-UA to give a quality rating of 1 (Best) to 3 (Worst). After this was done, the RFID Tag was read with the product ID and the product moved to the end of the station. A temperature/vibration sensor connected via EtherCAT and IO-Link monitored the linear actuators motor.
Packaging: When ready, places the product into either recycling or a box from the fourth station, when it has been retrieved. This station used a Siemens S7-1511 PLC using Profinet to talk to the Universal Robot, and S7-Comms to talk to the SCADA system. Or OPC-UA. We tested both.
Storage: This automated gantry would store and fetch items in a 3d stack. Depending on the quality of the product (1 or 2) a different colour box was selected and moved to station 3. Once confirmation of packaging was done, it would store the product under the same tag the RFID reader had. Products could then be ordered via the SCADA system to the other entry/exit point. The gantry used an Omron PLC + Drives with EtherCAT, and OPC-UA to the SCADA system.

SCADA: Ignition was used to co-ordinate all the stations and as a historian for data (we only had the system fully up for 4 days), which did handle order queueing, items per hour, quality monitoring etc...

Digital Twin: I whipped up in 10 hours a quick digital twin using Unity, simply streaming the OPC-UA data to a UDP stream via Node-Red as it was unfortunately only 1 way. Would have loved to expand upon this but we were very time limited.

We intentionally wanted to use multiple different vendors for the equipment, our employers (who sponsored our course) were kind enough to lend us most of the equipment. Thank god it was all ethernet based though...

It was definitely an opportunity I was glad to have, it was a trial course in Australia, far more use of real equipment and hands on than any of the university degrees would have.

Furman University Scholar Exchange - South Carolina Junior Academy of Science: A Programmable Logic Controller (PLC) for a 3D Printer to Improve Functionality

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Title

A Programmable Logic Controller (PLC) for a 3D Printer to Improve Functionality

School Name

South Carolina Governor's School for Science & Mathematics

Grade Level

12th Grade

Presentation Topic

Engineering

Presentation Type

Mentored

Abstract

A programmable logic controller (PLC) is an industrial computer system that allows for the monitoring and controlling of a computer's inputs and outputs using custom programs. For instance, these systems can be applied to assembly lines to increase reliability control in the manufacturing process. By implementing a control board and additional components such as terminal blocks to an off-the-shelf MendelMax 3.0 3D printer, a wiring panel is designed and installed to upgrade the printer's ease of use. This results in convenient access to components, an organized series of wires, as well as easier maintenance. A PLC, or control panel, was needed for the MendelMax 3.0 in the thermoplastics lab as many reoccurring problems resulted in the disuse of it; by having a control board, issues can be easily found and solved more efficiently. The design began with locating and mapping the fixed components (axis motors, IEC socket, USC port) and then finding the most effective placement of other moveable components (power supply unit (PSU) and RUMBA board, or motherboard) around the fixed ones. Through a series of trial-and-error and finding compromises between designs, a blueprint was finalized through an online diagramming tool called DigiKey Schemeit. After implementing the PLC board, additional steps were required to configure and calibrate the printer. The project was ultimately successful as the printer now functions properly, printing with precise parameters, after installing the PLC board. This design could be used on other 3D machines as well, making adjustments accordingly.

Location

Johns Hall 109

Start Date

3-28-2020 10:15 AM

Presentation Format

Oral Only

Group Project

Yes

Mar 28th, 10:15 AM

A Programmable Logic Controller (PLC) for a 3D Printer to Improve Functionality

Johns Hall 109

Renishaw plc 3D printers

Application

Professional

Industrial

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3D printer type

Tabletop

Food

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For home

Chocolate

Jewelry

Russian

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Full color

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606

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252

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144

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Gaminu

re:3D

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it is 3D

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Ac123Dc

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Ultibots, LLC.

Intelligent Machine Inc.

Metamaquina

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Multitec GmbH

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Sharebot

Nova 3D

QU-BD Inc.

RDMCU

Full Spectrum Laser LLC

PieceMaker Technologies

Printbot, Inc.

Terawatt Industries

botObjects

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NWRepRap

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Printed Worlds

Reprapsource

Twelvepro Co

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Stellamove Inc.

Make Mendel

Rapide 3D

Makealo

Crew Ltd.

Open cube

3D Kits

Coombes Solutions Ltd.

SHARK Limited Partnership

Smartfriendz

3D Monster

Kikai Labs

THY3D

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RepRap Diffusion

QSQM International Co.

Tumaker

Makism 3D Corp.

3dBotZ

ZMorph 3d

Eckertech Inc.

Imec Proto

miniFactory Oy Ltd

printMATE 3D

CMET Inc.

Arcam AB

3Geometry Manufacturing Systems Pvt Ltd

Electro Optical Systems

Trump Precision Machinery Co. , Ltd

Wuhan Binhu Mechanical & Electrical Co., Ltd.

Optomec Inc.

Shaanxi Hengtong Intelligent Machine Co., Ltd.

Matsuura Machinery Corporation

ExOne Company, LLC

Concept Laser GmbH

Instrument Tech Co, Ltd

UnionTech

Renishaw plc

D-MEC Ltd.

Realizer GmbH

SLM Solutions GmbH

Fabriconic LLC

Mark Forged

Keyence Corporation

SYS + ENG

Lithoz GmbH

DWS s.r.l.

Beijing TierTime Technology Co. Ltd

Carima

Mcor Technologies Ltd.

Asiga

Rapid Shape GmbH

solido ltd.

Blueprinter ApS

Kevvox Pte Ltd.

JER Education Technology Co., Ltd

Azuma Engineering Machinery Inc.

Space Monkey

Trimaker

Most Fun

Iniciativas 3D

IdeaLab 3d

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MakerDreams

i3Dbot Co. , Ltd

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Something3D

Cagelli Distribution

E Crew Vis

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Mankati

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3DQuality

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Unimix

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ENNOVA

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Magnum

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Wonwall

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EGL3D

Creality 3D

UNIMATECH

VolgoBot

ZVER 3D

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MicroFactory

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Shenzhen Anet Technology Co Ltd

MASS PORTAL SIA

Cyberon

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TotalZ

3dcon

Raise3D

OOO RUSSIAN ENGINEER

Vortex-3D

Flying bear

Print3D

ROBOINO

SoloPrint

Fun Distribution

Alekmaker

Cronos

TEVO 3D

3D printers from China

ZAV 3D printer

Epo3d

FLSUN 3D

WINBO

PROTOTYPE

UNIZ TECHNOLOGY

W2P Engineering GmbH

MAESTRO

Pi 3D printer

Shenzhen Tronxy Technology Co

Kelandi

Geeetech

3DCeram

Omaker

Builder 3D Printers

Creatable Labs

ROBOZE

Desktop Metal

Sintratec

CreatBot

ANYCUBIC

3dlaboratorio

OOO SPC "Lasers and Equipment"

Prusa Research

Prismlab

ivilol

Geralkom-3D

EqMex

Tsar3D

Zhuhai CTC Electronic Co. , Ltd

Shenzhen Aurora Technology Co., Ltd

Monoprice

Shenzhen Salon Technologies Co., Ltd.

Shenzhen Sundystar Technology Co., Ltd

Shenzhen Easythreed Technology Co., Ltd

WOW Innovation Technology Co., Ltd.

Jinhua Xingzhe 3D Technology Co., Ltd

Shenzhen Zhongxin Microscience Software Co., Ltd.

Shenzhen Yaying Trading Co. , Ltd

Z Bolt Co.

Anisoprint

Shanghai 3D ARTEL Science and Technology Co.

FABERANT 3D printers

Self-assembly 3D printers

Z Rapid Tech

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BLB Industries

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What it consists of and how it works RepRap 3D printer

The number of people interested in 3D printers is growing every day, and 2014 has become the absolute leader, if you look at the request statistics for several years, for example, through Yandex. In this regard, we decided to publish an article for the most part for people who are going to assemble a printer with their own hands using various components. At the same time, a person saves, gains additional knowledge and pleasure from the assembly process.

Almost all personal 3D printers use the same approach to the 3D printing process. Details may vary, but in general, the structure and principle of operation are the same. If you describe the 3D printer circuit very briefly, it looks like this: 4-5 stepper motors, a temperature sensor for the nozzle, a heating table, three end sensors that are at the zero mark of the axes, as well as a head and table heater. In addition, the composition may include a second extruder with a thermistor and a heater, a fan that cools the die, and end sensors with a maximum mark.

Connecting all this to a computer directly is impossible, therefore a controller is used, but a model cannot be placed in it directly, this requires a G-code for control - this is a simple set of commands with which you can set actions for the printer. Certain types of controller allow you to install a card reader, after which you can completely write the code to the Micro SD card. In this case, a few buttons and an LCD display are enough for control, even when the computer is turned off.

Controllers are most often made for Arduino IDE. Under it create almost all the firmware. The market leaders today are RAMPS, Generation Electronics and Sanguinololu. RAMPS is considered a leader in its field. Combination of Arduino and Pololu: it has five independent controllers. The fifth is for the second extruder. There is an exit to the extruder heaters and the heating table, thus, it becomes possible to supply plastic with different temperatures to the extruders. There are 6 limit sensor inputs, SD card connector, SPI and I2C.

Movement occurs in three dimensions - along the X, Y and Z axes. To do this, 3D printers have stepper motors that move with high precision and accuracy - usually 1.8 degrees per step. For accurate and fast movement, 3D printers use timing belts and rollers in the X and Y axes. Also, many use a threaded rod or special screws in the Z axis for even more precise positioning. The 3D printer is controlled by the controller, moving the print head (extruder) that extrudes the melted plastic, creating a model layer by layer.

NEMA-17 stepper motors

NEMA-17 is not a model name, but a stepper motor footprint that has three modes: full step, half step, and micro step.

During full stepping, stepper motors take 200 steps to turn the motor 360 degrees, during half stepping - 400, and during microstepping, it is possible to divide the step into 4, 8 and even 16 parts. Microstepping technology is complex, so many companies began to manufacture stepper motor controllers.

The operation of the controllers is as follows: first, the power goes to the engine, then to the logic part, then the direction and the “step” command are given to the control contacts. During the “step” command, the motor receives enough voltage to move the rotor one microstep, half step, or step, depending on the parameters set by the jumpers. Often, stepper motor controllers have a 1/16 mode. To regulate the voltage, a variable resistor is installed on the controller. It is an important element because steppers can be under 8V, 4V and 12V.

Extruder

Printer element that distributes plastic and other materials evenly over the work surface. The extruder melts and extrudes an ABS or PLA thermoplastic through a nozzle onto the table surface. The extruder is the most complex part of a 3D printer, the main components of which are: a plastic feed drive and a thermal head.

The filament drive ejects filament with a diameter of 1.75 or 3 mm. using a gear mechanism. Most modern drives use a stepper motor to better control the filament feed to the thermal head. The filament, after being fed into the extruder by a drive, passes into a thermal head, made from a piece of aluminum with a built-in heater. When the plastic reaches the thermal head, it heats up to a temperature of 170-260 degrees Celsius, depending on the type of plastic. While in a semi-liquid state, the plastic is extruded from the print head, which usually has a hole diameter in the range of 0.35 to 0.5 mm.

Print surface (platform, table)

The table is a work surface on which 3D parts are formed. The size of the work surface varies depending on the printer model, and is usually in the range of 150 to 200 square millimeters. Most manufacturers of 3D printers offer a heated platform - already in the kit or as an additional option. Also, there is always the opportunity to make a heated platform yourself from improvised material. The task of the platform is to prevent breaks or cracks in the model, as well as to ensure reliable adhesion between the first layers of the printed part and the working surface.

The platform surface is made of glass or aluminum for better heat distribution over the work platform and provides a smooth, even surface. Glass gives a more even surface, while aluminum distributes heat better in the case of a heated platform. To prevent the printed model from flying off during the creation process, the surface is often covered with some type of adhesive or film. Such materials often consist of Kapton or polyamide tape, depending on the type of plastic.

Linear Motor

The type of linear motor (drive) used on a particular 3D printer largely determines how accurately the device will print, how fast, and how often and how much the 3D printer will need to be serviced. Many 3D printers use smooth, precise rods for each axis, as well as plastic or bronze ball bearings to drive each rod. Linear ball bearings have gained a lot of popularity due to their durability and better performance, but they are often noisier than bronze ones, which, however, are more difficult to calibrate at the time of assembly.

Retainer (endstop, limit switches)

The range of motion of linear actuators is usually limited by a mechanical or optical detent. Roughly speaking, these are just stops that signal to the printer that it has come to the edge of the work surface in order to prevent it from going beyond the platform. EndStop are used to define the origin (0,0,0) for all three axes.

Although the latches are not required for 3D printers, having them will allow the printer to calibrate the position before each print process, which will make printing more accurate and accurate. End sensors are of two types: pressure and optical. Optical is more accurate, but in the case when there is no need for special accuracy (for example, X-Y), you can resort to savings and use pressure.

Frame

What holds all the above elements together is called the frame. The shape of the frames, as well as the material from which it is made, greatly affect the accuracy and quality of the print. Many 3D printers use threaded rods and other materials in the frame construction. Also, many printers use laser-cut plywood sheets to create the frame.