- Making Control system

This page is my work process for week 10 machine building. We plan to make Vacuum Forming.

1. The Parts I used

Below is the required parts which I picked up.

- Board

• Raspberry Pi Pico x1
• SPAEKFUN Logic Level Converter: x2
• Photocoupler TLP293 x2
• Pin Header1x2 P2.54 x10
• Pin Header1x4 P2.54 x2

- Output

• Solid State Relay: SSR-40DA x2
• Motor driver_Quimat 4A TB6600 x2
• Bipolar Stepper Motor 17HD48002H-22B x2

- Input

• Limit Switch_omron SS-01GL2 x4
• Push Button_PS21B-2 x4

- Power Supply

• CURE Switching Power (12V 10A 120W) x1
• Terminal Block　(T20C03)
• Power code (KB-D3247A) x1
• DC-DC converter kit (AE-OKL-T/6-W12N-C) x1
• AC inletx1
• Wall outlet x1
  • Embedded Mounting Frame WN3700 x1
  • Wide Outlet wn1061sw x2
  • Blank Tip WN3020MCW x1
• F cable (VVF 2.0x2) x 1m

2. Power Line (Plan)

Below is Plan for Power Line, Vacuum Forming.

3. Datasheet

- Raspberry Pi Pico (Pinout)

- Stepper 17HD48002H-22B

• 1 Step angle =1.8° (200 pulse(step) for 360°)

- Motor Driver TB6600

• Input Current: 0-5.0A
• Output Current: 0.5-4.0A
• Power (MAX): 160W

• Micro Step 1,2/A, 2/B, 4, 8, 16,32

• Microcontroller Connection is below in datasheet.
  

• Microcontroller Connection is below in DFROBOT.
  

-Solid State Relay: SSR-40DA

- Photocoupler TLP293

4. Board Making

I made board design for the assignment of week10 as below. For chip, I choose Raspberry Pi Pico as it has many GPIOasse.

- Schematic by Kicad.

- PCB by Kicad

- Milling

Milling details same as Week08.

- Soldering & tester check

5. Making Control Box & Panel, by laser cutting

5-1) Control BOX

• Consider the position of parts and size of control box size.
• I made Control BOX, using laser cutting machine.
  • Make Model
    • by Fusion360 and exported in SVG format about top face.
    • and Makecase
  • Laser cutting
    • Machine: FABOOL Laser CO2
    • Materials: veneer　t=4mm
    • Software: SmartDIYsCreator
    • Parameter: Speed 1500, Power 40, Times 3

- Attach the necessary parts to the base of the Control Box.

- Install the outer frame of the control box　　

Then, It's time to wire for the prototype.

5-2) Wiring

Wiring is done using many tools and terminal assortment. During wiring work.

• Limit Switch
• Power line (AC inlet) and Terminal block.
• Wall outlet:
  peel the cover of code about the length of guide on the outlet.

5-3) Panel

I made Push-button switch panel, using laser cutting machine.

• Make Model
  • by Fusion360
  • exported in SVG format about top face.
• Laser cutting
  • Machine: FABOOL Laser CO2
  • Materials: acrylic board
  • Software: SmartDIYsCreator
  • Parameter: Speed 900, Power 60, Times 2 Then I install Push-button switch to panel.

6. Assembly

It's time to assemble. Masuoka-san and I work for assemble together.

Install Motor

Install Limit Switch

Install Control box
Install Panel

Bundle the wires　　
Prototype1 assembly is Done.

After test ON 11-April, We choose electric heating stove to heat.
Install electric heating stove (Work on Progress)

7. Programming code

The completion code is as follows

// Pin definitions for stepper motors A and B
const int motorA_PUL = 16;
const int motorA_DIR = 17;
const int motorA_ENA = 18;

const int motorB_PUL = 19;
const int motorB_DIR = 20;
const int motorB_ENA = 21;

// Pin definitions for sStart button and limit switch 
const int limitSwitchAPin_up = 0;
const int limitSwitchBPin_up = 1;
const int limitSwitchAPin_down = 2;
const int limitSwitchBPin_down = 3;
const int upButtonPin = 4;
const int downButtonPin = 5;
const int heatButtonPin = 6;
const int startButtonPin = 7;

// Pin Definition for Relay
const int heater_relay = 27;
const int vacuum_relay = 28;

// Stepping motor step count and delay time
const int stepsPerRevolution = 200;
const int stepDelay = 200000 / stepsPerRevolution; // MicroSec

void setup() {
  // Setting of Pin 
  pinMode(motorA_DIR, OUTPUT);
  pinMode(motorA_PUL, OUTPUT);
  pinMode(motorA_ENA, OUTPUT);

  pinMode(motorB_DIR, OUTPUT);
  pinMode(motorB_PUL, OUTPUT);
  pinMode(motorB_ENA, OUTPUT);

  pinMode(upButtonPin, INPUT_PULLUP);
  pinMode(downButtonPin, INPUT_PULLUP);
  pinMode(startButtonPin, INPUT_PULLUP);
  pinMode(heatButtonPin, INPUT_PULLUP);
  pinMode(limitSwitchAPin_up, INPUT_PULLUP);
  pinMode(limitSwitchBPin_up, INPUT_PULLUP);
  pinMode(limitSwitchAPin_down, INPUT_PULLUP);
  pinMode(limitSwitchBPin_down, INPUT_PULLUP);

  // Setting of Relay pin
  pinMode(heater_relay, OUTPUT);
  pinMode(vacuum_relay, OUTPUT);
}

void loop() {

 // (1)When the up button is pressed
 if (digitalRead(upButtonPin) == LOW) {

     // Enable stepper motors
         digitalWrite(motorA_ENA, HIGH);
         digitalWrite(motorB_ENA, HIGH);

     //Rotate both stepper motors
      if (digitalRead(limitSwitchAPin_up) == HIGH) {
        rotateMotor_cw(motorA_DIR, motorA_PUL);
      }

      if (digitalRead(limitSwitchBPin_up) == HIGH) {
        rotateMotor_cw(motorB_DIR, motorB_PUL);
      }
    }

 // (2)When the down button is pressed
 if (digitalRead(downButtonPin) == LOW) {

     // Enable stepper motors
         digitalWrite(motorA_ENA, HIGH);
         digitalWrite(motorB_ENA, HIGH);

     //Rotate both stepper motors
      if (digitalRead(limitSwitchAPin_down) == HIGH) {
        rotateMotor_ccw(motorA_DIR, motorA_PUL);
      }

      if (digitalRead(limitSwitchBPin_down) == HIGH) {
        rotateMotor_ccw(motorB_DIR, motorB_PUL);
      }
    }

 // (3)When the heating button is pressed
 if (digitalRead(heatButtonPin) == LOW) {
     // Enable stepper motors
         digitalWrite(motorA_ENA, HIGH);
         digitalWrite(motorB_ENA, HIGH);

     // Rotate both stepping motors until both limit switches A and B are pressed
      while (digitalRead(limitSwitchAPin_up) == HIGH || digitalRead(limitSwitchBPin_up) == HIGH) {
       if (digitalRead(limitSwitchAPin_up) == HIGH) {
         rotateMotor_cw(motorA_DIR, motorA_PUL);
        }

       if (digitalRead(limitSwitchBPin_up) == HIGH) {
         rotateMotor_cw(motorB_DIR, motorB_PUL);
        }
     }
     // Heater relay ON when both limit switches A and B are pressed
        digitalWrite(heater_relay, HIGH);

     //Heating OFF when start button is pressed
      if (digitalRead(startButtonPin) == LOW) {        
       digitalWrite(heater_relay, LOW);
     }
 }

 // (4)When the start button is pressed
 if (digitalRead(startButtonPin) == LOW) {
     // Enable stepper motors
      digitalWrite(motorA_ENA, HIGH);
      digitalWrite(motorB_ENA, HIGH);

     // Rotate both stepping motors until both limit switches A and B are pressed
      while (digitalRead(limitSwitchAPin_down) == HIGH || digitalRead(limitSwitchBPin_down) == HIGH) {
       if (digitalRead(limitSwitchAPin_down) == HIGH) {
         rotateMotor_ccw(motorA_DIR, motorA_PUL);
        }

       if (digitalRead(limitSwitchBPin_down) == HIGH) {
         rotateMotor_ccw(motorB_DIR, motorB_PUL);
        }
     }

     // Vacuum relay ON for 10 seconds when both limit switches A and B are pressed
         digitalWrite(vacuum_relay, HIGH);
         delay(10000);                        
         digitalWrite(vacuum_relay, LOW);    
         delay(1000);
    }

}


// function definition 

void rotateMotor_cw(int motor_DIR_cw, int motor_PUL_cw) {
  digitalWrite(motor_DIR_cw, HIGH); // Rotate in clockwise direction
  digitalWrite(motor_PUL_cw, HIGH);
  delayMicroseconds(stepDelay);
  digitalWrite(motor_PUL_cw, LOW);
  delayMicroseconds(stepDelay);
}

void rotateMotor_ccw(int motor_DIR_ccw, int motor_PUL_ccw) {
  digitalWrite(motor_DIR_ccw, LOW); // Rotate in counterclockwise direction
  digitalWrite(motor_PUL_ccw, HIGH);
  delayMicroseconds(stepDelay);
  digitalWrite(motor_PUL_ccw, LOW);
  delayMicroseconds(stepDelay);
}

Reference code

In my case, I had a very hard time with the program code. The following sites and others helped me.

• TB6600 Stepper Motor Driver

  • Qiita Blog
  • Blog

• "INPUT_PULLUP" of arduino IDE

  • SWITCHSCIENCE blog
  • Arduino_DOCS

• C language learned by suffering

• OttoBlockly Sample code
• Arduino IDE Sample code
• ChatGPT

8. My Thought

• I am in charge of Making Control system for Machine building. It was very wonderful experience for me.
• There was so much to do for machine building that there was no time at all. (connections, programming, and wiring work, etc)
• Space for installing Control Box components is small. For future work, I leaned the outbox size should made it wider.
• Wires are disconnected and debugging is frequent, so I changed to caulking terminals that are difficult to disconnect.
• I've also learned that wiring with long length can result become inconvenience.