16. System integration

System Integration is the process of bringing together diverse components, systems, and subsystems to form a single, cohesive system that functions effectively. This process involves combining hardware, software, networks, and other technological elements to ensure that all components interact correctly and meet the functional and operational requirements of the complete system.

Objectives of System Integration

  • Enhance Functionality: Enable different systems and components to work together to provide complete functionality that would not be possible if they operated separately.
  • Operational Efficiency: Reduce redundancy and improve operational efficiency by centralizing and coordinating functions and data.
  • Improve Communication: Facilitate communication and data transfer between different systems and applications.
  • Increase Flexibility: Create a more adaptable and scalable system that can evolve and grow as needed.

Steps in the System Integration Process

  • Requirements Analysis: Define the system requirements and understand the specific needs of the integration.
  • System Design: Plan how the different components and systems will be integrated.
  • Technology Selection: Choose the appropriate tools, technologies, and methods for the integration.
  • Implementation: Carry out the integration itself, connecting and configuring the systems and components.
  • Testing: Verify that the integration has been correctly performed and that the complete system functions as expected.
  • Maintenance and Support: Provide ongoing maintenance and support to ensure that the integrated system continues to function correctly.

project

The project is an extrusion system for recycled 3D printing material. This project consists of three crucial components for its fabrication: electronics, the extrusion system, and the project structure. To manufacture this project, I referenced the extrusion system and structure of an existing recycling system. When creating my project, I will aim to simplify and economize the materials used, as I do not have all the tools, budget, and experience to produce a system of higher quality than the one I am referencing. Additionally, I do not have much time for its fabrication.

Electronics

Requirements Analysis:

For the electronics, I need to account for the high power consumption of the ceramic resistors, which will be responsible for heating the extrusion system. Therefore, my components must be capable of handling the current drawn by each of the ceramic resistors. I will use an ATmega328 microcontroller to fully control all the electronic components. This is because I need to control three NEMA17 motors, fans, input sensors for temperature and filament flow, as well as the project's control system, including an OLED display with buttons.

System Design:

For the design, I plan to use KiCad for the PCB and electronic design. The idea is to design the electronics in different modules to facilitate testing and reduce the complexity of the board.

Implementation:

Since the boards are independent or separate modules, it will be easier for me to manufacture and conduct independent tests on each component. Initially, the connections between them will be made using jumpers, and later on, I will use soldered wires between the boards.

Testing:

For testing, I will use an Arduino Nano since it has the same microcontroller. With the boards designed as separate modules, I will be able to conduct tests more easily.

extrusion system

Requirements Analysis:

For the extrusion system, I need a smooth metal tube to insert a drill bit that has a geometry similar to extrusion screws, as the drill bit is much cheaper than those screws. Additionally, I will need to learn how to use a lathe to manufacture the various pieces I will use in the extrusion system.

System Design:

For the design and fabrication, I first plan to make everything without set measurements, as I need to learn how to use the lathe and create something to see what I can improve. Later, I will test with established measurements and a more thought-out design.

Implementation:

To join the machined aluminum pieces with the metal tube, I plan to machine the aluminum pieces as precisely as possible to fit them with a press fit. Additionally, I will add a small screw to tighten them and prevent them from coming loose.

Testing:

The tests cannot be conducted until the entire extrusion system and part of the electronics are completed. This will be the most time-consuming process because I will also need part of the structure to perform the tests. Based on my experience with 3D printing, I know this could be challenging due to potential leaks of melted material and handling the extruder while it is hot.

structure

Requirements Analysis:

For the structure, I plan to use aluminum profiles available at the university. I don't need a specific measurement; I will simply use what the university has. For the connections between the profiles, I will create some robust 3D prints that will be screwed together with T-nuts.

System Design:

For the design of the pieces required for the structure, I will use SolidWorks to model the pieces and then proceed to 3D print them.

Implementation:

When printing the pieces, I will analyze the potential stresses required by the structure and modify the printing parameters to suit the use of the piece.

Testing:

For the tests, it will be sufficient to assemble the structure, and if something doesn't work, I will simply change it.