Objectives

design a machine that includes mechanism+actuation+automation+application
build the mechanical parts and operate it manually
actuate and automate your machine
document the group project and your individual contribution

Mechanical design, machine design

Velichappadu (വെളിച്ചപ്പാട്)

Screw hole Test

The purpose of a screw hole test is to determine the appropriate tolerance, screw fit, and optimal hole diameter for screw holes in 3D models or other application.We needed to test for M3 (3mm), M4 (4mm), M5 (5mm) and M6 (6mm) screws. 3D design was made in fusion. The files are then converted to step file and opened in bambu slicer.

In bambu lab A1 printer the screw test model is printed

Required clearance for screw holes

M3 = + 0.3
M4 = +0.2
M5 = +0.3
M6 = +0.1

I were assigned with preparing the BOM, which I updated in the group assignment page.We wanted two 6mm GT2 belts, each of 5m length which wasn't available in the inventory. So we purchased it. M3x75mm screws were also purchased from outside. We used neo pi wireless CNC controller made by our instructor saheen palayi, that was available in the lab. As there was no corner brackets available in the inventory we took it from Saheen's small milling machine. Rest of the materials were available in fab inventory.

As there wasn't any individual task to complete, I worked with Ashish and Revi in firmware testing.

In an existing CNC plotter, the firmware was tested.

Firmware is a type of specialized software programmed into a hardware device to control its basic functions and operations. Unlike regular software that runs on operating systems, firmware works at a lower level, providing the essential instructions that enable the hardware to initialize, communicate with other devices, and perform specific tasks. It is typically stored in non-volatile memory such as ROM, flash memory, or EEPROM, which allows it to persist even when the device is powered off. Firmware is crucial for ensuring that electronic devices function correctly and efficiently, and it can often be updated to fix bugs, improve performance, or enhance security.

ESP32 Grbl is a CNC controller project that uses an ESP32 microcontroller to run a version of the open-source Grbl firmware, which is commonly used to control CNC machines. Unlike traditional Grbl setups that rely on wired connections and a dedicated computer, ESP32 Grbl offers enhanced functionality through built-in Wi-Fi, Bluetooth, and web interface support. This allows users to wirelessly send G-code commands, monitor operations, and control the CNC machine from a smartphone, tablet, or computer, making the system more flexible and convenient.

Using ESP-NOW protocol, we tested the motor rotation. Then core XY system was tested. We moved the end effector in positive and negative X and Y directions. After some effort , homing functionality was successfully tested. The overall concept was tested by sending G-codes.

I helped Revi with assembling the machine.

This week helped me to understand about how machines work and how to build one.