Fab
Academy 2013
Gonzalo Pérez
PROJECT DEVELOPMENT
The
development of this project is based on the adaptation of the
mechanism of a knitting machine into an AXYZ 4008 CNC Router
Machine. The project is basically aimed at poor indigenous women
who live in the State of Chiapas. Initially, I wanted to make a
knitting machine, but due to the short period of time at the Fab
Academy, I was forced to make some changes during the entire
project process.
The
first thing I wanted to study is the mechanism of a traditional
hand weaver by itself, but this idea did not convince me at all,
because the hand weavers are complicated to handle. Therefore, I
was forced to study how the mechanisms of a conventional
knitting machine could imitate some of the mechanisms of a hand
weaver.
The main purpose of this project is to provide to at least one community of indigenous women with a CNC mechanism that recreates the knitted pieces in a faster and more efficient way, and to achieve this goal the first thing that was done is the initial approach of how to attack this problem.
The
hand weavers are complicated to handle and what I wanted with
this project is to provide a way CNC mechanism to at least one
community of indigenous women.
To achieve this goal the first thing that was done was the
initial idea of how you would have to attack this problem.
ADJUSTMENT OF A ROUTER CNC AXYZ 4008 MECHANISM FOR WEAVING
The
problem boot is raised.
Graph
of functioning
We propose the schematic of the problem
Approach
interaction of bits and atoms
FIRST STUDY PROPOSAL
As
the first proposal, I raised the removal of the Router and
replace it with an adaptation of it, which could be in the XYZ
axes, and it might be very interesting.
I made the first proposal of the Router without knowing exactly where I was going, and I was not sure how I might have the solution of the alteration for the knitting machine. Therefore, I gave myself the task of putting together each of the components, that may intervene in the alteration of the router, and I began to understand the problem.
THE
FIRST MODEL
This
was the first model to carry the remains of the laser
cutting,.where it clearly should had been knitted from one end
to another. Even though I did not know how to build it, it was
useful because I understood how the menara knitting should not
tangle the threads provided from the bottom up, without
return.
This
first model did not work.
THE SECOND MODEL
Since my professional development I have always resorted to the realization of three-dimensional models in any type of material. Creating three-dimensional models has helped me a great deal; while I am tracing these models manually, I am analyzing and quantifying each stroke. I have not replaced this design method even with an entry of a laser cut and CNC laser; on the contrary, each time I trace with pencil, I know beforehand that is the stroke I will repeat in the machine.
At first glance, it may seem that I am working twice; however, is the opposite, because when I solve the problem with the models, I know immediately how I will do the same with the laser machine and the CNC.
The
second model did not work.
THE THIRD MODEL AND END
I started to make this machine in a model to understand which could be the manufacturing process and also to understand which mechanisms may function with my adaptation of the CNC.
This is the adaptation of the AXYZ 4008 directly on the machine. This model is useful for now. If I were able to understand what mechanisms might work in my adaptation, I will be able to weave.
The parts that worried me the most how to solve,and needed more study, were the zipper mechanisms and the sensors, as well as the actuator and the handles of the needle. I had to take advice from a mechanic engineer and a mechatronic engineer who advised me, helped me answer any questions, and sizing each one of the parts of the alteration of the CNC
This is the first study image of how the router had to be with the placement of the needle. As it can be seen, I still did not have any idea what I could achieve later on.
After several designing attempts I had a better idea of what to do, and I finally knew where the project was headed
A Three-dimensional knitting machine with motion sensors and a rotation mechanism to tighten the thread.
FINAL
MODEL
ESTABLISHING
THE STRATEGY OF WORK
CUTTING THE BASIC PATS OF THE ALTERATION OF THE CNC MACHINE
The cut of the main piece was made in MDF 12 mm natural color and it was cut in the AXYZ 4008 with a 3/16 "drill bit.
Drawings for cutting
Download file adaptation.cdr (corel draw)
PLACEMENT AND DESIGN OF THE PARTS OF ADAPTATION
Once placed short separate pieces of each of the elements
1.
- Zipper
2. - Gear
3. - Pinion
4. - Needle
5. - Pulleys
The perforations were left for the placement of bolts sujeccion parts. It had many problems with the dimensions of the pieces. I had never imagined how complex might be to design a mechanism that all the parts work.
At the time of drilling we I still did not have the engines that will be used, so I do not know the diameter of the holes, and this was a problem.
Here are some sketches of what the needle may be. The challenge was that a bearing could be placed to revolve, for that this study model was conducted.
The parts were made from pre-cut 3mm MDF.
Download file gear train, zipper, pinion, needle and pulleys.cdr (corel draw)
Download file gear train, zipper, pinion, needle and pulleys.dxf
These images clearly depict how the pieces that intervene might be placed in the adaptation of the CNC.
DESIGN AND PRINTING OF THE NEEDLE IN 3D
One
of the most important parts of the project and which I devoted
more study time was the knitting needle part.
In
a first attempt I wanted to make the needle with the asignment
of composites, for it made a mold in ROLAND MDX40A
The other solution was to conduct a Rhino 3D needle that was properly proportioned. The needle was printed on a machine OBJET EDEN 250 and to avoid any shape error it was corrected in a netfabb four studio.
NEEDLE PRINTING IN 3D ON PRINTER OBJET EDEN 250
It was printed in high strength resin
The
end result of a clean 3D printing and ready to start testing
with the CNC turning radius.
The needle was built with a diameter of 2.7 mm in the
perforation to where Tejeria and was the same Diemnsion of the
party would subject.
The needle is 82mm high
Download file aguja_doble3.3dm
DESIGN
OF THE SUPPORT FOR ADAPTATION OF THE NEEDLE
There
were several tests made of the needle; first, I made this
model in board chassis (see the study of the needle).
On the first volume work study, several tests
were performed to design the needle clamp without a result. The
rotation of the needle was central to the overall function of
the tissue. In order to guarantee the rotation of the needle, a
bearing is placed which is held by means of two circles made of
acrylic.
Once I got to the final design and I placed the measurements, and then I proceeded to perform the drawing in AutoCAD 13.
Download file adaptation for needle.dxf
download file modification
adaptation for needle.dxf
The drawings were sent to cut on a 60w Laser Pro cutting power machine.
Comprises parts of the mechanism of the needle base are laser cut in MDF.
The final parts of the placement of the needle bearing and clamping.
This is the final result
MECHANISM DESIGN OF THE ROD, CRANK AND SLIDING
The engaging of the thread pulled and movement emulation of the needle of a sewing machine through the rod-crank mechanism, which allows an up and down sliding movement of the needle.
These images clearly depict how the pieces will be placed in the intervention of the CNC alteration.
Download
file rod, crank and sliding.cdr (corel draw)
Download
file rod, crank and sliding.dxf
DESIGN
OF THE TRAIN GEAR, THE PINION AND THE RACK
I
made a rack with a pulley to tighten thread avoiding any
problems that might arise from this function. To reduce the
motor speed I developed a gear train connected to the rack
pinion.
We
calculated the number of gear teeth according to the number of
revolutions needed.
Load
of the gears
Download file gear train, pinion and rack.cdr (corel draw)
Download file gear train, pinion and rack.dxf
ASSEMBLY
OF THE PARTS TO THE ADAPTATION OF THE CNC
The
machine is finally armed with the attachments.
ELECTRONIC DESIGN
The
electronic components used are the following:
1. - Metal gear motor with 100:1 gear ratio
Brand POLOLU
2.- Servomotor Model GS-5515MG
Brand
GOTECK
Metal
gear
3.
- Microswitch7 with lamina 5A
Model SS0501A
4.- Integrated Circuit SN754410NE which is an H-bridge Driver with diodes.
5.-
Terminal 2 way 3.5 mm
7.- 50 f-f wires 30 cm color
The
design of the 2 sensor boards were first made inEagle to
determine the upper and the lower limits of the rack zipper,
which are the following:
2
Way Terminal 3.5 mm
Microswitch
10
k Ω Resistor
2-pin
header for the connetion
Stroke schematic
Download file sensor_limit for eagle
The Eagle also took place in the design of a power board and spinner control for the gearbox.
The
schematic Stroke
Download file driver with l293 for eagle
WELDING
OF THE MOTOR DRIVER BOARDS
I Perform FabArduino, although I had problems with the Roland
MDX Models 40A and the plate was short, but with the help of a
razor detachment residual material that was not removed by the
models and proceeded to solder the components to schedule
FabArduino with help of tutorials regarding Anna Kaziunas
FabArduino. According to these tutorials programming is very
similar to the Arduino UNO with working in a home and all you
have to do is assign the corresponding pins of the Arduino UNO
FabArduino.
// Sweep
// This example code is in the public domain.
#include <Servo.h>
Servo myservo; // create servo object to control a servo
// a maximum of eight servo objects can be created
int pos = 0; // variable to store the servo position
void setup()
{
myservo.attach(9); // attaches the servo on pin 9 to the servo object
}
void loop()
{
for(pos = 0; pos < 180; pos += 1) // goes from 0 degrees to 180 degrees
{ // in steps of 1 degree
myservo.write(pos); // tell servo to go to position in variable 'pos'
delay(5); // waits 15ms for the servo to reach the position
}
for(pos = 180; pos>=1; pos-=1) // goes from 180 degrees to 0 degrees
{
myservo.write(pos); // tell servo to go to position in variable 'pos'
delay(5); // waits 15ms for the servo to reach the position
}
}
The result is:
Programa proyecto Final
Fecha: 17 de mayo del 2013
Autor: FABLAB México (FABMEX)
*/
//------------ Librerías --------------//
#include <Servo.h>
//------------ Constantes -------------//
const int velmotor = 5;
const int encmot = 6;
const int apagmot = 8;
Servo servo1;
//------------ Variables --------------//
int posicion;
int var = 0;
//------------ Configuración-----------//
//-----------entradas y salidas--------//
void setup()
{
pinMode(velmotor, OUTPUT);
pinMode(encmot, OUTPUT);
pinMode(apagmot, OUTPUT);
attachInterrupt(0, encendermot, FALLING);
attachInterrupt(1, apagarmot, FALLING);
servo1.attach(9);
}
//------------- Programa --------------//
//------------- Principal -------------//
void loop()
{
for (int aux = 0; aux<=99; aux++)
{
posicion=30;
servo1.write(posicion);
delay(1000);
posicion=150;
servo1.write(posicion);
delay(4000);
}
posicion=150;
servo1.write(posicion);
delay(60000);
/*posicion=30;
servo1.write(posicion);
delay(1000);
posicion=80;
servo1.write(posicion);*/
}
//---------- Funciones -----------//
//------ llamadas por las --------//
//-------- interrupciones --------//
void encendermot()
{
analogWrite(velmotor, 0);
//digitalWrite(encmot, LOW);
//digitalWrite(apagmot, HIGH);
}
void apagarmot()
{
analogWrite(velmotor, 180);
digitalWrite(encmot, LOW);
digitalWrite(apagmot, HIGH);
}
PROGRAMMING IN ARDUINO 1.0
To perform the control program of the adaptation of the router the ARDUINO 1.0.4 compiler was used.
Download file digital_weaver.ino
When
Final Draft will be held the following corrections:
Fab Modules problem and molds 40A Roland MDX
was resolved as follows :
In Linux (Ubuntu 12.04 ) using the Fab Modules for create file is *.rml
In Windows (Windows XP) VPanel is used to locate the origin and using the same load file *.rml . (Previously generated in fab modules) to make the cut board .
The board FAB ARDUINO was machined in the Roland Modela MDX 40A
although there were parts that no short or using a knife
eliminating unions or short plate following the wiring diagram .
It ended with the plate was FAB ARDUINO soldering
the components as indicated in the wiring diagram .
Using the developer FabISP, the FTDI cable and the
Arduino software 1.0.5 the boot sequence FAB ARDUINO was
scheduled.
Two tests were made with the FAB
ARDUINO
The first with the BLINK example code
that brings and Arduino 1.0.5
The second test with the SWEEP code that also
brings the Arduino 1.0.5 Sample program for controlling a
servomotor ( The servomotor rotates from 0 to 180° in one
direction with a speed and returns with a different or the same
speed according to the program) . In the second test with the
servo motor speed changes were made to confirm the operation of
the FAB ARDUINO
Changed
the ARDUINO UNO by FAB ARDUINO.
Modifications to this code to work with the FAB ARDUINO
(definition of inputs and outputs ) were performed.
/*
Programa proyecto Final
Fecha: 17 de mayo del 2013
Autor: FABLAB MÉXICO*/
//------------ Libraries --------------//
#include <Servo.h>
//------------ Const -------------//
const int velmotor =
2;
Change to digital in 5
const int encmot =
3;
Change to digital in 6
const int apagmot =
5;
Change to digital in 8
Servo servo1;
//------------ Variable --------------//
int posicion;
int var = 0;
//------------ Configuration in and out-----------//
void setup()
{
pinMode(velmotor, OUTPUT);
pinMode(encmot, OUTPUT);
pinMode(apagmot, OUTPUT);
attachInterrupt(0, encendermot, FALLING);
attachInterrupt(1, apagarmot, FALLING);
servo1.attach(9);
State equal because the FAB ARDUINO
}
have equal out for controlled the servo.
//------------- Program Principal --------------//
void loop()
{
for (int aux = 0; aux<=99; aux++)
{
posicion=30;
servo1.write(posicion);
delay(1000);
posicion=150;
servo1.write(posicion);
delay(4000);
}
posicion=150;
servo1.write(posicion);
delay(60000);
/*posicion=30;
servo1.write(posicion);
delay(1000);
posicion=80;
servo1.write(posicion);*/
}
//-------- Funtions Interrup --------//
void encendermot()
{
analogWrite(velmotor, 0);
//digitalWrite(encmot, LOW);
//digitalWrite(apagmot, HIGH);
}
void apagarmot()
{
analogWrite(velmotor, 180);
digitalWrite(encmot, LOW);
digitalWrite(apagmot, HIGH);
}
FAB ARDUINO was programmed with the modified code and test
tissue was performed , obtaining the proper functioning of the
final project.
PROGRAMMING IN GCODE
The
program I suggested my GURU and Nerea Tazcon was used GCode for
CNC movements.
The
first attempt I use was to watch the functioning of the machine
was once drawing in Rhino and Rhino CAM later, where it was
found that it may be possible to make the journey
into the CNC machine. However , my guru Beno, told me that I
could not do it, he would rather perform it in gcode.
The
programming was performed in gcode with the coordinates needed
to weave into habiliatda trabajao table in the CNC with the
studs-secured.
Download
file GCode.nc (open with note pad)
He
dismounted the AXYZ 4008 CNC router for Fitting your mount for
weaver.
4 screws are mainly used as clamping drill router fine
ASSEMBLY OF THE ADAPTATION AXYZ 4008 CNC ROUTER
He placed the adaptation of the weaver to AXYZ 4008 CNC
COMPONENTS OF ADAPTATION AXYZ 4008 CNC ROUTER
These
are the parts of the adaptation AXYZ 4008 CNC Router
Another important part of the project is the elaboration of the needle's hooks, which will hold the fabric, and must be 3mm MDF and cut into the laser cutter. The design was done first, and then cut in full. Because I did not know the exact dimensions, I decided to cut them a little bit bigger.
DESIGN SUJECCION POSTS THE NEEDLE
Download
file posts.cdr (corel draw)
We have to performed one more alteration of the post to support the base of the tissue, because the movement would not support the router, so we made a base and directly hit the post.
Another thing to be watched is the realization of the base of the weaver, which it will be 1.20 x 2.40 m and initially worked in the CNC with 1/16" drill bit on the router in order to mark the geometry of the route, plus we made a perforation with a drill bit of 1/2 " for the placement of the poles.
TABLE MAKING WORK WEAVER.
There were 99 holes for tissue poles and 2 but for supporting the ends of the fabric
PLACEMENT OF POSTS ON THE WORKBENCH FOR FABRIC
Once placed on the base poles are transported
- principles and practices, project management
- computer-aided design
- computer-controlled cutting
- electronics production
- 3D scanning and printing
- electronics design
- molding and casting
- embedded programming
- computer-controlled machining
- input devices
- composites
- interface and application programming
- output devices
- networking and communications
- mechanical design, machine design
- applications and implications
- invention, intellectual property, and income
- project development
- final project presentations