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P14311: PCB Isolation Router System

P14311: PCB Isolation Router System. Detailed Design Review December 5 th , 2013. Agenda. Project Background Review Detailed Design Reviews Bill of Materials and Budget Review Risk Management Preliminary MSD II Plan. Agenda. Project Background Review Scope of Project

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P14311: PCB Isolation Router System

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  1. P14311: PCB Isolation Router System Detailed Design Review December 5th, 2013

  2. Agenda • Project Background Review • Detailed Design Reviews • Bill of Materials and Budget Review • Risk Management • Preliminary MSD II Plan

  3. Agenda • Project Background Review • Scope of Project • Engineering Requirements Update

  4. Problem Statement • RIT students need rapid prototyping for creation of unique circuit boards • Requires multiple revisions to perfect each circuit board • Currently each iteration must be created off campus • Long lead times • Expensive • Limits circuit refinement • Students not involved in process

  5. Engineering Requirements Update

  6. Agenda • Detailed Design Reviews • Family Tree Diagram Review • Mobile Enclosure Review • Milling Machine Assembly Review • Base Cabinet Assembly Review • Electronics Control Box Review • Miscellaneous Electronics • Supply/Interconnect System Review • User Interface Assembly Review

  7. Family Tree Diagram

  8. Final Design

  9. Mobile Enclosure Design Review

  10. Mobile Enclosure • General Description • Mobile Computer Workstation • Pull-out tray • The bottom compartment adjusts 2 3/8” increments • Unit has four swivel casters (two with brake) with 4” dia. hard-rubber wheels • Louvered cutouts for ventilation and wire-management grommets • Mechanical Dimensions • Top Compartment, Inside Size • Width – 25 7/8” • Depth – 23 1/8” • Height – 23 3/8” • Bottom Compartment, Inside Size • Width – 25 7/8” • Depth – 22 3/8” • Height – 23 7/8” • Color • Light Gray • Material • 20- to 18-ga. Steel

  11. Milling Machine Assembly Review

  12. Zen Tool Works CNC DIY Kit • Electrical/Mechanical Characteristics: • Travel capacity: 7” (X) x 7” (Y) x 2” (Z) • High density PVC frame • Steel guide rods with precision linear bearings • Stainless steel M8 x 1.25 lead screws with ball bearing supports • Brass anti-backlash lead screw nuts • Shinano dual shaft NEMA 17 stepper motors

  13. Router Assembly

  14. Variable Speed Router Kit Basic Description: • Variable Speed Router Kit Materials: • Plastic body with cast aluminum base Size • Router dimensions: 3.75” diameter, 3.3 lb weight • Collet Size Variable speed: • 16,000-35,000 rpm  Motor Rating: • 1 hp Safety Listings: • UL and CSA Packaging: • Plastic carrying case with room for associated tools Electrical requirements: • 120V AC, 5.6A

  15. Collet Kit List of Components • 1/8 in. Precision Grade (PG) Colt collet (BOPG-COLT-1250) • Collet nut (BOPG-1618-NUT) • Spanner wrench (BOPG-1618-TLN) • Calibration blank (CB0000-1250-150MIT) • 118 ml of ColletCare (MI00-0096-118) • Solvent, light lubricant and corrosion inhibitor mixture that cleans, conditions and protects *All components can be purchased separately through the purchase source

  16. Router Support Structure

  17. Router Support Structure

  18. Air Pressure Solenoid • SMC 3 Port Solenoid Valve • Operating Pressure Range: 0 to 0.7 Mpa • Response Time ≤ 5 ms • Voltage: 24, 12, 6, 5, 3 volts • Port Size: M5 x 0.8 • Used to control air flow through debris management system • Nozzle will only be blowing when router is on • Power Supply for the solenoid and router will be the same

  19. Vacuum Clamp Assembly

  20. Vacuum Clamp Assembly • Made from aluminum • 13 x 13 grid pattern • Holes are ½” spacing • Support brackets inside of table to ensure a flat surface • Use RTV sealer during assembly to prevent leaks

  21. Registration System • Originally Plan: User defined pin locations • Problems with vacuum hole interference • Revised system includes pre-set pin hole locations

  22. Base Cabinet Assembly Review

  23. Vacuum System • Shop-Vac 5895400 model • Fits nicely into our system design • Provides more CFM and Power than Vacuum used for testing • Low cost(~ $70)

  24. Vacuum System Calculations Shop- Vac 5895400 Rigid(From Testing)

  25. Electronics Control Box Review

  26. Electronics Box • 15” x 15” x 4” Maximum • Aluminum • Cooling Fans to direct heat flow up and out of box • Mounted on outside of enclosure for easy access for maintenance

  27. Controller PCBA

  28. Controller PCBA Features: • Can be externally or USB powered • Works with Mach3 software via plug-in • Up to 100kHz operation • 49 digital inputs and 36 digital outputs • 2 analog inputs and 2 analog outputs • On-board interpolations with buffers for robust and fast operation • Jog, E-stop, limit switch, and reference inputs • Router speed control

  29. 26 & 16 Pin Header Pin Out

  30. Motor Drivers PCBA

  31. Motor Drivers PCBA Basic Information: • 0.5 to 2.5 amps phase current • Current selectable via jumper • If the PCBA is in an enclosed environment or the operational current is greater than or equal to 1.5A, incorporate an additional cooling method (Fan). • +10 VDC to +27 VDC power supply • Capable of 1, 2, 4, and 16 micro-steps per step • 3.3V and 5V logic compatible inputs • 500 KHz max step frequency • 0 °C To 70 °C operating temperature • LED power and enable indicators Board Dimensions: • Metric: (50 x 52) millimeters • Imperial: (2 x 2.05) inches Board height: • Metric: 15 millimeters • Imperial: 0.6 inches

  32. 10 Pin Header Pin Out

  33. I/O Interface Board Reasons for Having an I/0 Interface Board • Needed isolation for motor control signals • Gain stage to magnify temperature sensor signal • Will make connections between the Controller PCBA and I/Os much cleaner • Ability to host a variety of connector types including ribbon cable, flexible film connectors, and screw terminals Sizing: • Chose 4’’ x 4’’ footprint to ensure at least 2’’ spacing between each PCBA and the walls of the 15’’ x 15’’ enclosure.

  34. I/O Board Schematic Page 1:Signals From Controller Board Port 3

  35. I/O Board Schematic Page 2:Router/Vacuum Shutoff and Stepper Power

  36. I/O Board Schematic Page 3:Signals to Controller Board Port 4

  37. I/O Board Schematic Page 4:Analog Signals

  38. Miscellaneous Electronics

  39. Low Voltage Power Supply Electrical Specifications: Output Specifications: • Isolated output and ground for Channel 1 and Channel 2 • Channel 1 Ratings: 24V, 9.4A (Peak 16.7A) • Channel 2 Ratings: 5V, 5A • Total Rated power (for both channels): 250.6W Provides power to stepper motors (24V) and isolation board (5V)

  40. Interlock Switch When Interlock is broken • Sends a pause signal to controller board to pause the program • Stops power to: • Router • Motors • Switch has not yet been selected

  41. Emergency Stop Switch Stops power to entire system Contact Rating 8A @ 125 VAC 6A @ 24VDC E Switch L16 Series Illuminated, Pilot Indicator

  42. Solid State Relays Specifications: • Dual channel • Each output channel rated for 25A at 280VAC • Control voltage 4-15VDC • 4kVAC optical isolation between input and output • Zero-crossing voltage turn on • Latching input terminal • 80°C max operating temperature • 8.33millisecond turn-on time

  43. Supply/Interconnect System Review

  44. 120 VAC Power Cord • Plan to make our own custom power cord using. • Plug will be bought from manufacturer • Cabling will be type SJT • Length will be cut to size once we consult customer for preference • Why SJT? • Higher current rating than SVT • Higher temperature rating than SVT • Larger wire gauge will fit Example NEMA 5-15 polarized plug rated for 15A at 120VAC shown

  45. Signal Flow Table Example (UC300)

  46. Signal Flow Table Example (I/0 Board)

  47. Power Distribution LVPS 5VDC 24VDC Electronics Box I/O Interface Board Interlock Switch 120VAC PC Receptacle Box E-STOP 24VDC Motor Driver Board X 24VDC 60-250W Motor Driver Board Y Wall Outlet 120VAC SSR Box Motor Driver Board Z NO NO INTERLOCK_STATUS Main controller board COM E-STOP_STATUS NC Vacuum Receptacle Box Safety Relay PC USB Router Receptacle Box 1080W MAX 674W MAX

  48. Pressurized Air Line • Interior connection to mill head • Flexible air line to accommodate x and z direction movement • Adjustable nozzle position to maximize debris collection of vacuum • Exterior connection to compressed air supply • Standard ¼” NPT quick release fittings • Flexible air line to accommodate placement of entire machine • Supplied Pressure in lab is 80 psi • Regulator to adjust pressure to amount needed

  49. Vacuum Table and Debris Management Ducting • Schedule 40 PVC piping will be used for most vacuum ducting components • Smooth inner surface to minimize losses • Rigidity will prevent collapse • “Off-the-shelf” components • Movement • Vacuum table moves in y-direction only • Can use a rigid or flexible connection • Mill Head moves in x and z directions • Will require some flexible ducting

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