Foam Cutter Manual
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UCSD Design/Build/Fly
Foamcutter Manual
Yuting Huang
ythuang96@gmail.com
Updated:
December 6, 2018
Preface
Before operating the foamcutter, please read this manual carefully to avoid
injuries and damages to the equipment. All content in the text boxes are extremely important and should be given extra attention.
This foamcutter project was completed with funds from University of California San
Diego Design/Build/Fly, and is intended to make the manufacturing process of composite
planes easier.
All SolidWorks files, C code, MatLab scripts and operation manual are available for
download at the author’s Github page: https://github.com/ythuang96/FoamCutter. Please
email the author at ythuang96@gmail.com to report any bug in code or any improvement
suggestions.
This project was an improvement on the foamcutter design by Derek Ung and David
Cruz. Special thanks to Dr. Mark Anderson, UCSD MAE department for support of the
project. And thanks to Geo Lopez for his help during the project.
1
2
Contents
Preface
1
1 Preparations
5
1
2
3
4
Laptop Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.1
PuTTY Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
1.2
WinSCP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Assemble the Foamcutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
2.1
Connect the two Side Frames . . . . . . . . . . . . . . . . . . . . . .
11
2.2
Connect two Molex Connector . . . . . . . . . . . . . . . . . . . . . .
12
2.3
Install the Work Panel . . . . . . . . . . . . . . . . . . . . . . . . . .
12
2.4
Install the Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Foamcutter Software Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
3.1
Connect to the Pi . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
3.2
Calibrate Wire Origin . . . . . . . . . . . . . . . . . . . . . . . . . .
19
3.3
Install the Foamcutter Software . . . . . . . . . . . . . . . . . . . . .
21
3.4
Update the Foamcutter Software . . . . . . . . . . . . . . . . . . . .
22
G-Code Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
4.1
G-Code for Wing . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
4.2
G-Code for General Shapes . . . . . . . . . . . . . . . . . . . . . . .
25
2 Operate the FoamCutter
33
1
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
2
Start a Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
3
Secure the Foam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
4
End a Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
3
5
Cleaning Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 Raspberry Pi Setup
38
39
1
Install Raspbian on the Raspberry Pi . . . . . . . . . . . . . . . . . . . . . .
39
2
Install WiringPi on the Raspberry Pi . . . . . . . . . . . . . . . . . . . . . .
40
3
Making the Pi into a Wireless Hotspot . . . . . . . . . . . . . . . . . . . . .
41
Appendices
43
A C Code for the Foamcutter Program
44
1
foamcutter.c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
2
foamcutter_setup.h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
B MatLab Code for G-code Generation
63
1
DBF_foamcutter_general_shape.m . . . . . . . . . . . . . . . . . . . . . . .
63
2
DBF_foamcutter_wing.m . . . . . . . . . . . . . . . . . . . . . . . . . . . .
69
C Drawings
74
D Part List
86
E Purchase History
89
4
Chapter 1
Preparations
1
Laptop Setup
The foamcutter is controlled by a Raspberry Pi 3 B+. In order to communicate with
the Pi, a Windows laptop has to install PuTTY (or similar) to enable secure shell (SSH)
connection to the Pi, and WinSCP (or similar) for graphical file management on the Pi. A
Linux laptop have SSH capability built in, therefore, no software required.
Note:
This setup process is only required once per laptop.
formed, skip this section and continue to section 4.
1.1
If already per-
PuTTY Setup
Please follow the following steps for install and setup of PuTTY:
1. Download PuTTY at https://www.putty.org/ then install.
2. Launch PuTTY and a window similar to fig 1.1 below should show up:
5
Figure 1.1: PuTTY Launch Window
3. As shown in fig 1.2 below, in the “Host Name” field, enter “foamcutter.local", then
make sure Connection type is SSH. Next, in “Saved Session field”, enter “foamcutter",
and lastly, click save.
Figure 1.2: PuTTY Setup
4. The session with name “foamcutter" should show up in Saved Session as shown in
6
fig 1.3 below, and the PuTTY setup is completed.
Figure 1.3: Saved PuTTY Session
5. Note on using PuTTY: to copy text from PuTTY, simply select the text, do not press
“Control + C”. To paste text to PuTTY, simply right click mouse, do not press “Control
+ V”.
1.2
WinSCP Setup
Please follow the following steps for install and setup of WinSCP:
1. Download WinSCP at https://winscp.net/eng/download.php then install.
2. Launch WinSCP and a window similar to fig 1.4 below should show up:
7
Figure 1.4: WinSCP Launch Window
3. As shown in fig 1.5 below, make sure the protocol is “SFTP", then enter “foamcutter.local" for the host name, “pi" for the user name, and “ucsdaiaadbf" for the password.
Figure 1.5: WinSCP Setup
4. Click save, and a window shown in fig 1.6 below should pop up. Both “Save password" and “Create desktop shortcut" are recommended. Click “OK" and the setup for
WinSCP is completed.
8
Figure 1.6: WinSCP Setup continued
9
2
Assemble the Foamcutter
The entire foamcutter as shown in fig 1.7 below consists of two side frames each
having two axis of motion, four 4-feet long connection rods, and a work panel for securing
the foam.
Figure 1.7: Foamcutter Overview
Caution:
• Side frames are extremely heavy, lift with caution;
• Avoid bumping head onto the connection rods when leaning into and
out of the frame.
10
Do:
• Always make sure the two side frames are connected with the connection rods;
• Always push the two side frames firmly against each other before
tightening the thumb screws;
• Remember to plug in the two Molex connectors.
Don’t:
• Never let the side frames stand on their own;
• Never over tighten the thumb screws on the work panel;
• Never unscrew screws that are not thumb screws unless performing
repairs.
2.1
Connect the two Side Frames
The two side frames are connected with 4 connection rods, use the 4ft long connection
rods for performing cutting and use the 2ft long connection rods (not purchased yet) for
storage of the foamcutter. Each of the 4 connection rods are secured with two thumb screws
at each end shown in fig 1.8, loosen the thumb screws to remove the connection rod.
Figure 1.8: Thumb Screws for Connection Rods
11
During the installation of the connection rods, do not let the side frames stand on
their own. The side frames are capable of standing on their own, but are not designed to do
so: deformation will occur and degrade the accuracy. When installing the connection rods,
push the two side frames firmly against each other to make sure there are no gaps between
the side frames and the connection rods. Then tighten the thumb screws. An Allen key is
recommended to further tighten the thumb screws.
2.2
Connect two Molex Connector
There are two Molex connectors located at the two top corners of the foamcutter as
shown in fig 1.9 below. Make sure to connect them before operating the foamcutter. The
Molex connectors are foolproof, do not force it when unable to plug in.
Figure 1.9: Molex Connectors
2.3
Install the Work Panel
The work panel is connected to the two side frames at the four corners of the panel.
Each corner is secured with two thumb screws as shown in fig 1.10 below.
12
Figure 1.10: Work Panel Thumb Screws
The work panel should be oriented so that the guiding block, which is a long piece
of PVC screwed to the work panel (pointed by the red arrows in the fig 1.11 below) should
be at the closer side relative to the two horizontal motors (marked by the red circle in the
fig 1.11 below).
13
Figure 1.11: Work Panel Guiding Block Orientation
To install the work panel, first slide the work panel into the 4 supporting rods at the
4 corners with the correct orientation. Make sure all 4 corners sit securely in the supporting
rods, then tighten all 8 thumb screws.
14
2.4
Install the Wire
The wire is held to tension of approximately 10 lbs with a constant force spring. To
install the wire, follow the steps shown below.
(a) Step 1
(b) Step 2
(c) Step 3
(d) Step 4
Figure 1.12: Steps 1-4
1. Feed the wire through the small guiding hole on the side without the pulley.
2. Make a hoop at the end of the wire.
3. Put the hoop around the Nylon bolt and straighten the wire across the entire span of
the foamcutter.
4. Cut the wire at about 3ft longer than the span of the foamcutter. Then feed the end
of the wire through the small guiding hole on the side with the pulley.
15
(a) Step 5
(b) Step 6
(c) Step 7
(d) Step 8
Figure 1.13: Steps 5-8
5.
6.
7.
8.
On the back side of the pulley, feed the wire around the copper sleeve bearing.
Feed the end of the wire through one of the small mounting holes on the acrylic pulley.
Remove the nut stored on the alligator clip.
Wrap the wire around the nut.
16
(a) Step 9
(b) Step 10
(c) Step 11
(d) Step 12
(e) Step 13
(f) Step 14
Figure 1.14: Steps 9-12
9. Twist the wire around the nut.
10. Rotate the acrylic pulley clockwise to tighten the wire.
11. Hold the acrylic pulley by hand. Use a wrench to further tighten the spring by holding
17
onto the mounting screw of the spring and rotate counterclockwise.
12. Further tighten the spring with the wrench.
13. Tighten the spring to the approximate position shown in the figure.
14. Clip the alligator click next to the pulley. On the other end, clip the other alligator
clip on the back side of the guiding hole, and make sure the alligator clip does
not touch anything other than the hot wire.
3
Foamcutter Software Setup
3.1
Connect to the Pi
1. Perform the Laptop setup guide in Chapter 1 Section 1 if not already completed.
2. Plug in the power cord to the foamcutter to power on the Pi.
3. Connect to the WiFi hotspot named “foamcutter” with password “ucsdaiaadbf ” or
connect to the ethernet port to the ethernet port of the laptop with a ethernet cable.
4. SSH into the Pi by opening PuTTY and double click on the saved session named
“foamcutter”. Enter the user name “pi” then password “ucsdaiaadbf ”.
5. Open WinSCP, a window similar to fig 1.15 below should show up. The left hand side
are folders and files on your computer, while the right hand side is files on the Pi.
Make sure the right hand side is in the folder “/home/pi”, if not, navigate to it. To
create new folder on the Pi, use the “new directory” button. To upload files from
your computer to the Pi, simply drag the file/folder from the left half to the right half.
Figure 1.15: WinSCP Window
18
3.2
Calibrate Wire Origin
The 4 axes of the foamcutter each have one limit switch installed. Upon starting of
the program, the foamcutter moves all axes towards the negative direction until hitting the
limit switches. Then the foamcutter moves the 4 axes each a distance specified in the setting
file to reach the Origin. This calibration only needs to be performed once in a while
to improve accuracy. Please follow the steps to calibrate the wire origin:
1. Download the “User Package.zip” from https://github.com/ythuang96/FoamCutter,
and unzip it.
2. Create a new folder on the Pi called “foamcutter” in the directory of “/home/pi”.
3. Upload the files named “foamcutter.c”, “foamcutter_setup.h” and “Makefile”
from the ”User Package” just downloaded into the “foamcutter” folder just created
on the Pi.
4. Open PuTTY and run the following commands line by line:
• cd
• cd foamcutter
• make foamcutter
• sudo ./foamcutter
This will launch the foamcutter program.
5. When the program reads “I see the system is not homed yet, please press
ENTER to home the system:” press the Enter key. The foamcutter will move all
4 axes towards the negative direction until touching the limit switch. Then all 4 axes
will move towards the positive direction to the origin.
6. Place a Aluminum block on the work panel against the work panel guiding block, and
observe from top down as shown in fig 1.16 below. Both the far left and far right of
the wire should sit right against the aluminum block, measure the amount that needs
to be adjusted in millimeters.
19
Figure 1.16: Calibrate Wire Origin in the Horizontal Direction
7. Again, place a Aluminum block on the work panel against the work panel guiding
block, but observe horizontally as shown in fig 1.17 below. Both the far left and the
far right of the wire should sit at the same height. The height could be arbitrary,
but should be higher than the thumb screws on the work panel. Again, measure the
amount that needs to be adjusted in millimeters.
20
Figure 1.17: Calibrate Wire Origin in the Vertical Direction
8. Open WinSCP, navigate to “/home/pi/foamcutter” on the Pi (the right hand side
of the WinSCP window), and double click on the file “foamcutter_setup.h” to edit
it.
9. Find the 5 lines that read as the following:
// position of limit switch relative to cutter origin
#define LIM2ORIGIN_LX -4100
#define LIM2ORIGIN_RX -3550
#define LIM2ORIGIN_LY -2500
#define LIM2ORIGIN_RY -2400
and adjust the four numbers: if wish to move an axis 1mm further away (or closer) from
the limit switch, subtract (or add) 157 from the number corresponding to the axis. All
4 numbers must be negative integers, no decimal, and no equations (please
calculated the number yourself and replace the original number).
10. Save the file then repeat the process from step 4 to adjust the 4 numbers until the wire
sits at the desired location. Then save the 4 numbers on your computer.
3.3
Install the Foamcutter Software
1. Perform the Wire Origin Calibration guide in Chapter 1 Section 3.2 if not already
completed.
2. Open PuTTY and run the following commands line by line:
• cd
21
• cd foamcutter
• sudo make install foamcutter
3. Delete the folder “/home/pi/foamcutter” on the Pi.
4. You can now use sudo foamcutter to run the foamcutter program.
3.4
Update the Foamcutter Software
1. If a new version is available, download the “User Package.zip” from
https://github.com/ythuang96/FoamCutter, and unzip it.
2. Create a new folder on the Pi called “foamcutter” in the directory of “/home/pi”.
3. Upload the files named “foamcutter.c”, “foamcutter_setup.h” and “Makefile”
from the ”User Package” just downloaded into the “foamcutter” folder just created
on the Pi.
4.
• If wish to perform Wire Origin Calibration, proceed to Chapter 1 Section 3.2 step
4 to step 10. Then continue to the steps in Chapter 1 Section 3.3.
• If wish to use the previously calibrated parameters, open WinSCP, edit the file
“/home/pi/foamcutter_setup.h”, find the 5 lines that read as the following:
// position of limit switch relative to cutter origin
#define LIM2ORIGIN_LX -4100
#define LIM2ORIGIN_RX -3550
#define LIM2ORIGIN_LY -2500
#define LIM2ORIGIN_RY -2400
and change the 4 numbers to the previously calibrated parameters. Then proceed
to Chapter 1 Section 3.3 step 2 to step 4.
4
G-Code Generation
4.1
G-Code for Wing
1. Download the needed airfoil coordinates at
http://m-selig.ae.illinois.edu/ads/coord_database.html#S
2. Place the needed airfoil coordinate files in the same folder as the MatLab code
“DBF_foamcutter_wing.m” which is provided in the “User Package.zip” from
https://github.com/ythuang96/FoamCutter.
3. Enter the parameters into the MatLab script and run the script. A figure tracing the
the motion of the two ends of the wire should show up, and the G-code should be saved
in the same folder.
Note:
When cutting extremely tampered parts, figure similar to the fig 1.18 below might
show up during the G-code generation process:
22
Figure 1.18: Example Figure During G-code Generation for a Wing
The parameters used for this figure is shown below:
23
Figure 1.19: Example Parameters During G-code Generation for a Wing
Note that the root and tip cord length differed a lot, and the span is significantly
smaller than the cutter width, therefore, this is an extremely tapered cut. As a result, the
inverted airfoil shown in fig 1.18 above is expected. As explained in fig 1.20 below, for
extremely tapered cuts, the two ends of the wire could move in opposite directions, resulting
in the inverted airfoil shown in fig 1.18.
Figure 1.20: Sketch of an Extremely Tapered Cut
24
4.2
G-Code for General Shapes
Key Points:
• Make sure to increase AutoCAD precision;
• Make sure to scale the drawing by 25.4 in AutoCAD if the SolidWorks
file is in inches;
• Make sure to run “Explode” command in AutoCAD;
• Make sure there are no overlapping lines;
• Make sure to convert spline to polyline in AutoCAD and explode
again.
1. Export the projection of the top or side (or both) profiles from SolidWorks into .dxf
files, the steps are demonstrated with the payload bay shown in fig 1.21 below.
Figure 1.21: Sample Payload Bay
• The projection of the side profile can be obtained by slicing the part vertically in
the center: go to “Insert → Features → Split” as shown in fig 1.22 below:
25
Figure 1.22: SolidWorks Split Command
• In the pop up window, as shown in fig 1.23 below, in “Trim Tools” selected the
desired plane (the front plane in this case) then click “Cut Body”. In the “Resulting
Bodies” box, select one of the resulting bodies. Lastly, make sure the “Consume
cut bodies” check box is selected, and click the top left green check mark. This
will delete the selected half of the part (the brown half in fig 1.23).
26
Figure 1.23: SolidWorks Split Menu
• Right click on the cut plane and select “Export to DXF/DEG” to export the
projection of the side profile as shown in fig 1.24 below:
27
Figure 1.24: Export Side Profile
• The top plane of the part is the projection from above, therefore, skip the split
command and directly right click on the plane and export:
Figure 1.25: Export Top Profile
2. Open AutoCAD, increase the precision by clicking the top left red AutoCAD sign,
select “Drawing Utilities → Units” and increase the precision to 4 decimal points, as
shown in fig 1.26 below.
28
Figure 1.26: Increase AutoCAD Precision
3.
4.
5.
6.
Import the dxf files from SolidWorks.
Scale the drawing by 25.4 if the SolidWorks file is in inches.
Select all objects and run “Explode” command.
Select all Spline (if any), right click and select “Spline → Convert to Polyline” as shown
in fig 1.27 below. When ask to enter accuracy, enter 1 and press enter.
Figure 1.27: Convert Spline
7. Explode again (explode the polylines converted from spline).
29
8. Rotate and delete overlapping lines if necessary.
9. Select all lines and run “eattext” command, a window similar to fig 1.28 should pop
up, select “Edit an existing data extraction” then click the browse button.
Figure 1.28: Eattext Page 1
10. Browse for the extraction templates, select the template with or without arc depending
on the drawing. (The templates are included in the “User Package.zip” from
https://github.com/ythuang96/FoamCutter)
Figure 1.29: Browse for Data Extraction Templates
11. On page 2, check “include current drawing”, select the one that is not the current
drawing (if any) and click remove.
30
Figure 1.30: Eattext Page 2 Step 1
12. Then select the current drawing and click “Next”.
Figure 1.31: Eattext Page 2 Step 2
13. On page 3, make sure the drawing only has lines, or only has lines and arcs, depending
on the template used. If not, cancel the process, fix the drawing, and redo the “eattext”
command.
Figure 1.32: Eattext Page 3
14. Continue clicking “Next” until reaching page 6, name the data point file and save to
the desired location. Click “Next” then “Finish”.
31
Figure 1.33: Eattext Page 6
15. Put the .csv file from AutoCAD into the same folder as the MatLAB script
“DBF_foamcutter_general_shape.m” (provided in the “User Package.zip” from
https://github.com/ythuang96/FoamCutter) and run the MatLAB code. Follow the
prompts, and the G-code should be ready.
32
Chapter 2
Operate the FoamCutter
1
Switches
The foamcutter has 3 switches installed as shown in fig 2.1 below.
Figure 2.1: Three Switches of the Foamcutter
• Left most switch: Exit switch
Only operational when the foamcutter software is running.
Hold the switch for 4 seconds will stop all motor movement, exit the foamcutter software and shutdown the Raspberry Pi.
33
• Middle switch: Pause switch
Only operational when the foamcutter software is running. Toggle the switch up to
pause the motor movements.
Toggle the switch down to resume the motor movements.
• Right most switch: Wire Control switch
Operational regardless of foamcutter software.
Toggle the switch up will enable the wire heating when the wire power supply is turned
on and connected.
Toggle the switch down will enable the foamcutter software to control the wire heating.
The software automatically turns on the wire heating when starting the cut and turns
off the wire heating when cut ends. This switch should generally be left at the
down position for safety.
2
Start a Cut
Please follow the steps below to operate the foamcutter:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
3
Prepare the G-code following guide from Chapter 1 Section 4.
Assemble the foamcutter following guide from Chapter 1 Section 2.
Check that the Wire Control switch (right most switch) is toggled to the down position.
Plug in the power cord.
Plug in the power supply for the hot wire but do not turn it on.
On your laptop, connect to the WiFi network named “foamcutter”, with password
“ucsdaiaadbf or connect to the ethernet port to the ethernet port of the laptop with
a ethernet cable.
Open PuTTY and connect to the Pi with user name “pi” and password
“ucsdaiaadbf ”.
Open WinSCP and connect to the Pi. Upload the G-code file to the Pi folder
“/home/pi”.
In PuTTY, run: sudo foamcutter
The software will first check the Pause switch status and will prompt to toggle the
switch down if needed.
The software will then ask to perform the homing process. Double check that the
Molex connectors are connected, then press enter to perform homing.
The software will then enter the main menu, follow the prompts to select desired
options to perform cuts or move the wire.
Secure the Foam
The foam can be secured with acrylic plates with thumb screws on the three sides.
Follow the steps below to secure the foam on the work panel:
1. Measure the width of the foam that need to be cut.
34
2. Set one acrylic plate half of the width of the foam so that the foam will be centered
on the work panel. Make sure both ruler reads the same so that the acrylic plate is in
the vertical direction as shown in fig 2.2 below.
Figure 2.2: Secure the Foam Step 2
3. Secure the first plate with 3 thumb screws. Do not over tighten the thumbscrews,
or the threads on the work panel might be destroyed.
4. Place the foam on the work panel with one side firmly against the guiding block and
another side firmly against the first acrylic plate.
5. Place a second acrylic plate firmly against the foam and secure with 3 thumb screws
as shown in fig 2.3 below.
35
Figure 2.3: Secure the Foam Step 5
6. Secure the back of the foam with another acrylic plate and secure with 3 thumb screws
as shown in fig 2.4 below.
Figure 2.4: Secure the Foam Step 6
7. Place a small piece of aluminum block on top of the foam to prevent vertical movement
as shown in fig 2.5 below.
36
Figure 2.5: Secure the Foam Step 7
8. To secure very small pieces of foam, one of the acrylic plates can be flipped as shown
in fig 2.6 below.
Figure 2.6: Secure the Foam Step 6
4
End a Cut
To the cutting operation half way through a G-code:
• In the PuTTY session, press “Control + C”. This will stop the cut and exit the
program. It will also ask if desired to shutdown the Pi immediately.
37
• Or hold the Exit switch for more than 3 seconds. This will stop the cut and exit the
program, but will also immediately shutdown the Pi.
To exit the program after the cut is finished, apart form the two options listed above,
the user can also select the menu options to return to the main menu, and select the third
option to exit the program. It will also ask if desired to shutdown the Pi immediately.
5
Cleaning Up
After the Pi is properly turned off by:
• Press Enter when seeing “If you would like to shutdown the Pi now. Please
press ENTER. Otherwise, press ’n’ then press ENTER:” when exiting the
foamcutter software.
• Or run “sudo shutdown now” in PuTTY.
the green LED should flash a couple of times indicating the operating system is reading/writing to the SD card. After the green LED turns off, unplug the power cord and wrap it around
the acrylic electronics box. Also remember to turn off the power supply for the hot wire and
wrap the power cables for the hot wire around the two screws.
38
Chapter 3
Raspberry Pi Setup
Note:
All steps in this chapter are already performed on the currently used
Raspberry Pi, and do not need to be performed again unless the Raspberry
Pi or the SD card is damaged and needs replacement.
1
Install Raspbian on the Raspberry Pi
Raspbian is one of the recommended operating system for the Raspberry Pi. The
following steps are used to install Raspbian and setup the Pi.
1. Perform the Laptop setup guide in Chapter 1 Section 1 if not already completed.
2. Download the Raspbian Sketch Lite version at:
https://www.raspberrypi.org/downloads/raspbian/ The Lite version does not have
desktop support, but should be sufficient for the foamcutter.
3. Download and install Etcher at https://etcher.io/.
4. Plug in the SD card into a laptop and run Etcher.
5. In Etcher, select the raspbian image just downloaded, then select the SD card. Lastly,
click flash.
6. Wait for flash to complete, the SD card should now have two partition with one named
“boot”.
7. Enable SSH on the Pi by creating a file name “ssh” without any extension in the
partition named “boot” on the SD card.
8. Unplug the SD card from the laptop and plug into the Pi. Connect a Ethernet cable
from the Pi to same router your laptop is currently connected to.
9. Connect power to the Pi.
10. SSH into the Pi by opening up PuTTY and create a new session with host name:
“raspberrypi.local”. Note on using PuTTY: to copy text from PuTTY, simply select
the text, do not press “Control + C”. To paste text to PuTTY, simply right click mouse,
39
do not press “Control + V”.
11. Enter the user name “pi” then password “raspberry”.
12. Change the log in password: enter “passwd” on the command line and press Enter.
Enter the current password “raspberry”, then enter the new password “ucsdaiaadbf ”
twice.
13. Change the name of the Pi by entering “sudo raspi-config”, select “Network Options → Hostname”, then enter the new hostname: “foamcutter”, then press Enter.
14. Select “Finish”, then press Enter. When asked to reboot, select “Yes”.
2
Install WiringPi on the Raspberry Pi
WiringPi is a GPIO Interface library written for the Raspberry Pi. A complete guide
can be found at: http://wiringpi.com/. To install on the pi, follow the complete guide at:
http://wiringpi.com/download-and-install/ or follow the steps below:
1. Power on the Pi and open PuTTY on your laptop.
2. Double click on the saved PuTTY session named “foamcutter” as shown in fig 3.1
below.
Figure 3.1: SSH to the Raspberry Pi
3. Enter user name “pi” and password “ucsdaiaadbf ”.
4. Update the operating system using the following two command:
• sudo apt-get update
• sudo apt-get upgrade
5. Install GIT using:
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• sudo apt-get install git-core
6. Install WiringPi using:
• cd
• git clone git://git.drogon.net/wiringPi
• cd /wiringPi
• ./build
7. Completed when seeing:
All Done.
NOTE: To compile programs with wiringPi, you need to add:
-lwiringPi
to your compile line(s) To use the Gertboard, MaxDetect, etc.
code (the devLib), you need to also add:
-lwiringPiDev
to your compile line(s).
3
Making the Pi into a Wireless Hotspot
Do not perform the following procedure. This method seems to have
unsolved connection problems and is not recommended currently. Connection
through an Ethernet cable is recommended.
Making the Pi into a Wireless Hotspot will enable operation of the foamcutter even in
areas without a wireless network. The following steps are adapted from: https://elinux.org/RPIWireless-Hotspot
1. SSH into the Pi via PuTTY.
2. Run: sudo apt-get install hostapd udhcpd
3. Run: sudo nano /etc/udhcpd.conf This will open a text editor, use keyboard
instead of mouse to navigate.
• Find the line starting with interface and change to interface wlan0
• Find the line starting with opt router and change to opt router 192.168.42.1
• Press Control + O then Enter then Control + X to save and close file.
4. Run: sudo nano /etc/default/udhcpd
• Add # to the front of the line DHCPD_ENABLED="no"
• Press Control + O then Enter then Control + X to save and close file.
5. Run: sudo ifconfig wlan0 192.168.42.1
6. Run: sudo nano /etc/network/interfaces
• Add the following lines to the bottom of the file if the line iface wlan0 inet
dhcp is not present, otherwise replace it:
iface wlan0 inet static
address 192.168.42.1
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netmask 255.255.255.0
• Add # to the beginning of each of the following lines if present:
allow-hotplug wlan0
wpa-roam /etc/wpa_supplicant/wpa_supplicant.conf
iface default inet manual
• Press Control + O then Enter then Control + X to save and close file.
7. Run: sudo nano /etc/hostapd/hostapd.conf
• Add the following lines to the bottom of the file:
interface=wlan0
driver=nl80211
ssid=foamcutter
hw_mode=g
channel=6
macaddr_acl=0
auth_algs=1
ignore_broadcast_ssid=0
wpa=2
wpa_passphrase=ucsdaiaadbf
wpa_key_mgmt=WPA-PSK
rsn_pairwise=CCMP
8.
9.
10.
11.
12.
channel=1
ieee80211n=1
wmm_enabled=1
ht_capab=[HT40+][SHORT-GI-20][DSSS_CCK-40]
• Press Control + O then Enter then Control + X to save and close file.
Run: sudo nano /etc/default/hostapd
• Change the line from #DAEMON_CONF="" to
DAEMON_CONF="/etc/hostapd/hostapd.conf"
• Press Control + O then Enter then Control + X to save and close file.
Run: sudo nano /etc/default/hostapd
• Add net.ipv4.ip_forward=1 to the bottom of the file.
• Press Control + O then Enter then Control + X to save and close file.
Run: sudo update-rc.d hostapd enable
Run: sudo update-rc.d udhcpd enable
Run: sudo reboot
42
Appendices
43
Appendix A
C Code for the Foamcutter Program
1
foamcutter.c
The C code for the foamcutter program, foamcutter.c is attached below. Verison
1.0.0, lasted updated: 6/30/2018.
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/***********************************************************************
* FoamCutter
* This code is written for Design/Build/Fly CNC foamcutter.
* Written by Yuting Huang (ythuang96@gmail.com).
* Please report any bug to my email address.
*
* Last update: 6/30/2018
*
* Current Version: V 1.0.0
***********************************************************************/
#define VERSION_A 1
#define VERSION_B 0
#define VERSION_C 0
#include "foamcutter_setup.h"
typedef enum state_t{
HOMED, GCODE, EXITING
} state_t;
typedef struct position_t{
int32_t LX, LY, RX, RY;
} position_t;
typedef struct speed_t{
float LX, LY, RX, RY;
} speed_t;
typedef struct coord_t{
float LX_old, LY_old, RX_old, RY_old;
float LX, LY, RX, RY;
} coord_t;
typedef struct coord_lim_t{
float LX_max, LY_max, RX_max, RY_max;
float LX_min, LY_min, RX_min, RY_min;
} coord_lim_t;
/***********************************************************************
************************** GLOBAL VARIABLES ****************************
***********************************************************************/
state_t state_;
position_t target_position_;
position_t current_position_;
position_t reached_position_;
position_t stop_;
speed_t set_speed_;
coord_t coord_;
coord_lim_t coord_lim_;
float coord_offset_x_;
float coord_offset_y_;
int gcode_menu_option_;
int ETA_;
struct timespec start_time_;
FILE *ptr_file_;
int state_STOP_ = 0;
// Threads
pthread_t LX_thread;
pthread_t LY_thread;
pthread_t RX_thread;
pthread_t RY_thread;
pthread_t printing_thread;
pthread_t cut_manager;
pthread_t switch_thread;
struct sched_param params_motor_thread;
struct sched_param params_print_thread;
struct sched_param params_cut_manager;
struct sched_param params_switch_thread;
/***********************************************************************
*********************** FUNCTION DECLARATIONS **************************
***********************************************************************/
// THREADS
void* LX_thread_func(void* ptr);
void* LY_thread_func(void* ptr);
void* RX_thread_func(void* ptr);
void* RY_thread_func(void* ptr);
void* cut_manager_func(void* ptr);
void* print_func(void* ptr);
void* switch_thread_func(void* ptr);
// SYSTEM FUNCTIONS
void initialize_pin();
void home();
int loadtext(char* filename);
int check_cord(char* str);
int allreached();
void stop_all();
float cut_length_func();
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void drive(int pin_pul, int pin_dir, float speed, int32_t delta_pulse, int* ptr_current, int* ptr_stop, int polarity );
void cut_gcode(char* filename);
void moveto(float x, float y);
// MENU FUNCTIONS
void main_menu();
void gcode_menu();
void move_menu();
int menu(int numb_of_options);
int menu_enter();
int menu_yes();
int menu_enter_one(float* output, char* string);
int menu_enter_two(float* output1, float* output2, char* string);
// OTHER FUNCTIONS
void nsleep(uint64_t ns);
int file_filter(const struct dirent *entry);
void removespace(char* str);
void SigHandler(int dummy);
float max(float a, float b);
float min(float a, float b);
void print_time(int sec);
int str2f(char* str, float* output);
/***********************************************************************
******************************** MAIN **********************************
***********************************************************************/
int main(){
// Setup GPIO pins
if (wiringPiSetupGpio () == -1) {
printf("Initialization failed. Most likely you are not root\n");
printf("Please remember to use 'sudo foamcutter'.\n");
return 1 ;
}
initialize_pin(); digitalWrite(PIN_RELAY, LOW);
// Setup signal handler for CTRL+C
signal(SIGINT, SigHandler);
// Start motor threads
params_motor_thread.sched_priority = 90;
pthread_setschedparam(LX_thread, SCHED_FIFO, ¶ms_motor_thread);
pthread_create(&LX_thread, NULL, LX_thread_func, (void*) NULL);
pthread_setschedparam(LY_thread, SCHED_FIFO, ¶ms_motor_thread);
pthread_create(&LY_thread, NULL, LY_thread_func, (void*) NULL);
pthread_setschedparam(RX_thread, SCHED_FIFO, ¶ms_motor_thread);
pthread_create(&RX_thread, NULL, RX_thread_func, (void*) NULL);
pthread_setschedparam(RY_thread, SCHED_FIFO, ¶ms_motor_thread);
pthread_create(&RY_thread, NULL, RY_thread_func, (void*) NULL);
stop_.LX = stop_.LY = stop_.RX = stop_.RY = 0;
// Print Header
printf("\n");
printf("+---------------------------------------------------------------+\n");
printf("| DBF Foamcutter Program by Yuting Huang
|\n");
printf("| Current Version is V%d.%d.%d
|\n" \
, VERSION_A, VERSION_B, VERSION_C);
printf("| Contact me at ythuang96@gmail.com to report bugs
|\n");
printf("|
|\n");
printf("|---------------------------------------------------------------|\n");
printf("|
Brief User Instructions
|\n");
printf("| At any time in the program:
|\n");
printf("| 1. Press CTRL+C to exit the prgram
|\n");
printf("| 2. Long press EXIT button exit the prgram and shutdown the Pi |\n");
printf("| 3. Toggle PAUSE button to pause/resume all motor momevments
|\n");
printf("+---------------------------------------------------------------+\n\n");
// Check Pause Switch
int counter1 = 0;
if (state_ != EXITING) {
for (int i = 1; i<= 21; i++) {
if (digitalRead(PIN_PAUSE)) counter1 ++;
nsleep(500000);
}
if (counter1 > 10) printf("Please toggle the PAUSE switch to resume\n\n");
}
while (state_ != EXITING && counter1 > 10) {
counter1 = 0;
for (int i = 1; i<= 21; i++) {
if (digitalRead(PIN_PAUSE)) counter1 ++;
nsleep(500000);
}
}
// Start Switch Thread
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params_switch_thread.sched_priority = 50;
pthread_setschedparam(switch_thread, SCHED_FIFO, ¶ms_switch_thread);
pthread_create(&switch_thread, NULL, switch_thread_func, (void*) NULL);
// Home the system
if (state_ != EXITING) home();
while (state_ != EXITING) main_menu();
// stop all motors
stop_all();
// end swtich thread
pthread_join(switch_thread, NULL);
// end all motor threads
pthread_join(LX_thread, NULL); pthread_join(LY_thread, NULL);
pthread_join(RX_thread, NULL); pthread_join(RY_thread, NULL);
// print exit messages
printf("EXIT successful, Thank you for using the FoamCutter program.\n");
if (state_STOP_) {
printf("\nShuting down ... ...\n");
system("shutdown -P now");
return 0;
}
printf("\nIf you would like to shutdown the Pi now. Please press ENTER.\n");
printf("Otherwise, press 'n' then press ENTER:
"); fflush(stdout);
/****************** SHUTDOWN MENU OPTIONS ****************************/
fd_set input_set; struct timeval timeout;
timeout.tv_sec = 10; timeout.tv_usec = 0;
// Listening for input stream for any activity
FD_ZERO(&input_set); FD_SET(0, &input_set);
while (!select(1, &input_set, NULL, NULL, &timeout)) {
timeout.tv_sec = 10;
FD_ZERO(&input_set ); FD_SET(0, &input_set);
}
// get input
char input_option[256]; fgets(input_option,256,stdin);
// determine length of input
int i; for(i=0; input_option[i]!='\0'; i++); i --;
if (i == 1 && (input_option[0] == 'n' || input_option[0] == 'N')) {
// if chose not to shutdown
printf("\nOk, Please remember to use 'sudo shutdown now'\n");
printf("to shutdown the Pi before unpluging the power.\n\n");
}
else { // chose to shutdown
printf("\nShuting down ... ...\n");
system("shutdown -P now");
}
return 0;
}
/***********************************************************************
****************************** THREADS *********************************
***********************************************************************/
void* LX_thread_func(void* ptr){
while (state_ != EXITING) {
if (set_speed_.LX == 0 || reached_position_.LX == 1 || stop_.LX == 1) {
if (current_position_.LX == target_position_.LX){
reached_position_.LX = 1;
}
digitalWrite(PIN_LX_PUL, LOW);
nsleep(1000000);
}
else {
drive(PIN_LX_PUL, PIN_LX_DIR, set_speed_.LX, \
target_position_.LX - current_position_.LX, \
&(current_position_.LX), &(stop_.LX), POLARITY_LX);
if (!stop_.LX) reached_position_.LX = 1;
}
}
return NULL;
}
void* LY_thread_func(void* ptr){
while (state_ != EXITING) {
if (set_speed_.LY == 0 || reached_position_.LY == 1 || stop_.LY == 1) {
if (current_position_.LY == target_position_.LY){
reached_position_.LY = 1;
}
digitalWrite(PIN_LY_PUL, LOW);
nsleep(1000000);
}
else {
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drive(PIN_LY_PUL, PIN_LY_DIR, set_speed_.LY, \
target_position_.LY - current_position_.LY, \
&(current_position_.LY), &(stop_.LY), POLARITY_LY);
if (!stop_.LY) reached_position_.LY = 1;
}
}
return NULL;
}
void* RX_thread_func(void* ptr){
while (state_ != EXITING) {
if (set_speed_.RX == 0 || reached_position_.RX == 1 || stop_.RX == 1) {
if (current_position_.RX == target_position_.RX){
reached_position_.RX = 1;
}
digitalWrite(PIN_RX_PUL, LOW);
nsleep(1000000);
}
else {
drive(PIN_RX_PUL, PIN_RX_DIR, set_speed_.RX, \
target_position_.RX - current_position_.RX, \
&(current_position_.RX), &(stop_.RX), POLARITY_RX);
if (!stop_.RX) reached_position_.RX = 1;
}
}
return NULL;
}
void* RY_thread_func(void* ptr){
while (state_ != EXITING) {
if (set_speed_.RY == 0 || reached_position_.RY == 1 || stop_.RY == 1) {
if (current_position_.RY == target_position_.RY){
reached_position_.RY = 1;
}
digitalWrite(PIN_RY_PUL, LOW);
nsleep(1000000);
}
else {
drive(PIN_RY_PUL, PIN_RY_DIR, set_speed_.RY, \
target_position_.RY - current_position_.RY, \
&(current_position_.RY), &(stop_.RY), POLARITY_RY);
if (!stop_.RY) reached_position_.RY = 1;
}
}
return NULL;
}
void* cut_manager_func(void* ptr){
char buf[500];
while(state_ == GCODE && fgets(buf,500, ptr_file_)!=NULL){
while (state_ == GCODE && !allreached()) {
nsleep(10000000);
} // wait till last coord is reached
removespace(buf); // remove spaces
if (!strncmp(buf,"G4P",3)) { // check if is a pause statement
float temp; str2f(buf+3, &temp);
nsleep((uint64_t)(floor(temp*1.0E9)));
}
else if (!strncmp(buf,"G1",2)) { // if a cut statement
check_cord(buf); // read coordinates and update global coord_
// Update new target position
target_position_.LX = (int32_t)floor((coord_.LX + coord_offset_x_) * MM2PULSE);
target_position_.LY = (int32_t)floor((coord_.LY + coord_offset_y_) * MM2PULSE);
target_position_.RX = (int32_t)floor((coord_.RX + coord_offset_x_) * MM2PULSE);
target_position_.RY = (int32_t)floor((coord_.RY + coord_offset_y_) * MM2PULSE);
// Calculate time to move to the next coord
float dL = sqrt( pow(target_position_.LX - current_position_.LX,2.0) \
+ pow(target_position_.LY - current_position_.LY,2.0));
float dR = sqrt( pow(target_position_.RX - current_position_.RX,2.0) \
+ pow(target_position_.RY - current_position_.RY,2.0));
float time = (dL + dR)/2.0/FEEDRATE/MM2PULSE;
// Set speed for all 4 axis
set_speed_.LX = (target_position_.LX - current_position_.LX)/time/MM2PULSE;
set_speed_.LY = (target_position_.LY - current_position_.LY)/time/MM2PULSE;
set_speed_.RX = (target_position_.RX - current_position_.RX)/time/MM2PULSE;
set_speed_.RY = (target_position_.RY - current_position_.RY)/time/MM2PULSE;
if (state_ == GCODE) {
// Start the cut by setting reached_position_ to 0
reached_position_.LX = reached_position_.LY = 0;
reached_position_.RX = reached_position_.RY = 0;
// wait till new coord is reached
nsleep((uint64_t)(floor(time*1.0E9)));
}
} // end while --- read line by line
}
// if the state_ is still GCODE, but the while loop ended;
// means the end of file is reached, and therefore cut is complete
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if (state_ == GCODE) { state_ = HOMED;}
return NULL;
}
void* print_func(void* ptr){
struct timespec current_time;
int elapsed_time = 0;
int remain_time;
while(state_ == GCODE){
clock_gettime( CLOCK_REALTIME, ¤t_time);
elapsed_time = current_time.tv_sec - start_time_.tv_sec;
remain_time = ETA_ - elapsed_time;
printf("\r");
printf("%7.3f/%8.3f|%7.3f/%8.3f|%7.3f/%8.3f|%7.3f/%8.3f|
", \
current_position_.LX/MM2PULSE*MM2IN , current_position_.LX/MM2PULSE, \
current_position_.LY/MM2PULSE*MM2IN , current_position_.LY/MM2PULSE, \
current_position_.RX/MM2PULSE*MM2IN , current_position_.RX/MM2PULSE, \
current_position_.RY/MM2PULSE*MM2IN , current_position_.RY/MM2PULSE);
print_time(elapsed_time); printf("
|
");
print_time(remain_time); printf("
|");
fflush(stdout);
nsleep(1000000000); // run at 1 Hz
}
return NULL;
}
void* switch_thread_func(void* ptr){
int state_P = 0;
int counter_P, counter_S;
int counter_S2 = 0;
while (state_ != EXITING) {
counter_P = counter_S = 0;
for (int i = 1; i<= 41; i++) {
if (digitalRead(PIN_PAUSE)) counter_P ++;
if (digitalRead(PIN_STOP )) counter_S ++;
nsleep(500000);
}
if (counter_P > 25 && !state_P) {
stop_all();
state_P = 1;
}
else if (counter_P <= 15 && state_P && state_
state_P = 0;
stop_.LX = stop_.LY = stop_.RX = stop_.RY
digitalWrite(PIN_RELAY, HIGH);
}
else if (counter_P <= 15 && state_P && state_
state_P = 0;
stop_.LX = stop_.LY = stop_.RX = stop_.RY
}
== GCODE) {
= 0;
== HOMED) {
= 0;
if (counter_S > 25) counter_S2 ++;
else counter_S2 = 0;
if (counter_S2 == 100){
state_ = EXITING; stop_all(); state_STOP_ = 1;
printf("\n\n**************************** EXITING PROGRAM ****************************\n");
}
}
return NULL;
}
/***********************************************************************
************************** SYSTEM FUNCTIONS ****************************
***********************************************************************/
void initialize_pin(){
// Setup limit switch pins
pinMode(PIN_LX_LIM,INPUT); pullUpDnControl(PIN_LX_LIM,PUD_DOWN);
pinMode(PIN_LY_LIM,INPUT); pullUpDnControl(PIN_LY_LIM,PUD_DOWN);
pinMode(PIN_RX_LIM,INPUT); pullUpDnControl(PIN_RX_LIM,PUD_DOWN);
pinMode(PIN_RY_LIM,INPUT); pullUpDnControl(PIN_RY_LIM,PUD_DOWN);
// Setup motor dive pins
pinMode(PIN_LX_DIR,OUTPUT); pinMode(PIN_LX_PUL,OUTPUT);
pinMode(PIN_LY_DIR,OUTPUT); pinMode(PIN_LY_PUL,OUTPUT);
pinMode(PIN_RX_DIR,OUTPUT); pinMode(PIN_RX_PUL,OUTPUT);
pinMode(PIN_RY_DIR,OUTPUT); pinMode(PIN_RY_PUL,OUTPUT);
// Setup switches pins
pinMode(PIN_PAUSE,INPUT); pullUpDnControl(PIN_PAUSE,PUD_DOWN);
pinMode(PIN_STOP ,INPUT); pullUpDnControl(PIN_STOP ,PUD_DOWN);
// Setup relay control pin
pinMode(PIN_RELAY,OUTPUT);
return;
}
void home(){
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// Print Header
printf("I see the system is not homed yet, please press ENTER to home the system:
fflush(stdout);
if (menu_enter() == -2) return; // if EXITING state, end function
printf("Homing ...
"); fflush(stdout);
");
// Home the system
current_position_.LX = current_position_.LY = current_position_.RX = current_position_.RY = 0;
reached_position_.LX = reached_position_.LY = reached_position_.RX = reached_position_.RY = 0;
target_position_.LX = target_position_.LY = target_position_.RX = target_position_.RY = -640000;
// Home X axis
set_speed_.LY = set_speed_.RY = 0.0;
set_speed_.LX = set_speed_.RX = -1.0;
int counter1, counter2;
int state1 = 0; int state2 = 0;
while (state_ != EXITING && (!state1 || !state2)) {
counter1 = counter2 = 0;
for (int i = 1; i<= 41; i++) {
if (digitalRead(PIN_LX_LIM)) counter1 ++;
if (digitalRead(PIN_RX_LIM)) counter2 ++;
nsleep(20000);
}
if (counter1 > 30 && !state1) {
state1 = 1;
stop_.LX = 1;
set_speed_.LX = 0.0;
current_position_.LX = LIM2ORIGIN_LX;
reached_position_.LX = 1;
}
if (counter2 > 30 && !state2) {
state2 = 1;
stop_.RX = 1;
set_speed_.RX = 0.0;
current_position_.RX = LIM2ORIGIN_RX;
reached_position_.RX = 1;
}
}
if (state_ == EXITING) return;
nsleep(200000000);
target_position_.LX = LIM2ORIGIN_LX + 1000;
target_position_.RX = LIM2ORIGIN_RX + 1000;
set_speed_.LX
= set_speed_.RX
= +FEEDRATE;
stop_.LX = stop_.RX = 0;
reached_position_.LX = reached_position_.RX = 0;
while (state_ != EXITING && (!reached_position_.LX || !reached_position_.RX)) { nsleep(1000000);}
// Home Y axis
if (state_ == EXITING) return;
nsleep(500000000);
set_speed_.LX = set_speed_.RX = 0.0;
set_speed_.LY = set_speed_.RY = -1.0;
counter1 = counter2 = state1 = state2 = 0;
while (state_ != EXITING && (!state1 || !state2)) {
counter1 = counter2 = 0;
for (int i = 1; i<= 41; i++) {
if (digitalRead(PIN_LY_LIM)) counter1 ++;
if (digitalRead(PIN_RY_LIM)) counter2 ++;
nsleep(20000);
}
if (counter1 > 30 && !state1) {
state1 = 1;
stop_.LY = 1;
set_speed_.LY = 0.0;
current_position_.LY = LIM2ORIGIN_LY;
reached_position_.LY = 1;
}
if (counter2 > 30 && !state2) {
state2 = 1;
stop_.RY = 1;
set_speed_.RY = 0.0;
current_position_.RY = LIM2ORIGIN_RY;
reached_position_.RY = 1;
}
}
if (state_ == EXITING) return;
nsleep(500000000);
// Move to orgin
if (state_ == EXITING) return;
printf("All limits reached, Moving to Origin ...
"); fflush(stdout);
target_position_.LX = target_position_.LY = target_position_.RX = target_position_.RY = 0;
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set_speed_.LX
= set_speed_.LY
= set_speed_.RX
stop_.LX = stop_.LY = stop_.RX = stop_.RY = 0;
= set_speed_.RY
= +FEEDRATE;
reached_position_.LY = reached_position_.RY = reached_position_.LX = reached_position_.RX = 0;
while (state_ != EXITING && !allreached()) { nsleep(1000000);}
if (state_ == EXITING) return;
state_ = HOMED;
printf("Homing Complete! \n\n");
return;
}
int loadtext(char* filename){
float pause_time = 0.0;
float cut_length = 0.0;
int asym_cut = 0;
int error = 0; // set error to 1 will return to main menu
float span;
float coord_x_min;
float coord_y_min;
float width;
float height;
coord_lim_.LX_max
coord_lim_.LY_max
coord_lim_.RX_max
coord_lim_.RY_max
coord_.LX_old
coord_.LY_old
coord_.RX_old
coord_.RY_old
=
=
=
=
=
=
=
=
coord_lim_.LX_min
coord_lim_.LY_min
coord_lim_.RX_min
coord_lim_.RY_min
coord_.LX
coord_.LY
coord_.RX
coord_.RY
=
=
=
=
=
=
=
=
0.0;
0.0;
0.0;
0.0;
0.0;
0.0;
0.0;
0.0;
coord_offset_x_ = coord_offset_y_ = 0.0;
/*************************** READ FILE *******************************/
FILE *ptr_file; char buf[500];
ptr_file =fopen(filename, "r");
int line_numb = 1;
while (fgets(buf,500, ptr_file)!=NULL){ // get line by line
removespace(buf); // remove spaces
if (!strncmp(buf,"G4P",3)) { // check if is a pause statement
float temp;
if (str2f(buf+3, &temp)) {pause_time += temp;}
else {
printf("G-code error at line %d. Returning to Main Menu.\n\n",line_numb);
error = 1;
return 1;
}
}
else if (!strncmp(buf,"G1",2)) { // if a cut statement
if (check_cord(buf)) { // check if statement is valid
cut_length += cut_length_func();
if (fabs(coord_.LX - coord_.RX) + fabs(coord_.LY - coord_.RY) > 0.0001 ) {
asym_cut ++;
}
// update the max/min coordinates
coord_lim_.LX_max = max(coord_lim_.LX_max, coord_.LX);
coord_lim_.LX_min = min(coord_lim_.LX_min, coord_.LX);
coord_lim_.LY_max = max(coord_lim_.LY_max, coord_.LY);
coord_lim_.LY_min = min(coord_lim_.LY_min, coord_.LY);
coord_lim_.RX_max = max(coord_lim_.RX_max, coord_.RX);
coord_lim_.RX_min = min(coord_lim_.RX_min, coord_.RX);
coord_lim_.RY_max = max(coord_lim_.RY_max, coord_.RY);
coord_lim_.RY_min = min(coord_lim_.RY_min, coord_.RY);
}
// if not a valid line, print error message and stop reading
else {
printf("G-code error at line %d. Returning to Main Menu.\n\n",line_numb);
error = 1;
return 1;
}
}
line_numb ++;
} // end while --- read line by line
fclose(ptr_file); // read complete
if (!error && state_ != EXITING) { // if no reading error occured
coord_x_min = min(coord_lim_.LX_min,coord_lim_.RX_min);
coord_y_min = min(coord_lim_.LY_min,coord_lim_.RY_min);
} // end if --- check error
/**************** FIRST: check if offset is needed *******************/
// check x
if (coord_x_min < 0 && state_ != EXITING && !error){
printf("I see you have a min x coordinate of %7.3f in (%8.3f mm)\n", \
coord_x_min*MM2IN, coord_x_min);
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printf("A negative value is not allowed\n");
printf("You can use the minimum offset, or enter one yourself\n");
printf("Would you like to use the minimum offset for x?\n");
if (!menu_yes()){
while(state_ != EXITING) {
int temp = menu_enter_one(&coord_offset_x_,"Please enter the x offset");
if
(temp == -1) {printf("Invalid input, please enter again.\n\n");}
else if (temp == 1) {
if (coord_offset_x_ < - coord_x_min) {
printf("Insufficient x offset, please enter a bigger x offset\n\n");
}
else break;
}
}
}
else { coord_offset_x_ = - coord_x_min;}
}
// check y
if (coord_y_min < 0 && state_ != EXITING && !error){
printf("I see you have a min y coordinate of %7.3f in (%8.3f mm)\n", \
coord_y_min*MM2IN, coord_y_min);
printf("A negative value is not allowed\n");
printf("You can use the minimum offset, or enter one yourself\n");
printf("If you are cutting part of a 3-piece wing\n");
printf("I would recommend enter the same offset for all 3 pieces.\n");
printf("It will make the vaccum bagging easier\n\n");
printf("Would you like to use the minimum offset for y?\n");
if (!menu_yes()){
while(state_ != EXITING) {
int temp = menu_enter_one(&coord_offset_y_,"Please enter the y offset");
if
(temp == -1) {printf("Invalid input, please enter again.\n\n");}
else if (temp == 1) {
if (coord_offset_y_ < - coord_y_min) {
printf("Insufficient y offset, please enter a bigger y offset\n\n");
}
else break;
}
}
}
else { coord_offset_y_ = - coord_y_min;}
}
coord_y_min += coord_offset_x_;
coord_y_min += coord_offset_y_;
coord_lim_.LX_max += coord_offset_x_; coord_lim_.LX_min += coord_offset_x_;
coord_lim_.LY_max += coord_offset_y_; coord_lim_.LY_min += coord_offset_y_;
coord_lim_.RX_max += coord_offset_x_; coord_lim_.RX_min += coord_offset_x_;
coord_lim_.RY_max += coord_offset_y_; coord_lim_.RY_min += coord_offset_y_;
if (coord_lim_.LX_max > X_MAX || coord_lim_.RX_max > X_MAX) {
printf("X axis out of bound, maximum X distance is 29 inches\n");
printf("Returning to G-code Menu\n\n");
error = 1; gcode_menu_option_ = -1;
}
if (coord_lim_.LY_max > Y_MAX || coord_lim_.RY_max > Y_MAX) {
printf("Y axis out of bound, maximum Y distance is 16 inches\n");
printf("Returning to G-code Menu\n\n");
error = 1; gcode_menu_option_ = -1;
}
/************** SECOND: determine and check foamsize *****************/
if(!asym_cut && state_ != EXITING && !error){ // if not an asymetric cut
printf("I see this is a symmetric cut\n");
printf("The minimum require foam size is:\n");
width = coord_lim_.LX_max;
height = coord_lim_.LY_max;
printf("Width
(x-direction): %7.3f in (%8.3f mm)\n", width*MM2IN, width);
printf("Thickness (y-direction): %7.3f in (%8.3f mm)\n", height*MM2IN, height);
printf("Please leave some extra space.\n");
}
else if (asym_cut && state_ != EXITING && !error){ // if an asymetric cut
printf("I see this is an asymmetric cut\n");
printf("The minimum require foam size depends on the span of the cut.\n");
printf("Please enter the span size of the cut.\n");
while(state_ != EXITING && menu_enter_one(&span,"Please enter the span size") == -1) {
printf("Invalid input, please enter again.\n\n");
}
width = min(coord_lim_.LX_max,coord_lim_.RX_max) + \
fabs(coord_lim_.LX_max-coord_lim_.RX_max)*(CUTTERWIDTH + span)/2.0/CUTTERWIDTH;
height = min(coord_lim_.LY_max,coord_lim_.RY_max) + \
fabs(coord_lim_.LY_max-coord_lim_.RY_max)*(CUTTERWIDTH + span)/2.0/CUTTERWIDTH;
if (state_ != EXITING){
printf("Width
(x-direction): %7.3f in (%8.3f mm)\n", width*MM2IN, width);
printf("Thickness (y-direction): %7.3f in (%8.3f mm)\n", height*MM2IN, height);
printf("Please leave some extra space.\n");
}
}
if(state_ != EXITING && !error){
printf("Does this look correct and matches your foam size?\n"); fflush(stdout);
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if (!menu_yes()){
printf("Looks like there's something wrong. Returning to G-code Menu.\n\n");
error = 1; gcode_menu_option_ = -1;
}
}
/******************* THIRD: review cut settings **********************/
if (state_ != EXITING && !error){
printf("***************************** CUT SETTINGS ******************************\n");
printf("G-code file: %s.\n", filename);
if (asym_cut) {
printf("Asymetric Cut of span %7.3f in (%8.3f mm)\n", span*MM2IN, span);
}
else {printf("Symmetric Cut\n");}
printf("Minimum Foam Size:\n");
printf("Width
(x-direction): %7.3f in (%8.3f mm)\n", width*MM2IN, width);
printf("Thickness (y-direction): %7.3f in (%8.3f mm)\n", height*MM2IN, height);
if (coord_offset_x_) {
printf("x offset of %7.3f in (%8.3f mm)", coord_offset_x_*MM2IN, coord_offset_x_);
}
else {printf("No x offset");}
printf(" and ");
if (coord_offset_y_) {
printf("y offset of %7.3f in (%8.3f mm)", coord_offset_y_*MM2IN, coord_offset_y_);
}
else {printf("No y offset");}
printf("\n");
printf("Estimate total time of cut: ");
ETA_ = round(pause_time + cut_length/FEEDRATE );
print_time(ETA_); printf("\n");
if (asym_cut) {printf("Please make sure the foam is centered.\n");}
printf("\nWould you like to start the cut?\n");
if (!menu_yes()){
printf("OK, setting incorrect. Returning to G-code Menu.\n\n");
error = 1; gcode_menu_option_ = -1;
}
}
return error;
}
int check_cord(char* str){
coord_.LX_old = coord_.LX; coord_.LY_old = coord_.LY;
coord_.RX_old = coord_.RX; coord_.RY_old = coord_.RY;
char* ptr_X = strchr(str, 'X');
char* ptr_Y = strchr(str, 'Y');
char* ptr_Z = strchr(str, 'Z');
char* ptr_A = strchr(str, 'A');
if (ptr_X && ptr_Y && ptr_Z && ptr_A && \
(ptr_X < ptr_Y) && (ptr_Y < ptr_Z) &&(ptr_Z < ptr_A) ){
char temp1[20], temp2[20], temp3[20], temp4[20];
float tempf1, tempf2, tempf3, tempf4;
strncpy(temp1,ptr_X+1,ptr_Y-ptr_X-1); temp1[(ptr_Y-ptr_X-1)] = '\0';
strncpy(temp2,ptr_Y+1,ptr_Z-ptr_Y-1); temp2[(ptr_Z-ptr_Y-1)] = '\0';
strncpy(temp3,ptr_Z+1,ptr_A-ptr_Z-1); temp3[(ptr_A-ptr_Z-1)] = '\0';
strncpy(temp4,ptr_A+1,10
);
if(str2f(temp1, &tempf1) && str2f(temp2, &tempf2) && \
str2f(temp3, &tempf3) && str2f(temp4, &tempf4)){
coord_.LX = tempf1; coord_.LY = tempf2;
coord_.RX = tempf3; coord_.RY = tempf4;
return 1;
}
else return 0;
}
else return 0;
}
int allreached() {
return reached_position_.LX * reached_position_.LY * reached_position_.RX * reached_position_.RY;
}
void stop_all() {
stop_.LX = stop_.LY = stop_.RX = stop_.RY = 1;
digitalWrite(PIN_RELAY,LOW);
return;
}
float cut_length_func(){
float L_length = sqrt(pow((coord_.LX - coord_.LX_old),2.0) + pow((coord_.LY - coord_.LY_old),2.0));
float R_length = sqrt(pow((coord_.RX - coord_.RX_old),2.0) + pow((coord_.RY - coord_.RY_old),2.0));
return (L_length + R_length)/2.0;
}
void drive(int pin_pul, int pin_dir, float speed, int32_t delta_pulse, int* ptr_current, int* ptr_stop, int polarity ){
int inc;
if
(speed*polarity > 0) { digitalWrite(pin_dir, HIGH); inc = 1*polarity;}
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else if (speed*polarity < 0) { digitalWrite(pin_dir, LOW ); inc = -1*polarity;}
// the time between pulses, calculated from speed
// 4000 is the sleep time in the loop;
// 100000 is the approximate code execution time;
uint64_t sleep_time = floor(1000000000.0/MM2PULSE/fabs(speed)) - 4000 - 100000;
nsleep(5000); // ensure dir pin leads by at least 5 microsec
for (int i = 0; i < abs(delta_pulse); i++) { // send out desired number of pulses
digitalWrite(pin_pul, HIGH);
nsleep(4000); // ensure pulse width of at least 2 microsec
digitalWrite(pin_pul, LOW );
*ptr_current += inc;
if (*ptr_stop) break; // stop the motor if stop is a 1;
nsleep(sleep_time);
}
return;
}
void cut_gcode(char* filename){
state_ = GCODE;
if (state_ == EXITING) return;
moveto(-5.0,0.0);
while (state_ != EXITING && !allreached()){ nsleep(1000000);}
if (state_ == EXITING) return;
printf("Please connect and turn on the power supply for the hot wire\n");
printf("Please make sure the voltage is approximately 10V, and press ENTER to continue:
fflush(stdout);
if (menu_enter() == -2) return;
digitalWrite(PIN_RELAY,HIGH);
printf("Please now adjust the power supply to the desired current.\n");
printf("Recommend 2.1 to 2.3 Amps, depending on the cut span.\n");
printf("Use higher current for wider cuts.\n");
printf("Increase current if wire bows significantly.\n");
printf("Press ENTER to start cutting:
");
fflush(stdout);
if (menu_enter() == -2) return;
printf("Heating wire ... ..."); fflush(stdout);
if (state_ != EXITING) nsleep(5000000000);
if (state_ == EXITING) return;
printf(" Cut Starting\n");
moveto(0.0,0.0);
while (state_ != EXITING && !allreached()) nsleep(1000000);
if (state_ == EXITING) return;
");
coord_.LX_old = coord_.LX = 0.0;
coord_.LY_old = coord_.LY = 0.0;
coord_.RX_old = coord_.RX = 0.0;
coord_.RY_old = coord_.RY = 0.0;
clock_gettime( CLOCK_REALTIME, &start_time_);
ptr_file_ =fopen(filename, "r");
printf("
LX
|
LY
printf("
in /
mm
|
in /
mm
|
|
in
RX
/
mm
|
|
in
RY
/
mm
|
|
Elapsed
params_print_thread.sched_priority = 40;
params_cut_manager.sched_priority = 99;
pthread_setschedparam(printing_thread, SCHED_FIFO, ¶ms_print_thread);
pthread_create(&printing_thread, NULL, print_func, (void*) NULL);
pthread_setschedparam(cut_manager, SCHED_FIFO, ¶ms_cut_manager);
pthread_create(&cut_manager, NULL, cut_manager_func, (void*) NULL);
while (state_ == GCODE) nsleep(100000);
fclose(ptr_file_); // read complete
if (state_ != EXITING) moveto(-5.0,0.0);
while (state_ != EXITING && !allreached()) nsleep(1000000);
digitalWrite(PIN_RELAY,LOW);
if (state_ != EXITING) moveto( 0.0,0.0);
while (state_ != EXITING && !allreached()) nsleep(1000000);
if (state_ != EXITING) printf("\nCut Complete, Returning to Main Menu.\n\n");
pthread_join(cut_manager, NULL);
pthread_join(printing_thread, NULL);
return;
}
void moveto(float x, float y){
target_position_.LX = target_position_.RX = (int32_t)floor(x * MM2PULSE);
target_position_.LY = target_position_.RY = (int32_t)floor(y * MM2PULSE);
// Set speed for all 4 axis
if
(target_position_.LX > current_position_.LX) set_speed_.LX = +FEEDRATE;
else if (target_position_.LX < current_position_.LX) set_speed_.LX = -FEEDRATE;
else if (target_position_.LX == current_position_.LX) set_speed_.LX = 0.0;
if
(target_position_.LY > current_position_.LY) set_speed_.LY = +FEEDRATE;
else if (target_position_.LY < current_position_.LY) set_speed_.LY = -FEEDRATE;
else if (target_position_.LY == current_position_.LY) set_speed_.LY = 0.0;
54
TIME
|\n");
| Remaining |\n");
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if
(target_position_.RX > current_position_.RX) set_speed_.RX = +FEEDRATE;
else if (target_position_.RX < current_position_.RX) set_speed_.RX = -FEEDRATE;
else if (target_position_.RX == current_position_.RX) set_speed_.RX = 0.0;
if
(target_position_.RY > current_position_.RY) set_speed_.RY = +FEEDRATE;
else if (target_position_.RY < current_position_.RY) set_speed_.RY = -FEEDRATE;
else if (target_position_.RY == current_position_.RY) set_speed_.RY = 0.0;
if (state_ != EXITING) {
// Start the cut by setting reached_position_ to 0
reached_position_.LX = reached_position_.LY = 0;
reached_position_.RX = reached_position_.RY = 0;
}
return;
}
/***********************************************************************
*************************** MENU FUNCTIONS *****************************
***********************************************************************/
void main_menu() {
printf("******************************* MAIN MENU *******************************\n");
printf("Please choose from the following options:\n");
printf("a. Load and cut from G-Code;\n");
printf("b. Move wire to specified location;\n");
printf("c. Exit Program.\n");
printf("Please enter the corresponding letter and press ENTER key:
");
fflush(stdout);
switch (menu(3)) {
case 0: {gcode_menu();
break;
case 1: {move_menu();
break;
case 2: {state_ = EXITING;
break;
case -1: {printf("Invalid option. Let's try again.\n\n"); break;
case -2: {
break;
}
return;
}
}
}
}
}
}
void gcode_menu() {
if (state_ != EXITING && (current_position_.LX || \
current_position_.LY || current_position_.RX || current_position_.RY)){
printf("I see the wire is not at origin. Plesse press ENTER to move wire to origin:
fflush(stdout);
if (menu_enter() != -2) {
moveto(0.0,0.0);
while (state_ != EXITING && !allreached()){ nsleep(1000000);}
printf("Origin Reached\n\n");
}
}
gcode_menu_option_ = -1;
int n = 10;
while (state_ != EXITING && gcode_menu_option_ == -1){
printf("****************************** GCODE MENU *******************************\n");
// keep looping when menu selection is invalid
struct dirent **namelist;
n = scandir("/home/pi/", &namelist, file_filter, alphasort);
// scan for files with .txt extension
if (n == 0) {
printf("I do not see any txt files in '/home/pi/' directory\n");
printf("Please put the desired gcode file in '/home/pi/' directory.\n");
printf("Returning to Main Menu.\n\n");
break;
}
else if (n > 9){
printf("Too many txt files in '/home/pi/' directory\n");
printf("Please clean it up.\n");
printf("Returning to Main Menu.\n\n");
break;
}
else{
printf("I see there are %d txt files listed below:\n\n",n);
int i = 0;
while (i++ < n){
printf("%d:
%s\n", i, namelist[i-1]->d_name);
}
printf("0:
None of the above, or Return to Main Menu\n\n");
printf("Please select one by entering the corresponding number then press ENTER:
fflush(stdout);
gcode_menu_option_ = menu(n+1);
if (gcode_menu_option_ >= 1) {
printf("You selected: '%s'
switch (menu_yes()){
case 1:
");
");
is that correct?\n",namelist[gcode_menu_option_-1]->d_name);
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if (state_ != EXITING && !loadtext(namelist[gcode_menu_option_-1]->d_name) ) {
if (state_ != EXITING) cut_gcode(namelist[gcode_menu_option_-1]->d_name);
return;
}
break;
case 0:
printf("OK, Let try again\n\n");
gcode_menu_option_ = -1;
break;
}
}
else if (gcode_menu_option_ == 0 ) {
printf("Please put the desired gcode file in the working directory.\n");
printf("Returning to Main Menu.\n\n");
break;
}
else if (gcode_menu_option_ == -1 ) { // Invalid input
printf("Invalid Input, let's try again.\n\n");
}
else if (gcode_menu_option_ == -2 ) { // EXITING state
break;
} // end of if --- menu input check
} // end of if --- file number check
} // end of while
return;
} // end of gcode_menu
void move_menu(){
float x,y;
while (state_ != EXITING){
float current_x = (current_position_.LX + current_position_.RX)/2.0/MM2PULSE;
float current_y = (current_position_.LY + current_position_.RY)/2.0/MM2PULSE;
printf("******************************* MOVE MENU *******************************\n");
printf("The current wire position is (x,y) = (%.3f,%.3f) in = (%.3f,%.3f) mm\n", \
current_x*MM2IN,current_y*MM2IN,current_x,current_y);
printf("Please choose from the following options:\n");
printf("a. Move wire to a specific location relative to origin (Absolute Location);\n");
printf("b. Move wire to a specific location relative to current position (Increment);\n");
printf("c. Move wire to origin;\n");
printf("d. Return to Main Menu;\n");
printf("Please enter the corresponding letter and press ENTER key:
");
fflush(stdout);
switch (menu(4)) {
case 0: { // Move to a specific location
while(state_ != EXITING && \
(menu_enter_two(&x,&y,"Please enter the destination x and y coordinates RELATIVE TO ORIGIN") == -1 \
|| x < 0 || y <0)) {
printf("Invalid input, please enter again. Please note that negative destination is not allowed.\n\n");
}
if (state_ != EXITING) {
printf("|
|
Current
|
Increment
|
Destination
|\n");
printf("| Inch | %7.3f, %7.3f | %7.3f, %7.3f | %7.3f, %7.3f |\n", \
current_x*MM2IN, current_y*MM2IN, (x-current_x)*MM2IN, (y-current_y)*MM2IN, x*MM2IN, y*MM2IN);
printf("| MM | %8.3f, %8.3f | %8.3f, %8.3f | %8.3f, %8.3f |\n", \
current_x, current_y, (x-current_x), (y-current_y), x, y);
printf("Continue?\n");
switch (menu_yes()){
case 1:
if (state_ != EXITING ) {
printf("Moving ... ..."); fflush(stdout);
moveto(x,y);
while (state_ != EXITING && !allreached()){ nsleep(1000000);}
if (state_ != EXITING) printf(" Destination Reached\n\n");
}
break;
case 0:
printf("OK, Let try again\n\n");
break;
}
}
break; } // end case --- move to a specific location
case 1: { // Move to a specific location
while(state_ != EXITING && \
(menu_enter_two(&x,&y,"Please enter the destination x and y coordinates RELATIVE TO CURRENT POSITION") == -1 \
|| x+current_x < 0 || y+current_y <0)) {
printf("Invalid input, please enter again. Please note that negative destination is not allowed.\n\n");
}
if (state_ != EXITING) {
printf("|
|
Current
|
Increment
|
Destination
|\n");
printf("| Inch | %7.3f, %7.3f | %7.3f, %7.3f | %7.3f, %7.3f |\n", \
current_x*MM2IN, current_y*MM2IN, x*MM2IN, y*MM2IN, (x+current_x)*MM2IN, (y+current_y)*MM2IN);
printf("| MM | %8.3f, %8.3f | %8.3f, %8.3f | %8.3f, %8.3f |\n", \
current_x, current_y, x, y, (x+current_x), (y+current_y));
printf("Continue?\n");
switch (menu_yes()){
case 1:
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if (state_ != EXITING ) {
printf("Moving ... ..."); fflush(stdout);
moveto(x+current_x,y+current_y);
while (state_ != EXITING && !allreached()){ nsleep(1000000);}
if (state_ != EXITING) printf(" Destination Reached\n\n");
}
break;
case 0:
printf("OK, Let try again\n\n");
break;
}
}
break; } // end case --- move to a specific location
case 2: { //case --- move to origin
if (!current_position_.LX && !current_position_.LY && \
!current_position_.RX && !current_position_.RY) {
printf("Already at Origin\n\n");
}
else{
printf("Move to Orignin. Continue?\n");
switch (menu_yes()){
case 1:
printf("Moving ... ..."); fflush(stdout);
moveto(0.0,0.0);
while (state_ != EXITING && !allreached()){ nsleep(1000000);}
if (state_ != EXITING) printf(" Origin Reached\n\n");
break;
case 0:
printf("OK, Let try again\n\n");
break;
}
}
break; } // end case --- move to origin
case -1: {printf("Invalid option. Let's try again.\n\n"); break; }
default: {return;
break; }
} // end switch
} // end while
return;
}
int menu(int numb_of_options){
// pass in number of menu options, maximum of 10 options
// return 0 to (numb_of_options - 1) if input is within the range
// return -1 for invalid input
// return -2 when state_ is exiting
if (state_ == EXITING) return -2;
fd_set
input_set;
struct timeval timeout;
timeout.tv_sec = 10;
timeout.tv_usec = 0;
// Listening for input stream for any activity
// If there
FD_ZERO(&input_set );
FD_SET(0, &input_set);
while (state_ != EXITING && !select(1, &input_set, NULL, NULL, &timeout)) {
timeout.tv_sec = 1;
FD_ZERO(&input_set );
FD_SET(0, &input_set);
}
if (state_ ==
EXITING) return -2;
// get input
char input_option[256]; fgets(input_option,256,stdin);
// determine length of input
int i; for(i=0; input_option[i]!='\0'; i++); i --;
int result;
if (i == 1) {
if
(input_option[0] >= 48 && input_option[0] <= 57) {
result = input_option[0]-48;
}
else if(input_option[0] >= 65 && input_option[0] <= 74) {
result = input_option[0]-65;
}
else if(input_option[0] >= 97 && input_option[0] <= 106) {
result = input_option[0]-97;
}
else result = -1;
}
else result = -1;
if (result >= numb_of_options) result = -1;
printf("\n");
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return result;
}
int menu_enter(){
// return 1 if anthing is entered, including ENTER key
// return 0 if m is entered
// return -2 when state_ is exiting
if (state_ == EXITING) return -2;
fd_set
input_set;
struct timeval timeout;
timeout.tv_sec = 10;
timeout.tv_usec = 0;
// Listening for input stream for any activity
FD_ZERO(&input_set );
FD_SET(0, &input_set);
while (state_ != EXITING && !select(1, &input_set, NULL, NULL, &timeout)) {
timeout.tv_sec = 1;
FD_ZERO(&input_set );
FD_SET(0, &input_set);
}
if (state_ ==
EXITING) return -2;
// get input
char input_option[256]; fgets(input_option,256,stdin);
// determine length of input
int i; for(i=0; input_option[i]!='\0'; i++); i --;
if (i == 1 && (input_option[0] == 'm' || input_option[0] == 'M')) {
printf("\n"); return 0; // return 0 if input is 'm' or 'M'
}
else {printf("\n"); return 1; }
}
int menu_yes(){
// return 1 if anthing is entered, including ENTER key
// return 0 if n is entered
// return -2 when state_ is exiting
if (state_ == EXITING) return -2;
printf("Press ENTER for YES, or 'n' then ENTER for NO:
fd_set
input_set;
struct timeval timeout;
timeout.tv_sec = 10;
timeout.tv_usec = 0;
"); fflush(stdout);
// Listening for input stream for any activity
FD_ZERO(&input_set );
FD_SET(0, &input_set);
while (state_ != EXITING && !select(1, &input_set, NULL, NULL, &timeout)) {
timeout.tv_sec = 1;
FD_ZERO(&input_set );
FD_SET(0, &input_set);
}
if (state_ ==
EXITING) return -2;
// get input
char input_option[256]; fgets(input_option,256,stdin);
// determine length of input
int i; for(i=0; input_option[i]!='\0'; i++); i --;
if (i == 1 && (input_option[0] == 'n' || input_option[0] == 'N')) {
printf("\n"); return 0; // return 0 if input is 'm' or 'M'
}
else {printf("\n"); return 1;}
}
int menu_enter_one(float* output, char* string){
float scale = 1.0;
if (state_ == EXITING) return -2;
printf("Would you like to enter the coordinate in inches?\n");
switch (menu_yes()) {
case 1: scale = 25.4; printf("%s in inches then press ENTER:
", string); break;
case 0: scale = 1.0; printf("%s in millimeters then press ENTER:
", string); break;
}
fflush(stdout);
if (state_ == EXITING) return -2;
fd_set
input_set;
struct timeval timeout;
timeout.tv_sec = 10;
timeout.tv_usec = 0;
// Listening for input stream for any activity
// If there
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FD_ZERO(&input_set );
FD_SET(0, &input_set);
while (state_ != EXITING && !select(1, &input_set, NULL, NULL, &timeout)) {
timeout.tv_sec = 1;
FD_ZERO(&input_set );
FD_SET(0, &input_set);
}
if (state_ ==
EXITING) return -2;
// get input
char input_option[256]; fgets(input_option,256,stdin);
// remove white spaces
removespace(input_option);
float temp;
if (str2f(input_option, &temp)) {
*output = temp*scale;
printf("\n"); return 1;
}
else {printf("\n"); return -1;}
}
int menu_enter_two(float* output1, float* output2, char* string){
float scale = 1.0;
if (state_ == EXITING) return -2;
printf("Would you like to enter the coordinate in inches?\n");
switch (menu_yes()) {
case 1:
scale = 25.4;
printf("%s in INCHES \nseparated with comma then press ENTER:
", string);
break;
case 0:
scale = 1.0;
printf("%s in MM \nseparated with comma then press ENTER:
", string);
break;
}
fflush(stdout);
if (state_ == EXITING) return -2;
fd_set
input_set;
struct timeval timeout;
timeout.tv_sec = 10;
timeout.tv_usec = 0;
// Listening for input stream for any activity
// If there
FD_ZERO(&input_set );
FD_SET(0, &input_set);
while (state_ != EXITING && !select(1, &input_set, NULL, NULL, &timeout)) {
timeout.tv_sec = 1;
FD_ZERO(&input_set );
FD_SET(0, &input_set);
}
if (state_ == EXITING) return -2;
// get input
char input_option[256]; fgets(input_option,256,stdin);
// remove white spaces
removespace(input_option);
// get the two
char* ptr = strchr(input_option, ',');
if (ptr == NULL) {return -1;}
char temp1[20]; strncpy(temp1,input_option,ptr-input_option);
temp1[(ptr-input_option)] = '\0';
char temp2[20]; strncpy(temp2,ptr+1,20);
float temp1f, temp2f;
if (str2f(temp1, &temp1f) && str2f(temp2, &temp2f)) {
*output1 = temp1f*scale;
*output2 = temp2f*scale;
printf("\n"); return 1;
}
else {return -1;}
}
/***********************************************************************
*************************** OTHER FUNCTIONS ****************************
***********************************************************************/
// Sleep for nanoseconds
void nsleep(uint64_t ns){
struct timespec req,rem;
req.tv_sec = ns/1000000000;
req.tv_nsec = ns%1000000000;
// loop untill nanosleep sets an error or finishes successfully
errno=0; // reset errno to avoid false detection
while(nanosleep(&req, &rem) && errno==EINTR){
req.tv_sec = rem.tv_sec;
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req.tv_nsec = rem.tv_nsec;
}
return;
}
// Filter out file without .txt extension
int file_filter(const struct dirent *entry){
return !strcmp(entry->d_name + strlen(entry->d_name) -4, ".txt");
}
// Remove space in a string
void removespace(char* str) {
int i,j=0;
for(i=0;str[i]!='\0';i++) {
if(str[i]!=' ' && str[i] != 10 && str[i] != 13)
str[j++]=str[i];
}
str[j]='\0';
return;
}
// Signal Handler for CTRL+C
void SigHandler(int dummy) {
state_ = EXITING; stop_all();
printf("\n\n**************************** EXITING PROGRAM ****************************\n");
return;
}
float max(float a, float b) {
if(a >= b) return a;
else return b;
}
float min(float a, float b) {
if(a >= b) return b;
else return a;
}
void print_time(int sec){
if (sec <= 0) printf("00:00");
else printf("%02d:%02d", (int)floor(sec /60.0),sec % 60);
return;
}
int str2f(char* str, float* output){
removespace(str);
float out = 0;
int dec_location;
int dec_numb = 0;
int i; for(i=0; str[i] !='\0'; i++);
int length = i;
int j =1;
for(int i = length-1; i >= 0; i--) {
if (str[i]>=48 && str[i]<=57){out = out+j*(str[i]-48); j = j*10;}
else if (str[i] == 46) {dec_numb ++; dec_location = i;}
else if (i == 0 && str[i] == 43) {out = +out;}
else if (i == 0 && str[i] == 45) {out = -out;}
else return 0;
}
if (dec_numb == 0) {out = out;}
else if (dec_numb == 1) {out = out/pow(10.0,length-1-dec_location);}
else {return 0;}
*output = out;
return 1;
}
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foamcutter_setup.h
The setting file, foamcutter_setup.h is attached below.
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/*******************************************************************************
* foamcutter_setup.h
*******************************************************************************/
#ifndef FOAMCUTTER_SETUP
#define FOAMCUTTER_SETUP
#include
#include
#include
#include
#include
#include
#include
#include
#include
#include
#include
#include
#include
#include
// Cutter Width
#define CUTTERWIDTH (36.0*IN2MM) // inches
// Unit
#define
#define
#define
#define
#define
Conversion
IN2MM 25.4
MM2IN (1.0/25.4)
IN2REV 10.0 // Lead screw 10 TPI
REV2PULSE 400.0 // depend on the switch settings on the motor drive
MM2PULSE ( IN2REV / IN2MM * REV2PULSE) // 157.48 PULSE = 1 mm
// Settings
#define FEEDRATE 0.8 // unit: mm/s
#define FEEDRATE_PUL (FEEDRATE*MM2PULSE)
// position of limit switch relative to cutter origin
#define LIM2ORIGIN_LX -4100
#define LIM2ORIGIN_RX -3550
#define LIM2ORIGIN_LY -2500
#define LIM2ORIGIN_RY -2400
// Motor Drive Pins
#define PIN_LX_DIR 14
#define PIN_LX_PUL 15
#define PIN_LY_DIR 18
#define PIN_LY_PUL 23
#define PIN_RX_DIR 24
#define PIN_RX_PUL 25
#define PIN_RY_DIR 8
#define PIN_RY_PUL 7
// Limit Switches
#define PIN_LX_LIM
#define PIN_LY_LIM
#define PIN_RX_LIM
#define PIN_RY_LIM
6
13
19
26
// Relay
#define PIN_RELAY 12
// Buttons
#define PIN_PAUSE 17
#define PIN_STOP 27
// Motor Polarity
// set to +1 or -1
// reverse the setting if the wire moves away from the limit switch during homing.
#define POLARITY_LX +1
#define POLARITY_LY -1
#define POLARITY_RX +1
#define POLARITY_RY -1
// MAX cut area
#define X_MAX (29.0*IN2MM)
#define Y_MAX (16.0*IN2MM)
#endif
// 29 in
// 16 in
//FOAMCUTTER_SETUP
62
Appendix B
MatLab Code for G-code Generation
1
DBF_foamcutter_general_shape.m
The MatLab code for generating G-code for general shape,
DBF_foamcutter_general_shape.m is attached below. Last updated: 8/26/2018.
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%% DBF Foamcutter for Genearl Shapes
% This code is written by Yuting Huang (ythuang96@gmail.com);
% Please report all bug to the author's email address.
% Last updated: 8/26/2018
% This is written for DBF foamcutting, to generate G-code from general shape
% AutoCAD drawings.
%% User Manual
% 1. Export lines and arcs form AutoCAD, save as csv file.
% 2. Copy the csv file to the same folder as this MatLab code.
% 3. Run Code and done!
% Press CRT+C at anytime to terminate code.
%% -----------------------------------------------------------------------%% -----------------------------------------------------------------------%% -----------------------------------------------------------------------%% -----------------------------------------------------------------------clear all; close all; clc;
tolerance = 0.0002;
accuracy = 2; % length in mm of segments when breaking arc
%% Determine Units
% GUI stuff
UIControl_FontSize_bak = get(0, 'DefaultUIControlFontSize' );
set(0, 'DefaultUIControlFontSize' , 30);
unit = menu( 'Is Drawing in millimeters?' ,'Yes','No');
if unit == 1; % if drawing is in mm, continue generation of G-code
%% Check the current folder for csv files
D = dir( '*.csv');
if ~length(D) % if no .csv file exsist print error message
fprintf( 'I could not find any file with .csv' );
fprintf( ' estension in the current folder.\n' );
fprintf( 'Please move the .csv file created by AutoCAD ' );
fprintf( '''eattext'' command into the current ' );
fprintf( 'working folder and try again.\n' );
else
% Create a menu to select csv files in the current folder
string = [ 'file = menu(''I detected ' num2str(length(D)) ...
' csv files list below, please select one'',' ];
for i = 1:length(D); string = [string '''' D(i).name ''',']; end
string = [string '''None of the above'');' ];
eval(string);
if file <= length(D);
filename = D(file).name(1:end-4); clear string;
if file <= length(D) && file;
%% Inport File
inport = csvread([filename '.csv'],1,2);
[m,n] = size(inport);
% make changes if there are only lines
if n ==4; inport = [zeros(m,5) , inport]; end
%% Eliminate 0 length lines
k = 1;
for i = 1:size(inport,1);
if any(inport(i,6:9)64~= [0 0 0 0]) && ...
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all(inport(i,6:7) == inport(i,8:9));
m = m-1;
else temp(k,:) = inport(i,:); k = k+1;
end
end
inport = temp; clear temp k i D file;
%% Seperate Arc With line
n_arc = 0; n_line = 0;
for i = 1:m;
if all(inport(i,6:9) == [0 0 0 0]);
n_arc = n_arc + 1; arc(n_arc,:) = inport(i,1:5);
else n_line = n_line + 1;
line(n_line,:) = inport(i,6:9);
end
end
%% Break Arcs into lines
alllines = line;
for i = 1:n_arc;
n_segment = ceil(2*pi*arc(i,3)*arc(i,5)/360/accuracy);
dtheta = arc(i,5)/n_segment;
arcpoints = zeros(n_segment+1,2);
for j = 1:n_segment+1; % break arc into points
theta = arc(i,4) + (j-1)*dtheta;
arcpoints(j,:) = arc(i,1:2) + ...
arc(i,3).*[cosd(theta),sind(theta)];
end
% chage the start and end point so that the arc join
% the lines
for j = 1:n_line;
if abs(arcpoints(1,:) - line(j,1:2)) <= 0.01;
arcpoints(1,:) = line(j,1:2);
elseif abs(arcpoints(1,:) - line(j,3:4)) <= 0.01;
arcpoints(1,:) = line(j,3:4);
end
if abs(arcpoints(end,:) - line(j,1:2)) <= 0.01;
arcpoints(end,:) = line(j,1:2);
elseif abs(arcpoints(end,:) - line(j,3:4)) <= 0.01;
arcpoints(end,:) = line(j,3:4);
end
end
% put all lines with arc points together
alllines = [alllines ; arcpoints(1:end-1,:) , ...
arcpoints(2:end,:)];
end
%% Sort the lines in order
sort(1,:) = alllines(1,:);
alllines(1,:) = [];
for i = 2:size(alllines,1)+1;
compare = sort(i-1,3:4);
[n2,~] = size(alllines);
for j = 1:n2;
if all(abs(compare - alllines(j,1:2)) <= tolerance);
sort(i,:) = alllines(j,:);
alllines(j,:)
65 = []; check = 1; break;
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elseif all(abs(compare - alllines(j,3:4)) <= tolerance);
sort(i,1:2) = alllines(j,3:4);
sort(i,3:4) = alllines(j,1:2);
alllines(j,:) = []; check = 1; break;
end
end
if ~check
% cannot find the another line that connects with
% the previous
fprintf( 'There is an open countour.\n' );
fprintf( 'This is most likely caused by an ' );
fprintf( 'extra line underneath a long line.\n' );
fprintf( 'Please check your drawing.\n' );
return;
end
check = 0;
end
sort2 = [sort(:,1:2); sort(end,3:4)];
%% Shift to positive
min_x = min(sort2(:,1)); min_y = min(sort2(:,2));
sort2(:,1) = sort2(:,1) - min_x;
sort2(:,2) = sort2(:,2) - min_y;
max_x = max(sort2(:,1)); max_y = max(sort2(:,2));
%% Plot Curve
figure(1); set(1, 'position',[0 0 1920 1080]); hold on;
plotx = sort2(:,1); ploty = sort2(:,2); plot(plotx,ploty );
title( 'Drawing Unit mm' ,'fontsize',30);
axis equal;
%% Plot number
[n,~] = size(sort2);
j = 1; index = [];
for i = 1:n-1;
if sort2(i,1) == 0 || sort2(i,1) == max_x ...
|| sort2(i,2) == 0 || sort2(i,2) == max_y;
text(plotx(i),ploty(i),sprintf( '%d',j),'fontsize',20);
j = j+1; index = [index, i];
end
end
hold off;
%% Determine Start Point
start = index(input( 'Which point would you like to start?
' ));
sort3 = [sort2(start:end-1,:) ; sort2(1:start-1,:); ...
sort2(start,:)];
%% Cut Direction Reverse if chosen to
direction = menu([ 'The Current Cut Direction is shown in' , ...
'the Figure with Increasing Number,' , ...
'Reverse Cut Direction?' ,'N0','YES']);
if direction == 2; final = rot90(sort3',1);
elseif direction == 1; final = sort3; end
%% Final Plot
clf; hold on;
finalx = final(:,1); finaly = final(:,2);
plot(finalx,finaly);
title( 'Final shape on Foam
66 Cutter, Drawing Unit mm' , ...
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'fontsize',30);
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j = 1;
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for i = 1:n
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if final(i,1) == 0 || final(i,1) == max_x ...
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|| final(i,2) == 0 || final(i,2) == max_y;
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text(finalx(i),finaly(i),sprintf( '%d',j),'fontsize',20);
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j = j+1;
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if j == 4; break; end
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end
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end
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axis equal; hold off;
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set(0, 'DefaultUIControlFontSize' , UIControl_FontSize_bak);
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%% Generate G-code
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fidw = fopen([filename '.txt'],'wt');
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fprintf(fidw, 'G21\n'); fprintf(fidw, 'M49\n');
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fprintf(fidw, 'F80\n'); fprintf(fidw, 'S80\n');
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fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A % 8.3f\n' ...
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,0,0,0,0);
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fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A % 8.3f\n' ,...
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finalx(1),finaly(1),finalx(1),finaly(1));
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for i = 2:length(finalx)-1
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fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A % 8.3f\n' ...
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,finalx(i),finaly(i),finalx(i),finaly(i));
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% Calculate Length
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length = sqrt((finalx(i)-finalx(i-1))^2 + ...
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(finaly(i)-finaly(i-1))^2);
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if length >= 100;
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fprintf(fidw,sprintf( 'G4 P%d\n',floor(length/100) ) );
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end
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% Add 1 sec pause per 100 mm cut for long cuts
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end
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fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A % 8.3f\n' ...
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,finalx(end),finaly(end),finalx(end),finaly(end));
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fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A % 8.3f\n' ...
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,0,0,0,0);
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fprintf(fidw, 'M2');
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fclose(fidw);
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disp([ 'The G-Code is saved as ''' filename ...
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'.txt'' in this folder. ' ]);
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set(gcf, 'PaperUnits','inches','PaperPosition',[0 0 16 9]);
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print(filename, '-dpng','-r240');
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else % if 'none of the above selectee'
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fprintf( 'Please move your desired file to the current' );
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fprintf( ' folder and try again.\n' );
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end
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else % if no file selected
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fprintf( 'Please move your desired file to the current' );
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fprintf( ' folder and try again.\n' );
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end % end file selection check
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end % end file exsistence check
214 else % if drawing not in mm, print error message
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fprintf( 'Please go back to AutoCAD and use the ''Scale''' );
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fprintf( ' command to scale the drawing
67 by 25.4. \n' );
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fprintf( 'Inches do not provide high enough accuracy\n' );
218 end % end 'unit' check
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2
DBF_foamcutter_wing.m
The MatLab code for generating G-code for wing, DBF_foamcutter_wing.m is
attached below. Last updated: 8/23/2018.
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%% DBF Foamcutter for Wing
% This code is modified by Yuting Huang (ythuang96@gmail.com) based on
% Dr.Anderson's code written on Scilab.
% Please report all bug to the author's email address.
% Last updated: 8/23/2018
% This is written for DBF foamcutting, to generate G-code from wing
% prameters.
clear all; close all; clc;
%% Enter Parameters Below
% airfoil section file for root
root_filename = 'AH-79-100.dat';
% root chord length [in]
root_chord = 6;
% airfoil section file for tip
tip_filename = 'E216.dat';
% tip chord length [in]
tip_chord = 3;
% root chord has to be greater or equal to tip chord
% +1 for right wing, -1 for left wing
right_wing = 1;
% semi-span [in]
semi_span = 3;
% leading edge sweep [deg]
LE_sweep = 0;
% twist [deg]
twist = 0.0;
% g-code output file name
g_filename = 'HTail';
% width of CNC cutter [in]
cutter_width = 39;
% scale the cord length to accomodaate for broken trailing edge
% recommend using 1.2, then cut trailing edge with a blade to desired
% length.
scale_factor = 1.2;
%% -----------------------------------------------------------------------%% -----------------------------------------------------------------------%% -----------------------------------------------------------------------%% -----------------------------------------------------------------------%% Open File
fid = fopen(root_filename);
temp = textscan(fid, '%f %f','headerLines', 1);
fclose(fid);
root_pts = [temp{1}, temp{2}];
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fid = fopen(tip_filename);
temp = textscan(fid, '%f %f','headerLines', 1);
fclose(fid);
tip_pts = [temp{1}, temp{2}];
clear temp fid;
%% Deconstruct Airfoil into Upper and Lower Parts
root_size = size(root_pts,1);
root_turn_point = find(root_pts(:,2)<0,1) - 1;
root_upper_x = root_pts(1:root_turn_point, 1);
root_upper_y = root_pts(1:root_turn_point, 2);
root_lower_x = root_pts(root_turn_point:root_size, 1);
root_lower_y = root_pts(root_turn_point:root_size, 2);
tip_size = size(tip_pts,1);
tip_turn_point = find(tip_pts(:,2)<0,1) - 1;
tip_upper_x = tip_pts(1:tip_turn_point, 1);
tip_upper_y = tip_pts(1:tip_turn_point, 2);
tip_lower_x = tip_pts(tip_turn_point:tip_size, 1);
tip_lower_y = tip_pts(tip_turn_point:tip_size, 2);
%% Interpolate
n = 301;
root_upper_yp =
root_upper_xp =
root_lower_yp =
root_lower_xp =
tip_upper_yp
tip_upper_xp
tip_lower_yp
tip_lower_xp
=
=
=
=
interp1(root_upper_x,root_upper_y,linspace(1,0,n)');
linspace(1,0,n)';
interp1(root_lower_x,root_lower_y,linspace(0,1,n)');
linspace(0,1,n)';
interp1(tip_upper_x,tip_upper_y,linspace(1,0,n)');
linspace(1,0,n)';
interp1(tip_lower_x,tip_lower_y,linspace(0,1,n)');
linspace(0,1,n)';
%% Scale to Chord Length
% chord length on machine
root_chord_ext = root_chord + ...
0.5*(root_chord - tip_chord)*(cutter_width - semi_span)/semi_span;
tip_chord_ext = root_chord - ...
0.5*(root_chord - tip_chord)*(cutter_width + semi_span)/semi_span;
root_upper_xp = root_chord_ext*root_upper_xp;
root_upper_yp = root_chord_ext*root_upper_yp;
root_lower_xp = root_chord_ext*root_lower_xp;
root_lower_yp = root_chord_ext*root_lower_yp;
tip_upper_xp = tip_chord_ext*tip_upper_xp;
tip_upper_yp = tip_chord_ext*tip_upper_yp;
tip_lower_xp = tip_chord_ext*tip_lower_xp;
tip_lower_yp = tip_chord_ext*tip_lower_yp;
%% Rotate Tip by Twist Angle
c4 = tip_chord/4;
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twist_rad = (pi/180)*twist;
tip_upper_xpr = tip_upper_xp*cos(twist_rad) ...
+ tip_upper_yp*sin(twist_rad) + c4*(1.0-cos(twist_rad));
tip_upper_ypr = -tip_upper_xp*sin(twist_rad) ...
+ tip_upper_yp*cos(twist_rad) + c4*sin(twist_rad);
tip_lower_xpr = tip_lower_xp*cos(twist_rad) ...
+ tip_lower_yp*sin(twist_rad) + c4*(1.0-cos(twist_rad));
tip_lower_ypr = -tip_lower_xp*sin(twist_rad) ...
+ tip_lower_yp*cos(twist_rad) + c4*sin(twist_rad);
%% Use Sweep Angle to Shift Tip Relative to Root
sweep_shift = cutter_width*tan(LE_sweep*pi/180);
tip_upper_xpr = tip_upper_xpr + sweep_shift;
tip_lower_xpr = tip_lower_xpr + sweep_shift;
%% Swap x-axis to Start Cut on
root_upper_xp = root_chord_ext
root_lower_xp = root_chord_ext
tip_upper_xpr = root_chord_ext
tip_lower_xpr = root_chord_ext
Trailing Edge
- root_upper_xp;
- root_lower_xp;
- tip_upper_xpr;
- tip_lower_xpr;
%% Combine Upper and Lower Surfaces
root_x = [root_upper_xp; root_lower_xp];
root_y = [root_upper_yp; root_lower_yp];
tip_x = [tip_upper_xpr; tip_lower_xpr];
tip_y = [tip_upper_ypr; tip_lower_ypr];
%% Make a Plot of Root and Tip
set(0,'defaultlinelinewidth' ,2)
set(0,'defaultaxeslinewidth' ,1)
set(0,'defaultaxesfontsize' ,20)
figure(1); set(1, 'position',[0 0 1920 1080]); hold on;
plot(root_x,root_y);
plot(tip_x,tip_y);
legend1 = legend( 'Root','Tip');
set(legend1, 'interpreter','latex'); set(legend1, 'fontsize',18);
title('Wing on FoamCutter' ,'interpreter','latex','fontsize',25);
xlabel('X [in]','interpreter','latex','fontsize',25);
ylabel('Y [in]','interpreter','latex','fontsize',25);
axis equal; grid on;
%% Write G-code File
root_x = scale_factor*root_x*25.4;
root_y = scale_factor*root_y*25.4;
tip_x = scale_factor*tip_x*25.4;
tip_y = scale_factor*tip_y*25.4;
fidw = fopen([g_filename '.txt'],'wt');
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fprintf(fidw, 'G21\n'); fprintf(fidw, 'M48\n');
fprintf(fidw, 'F80\n'); fprintf(fidw, 'S80\n');
fprintf(fidw, 'G1
X % 8.3f
Y % 8.3f
Z % 8.3f
A % 8.3f\n' ,0,0,0,0);
if right_wing > 0
fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A %
root_x(1),root_y(1),tip_x(1),tip_y(1));
fprintf(fidw, 'G4 P5\n');
for i=length(root_x):-1:1
fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f
root_x(i),root_y(i),tip_x(i),tip_y(i));
end
else
fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f A %
tip_x(1),tip_y(1),root_x(1),root_y(1));
fprintf(fidw, 'G4 P5\n');
for i=length(root_x):-1:1
fprintf(fidw, 'G1 X % 8.3f Y % 8.3f Z % 8.3f
tip_x(i),tip_y(i),root_x(i),root_y(i));
end
end
fprintf(fidw, 'G1 X % 8.3f
fprintf(fidw, 'M2');
Y % 8.3f
Z % 8.3f
fclose(fidw);
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8.3f\n' , ...
A % 8.3f\n' , ...
8.3f\n' , ...
A % 8.3f\n' , ...
A % 8.3f\n' ,0,0,0,0);
Appendix C
Drawings
The complete SolidWorks drawings can be found at
https://github.com/ythuang96/FoamCutter. The following is the complete assembly in
SolidWorks:
Drawings attached below are all aluminum pieces that required machining. But the
drawings are not drawn in compliance with engineering standards and therefore should only
be used as a reference when machining yourself.
74
7.736
8.000
5.965
4.390
3.610
2.035
1
0
0.264
2
X4
0
0.394
B
B
1.969
M6
Close Fit X10
Drill B
0
0.610
23.417
24.000
21.843
X2
11.500
12.000
12.500
2.157
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0
0.583
60
2.362
0
0.80
1.50
1.390
2.000
1/4-20
Close Fit X3
Drill F
A
M6
Close Fit X8
Drill B
TITLE:
SIZE
A
Al Sheet 1
Al Sheet 2
DWG. NO.
SCALE: 1:2
2
A
1
1
WEIGHT:
REV
SHEET 1 OF 11
0
0.394
7.638
8.000
0.591
B
1.162
1.772
1.862
1.969
1/4-20
Close Fit X4
Drill F
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0
M6
Close Fit X8
Drill B
5.138
60
2.362
0
2.756
B
6.063
5.244
5.441
4.500
4.000
3.500
1.937
1
0
0.362
2
0
1.522
1.772
2.022
4-40
Close Fit X2
Drill #34
A
TITLE:
SIZE
A
Al Sheet 3-1
Al Sheet 3-2
DWG. NO.
SCALE: 1:2
2
A
1
1
WEIGHT:
REV
SHEET 2 OF 11
1
X2
1.969
0.394
0
2
0
B
B
0.375
0.750
3.500
2.800
0.900
77
0
M6
Close Fit X2
Drill B
0
0.550
1.500
A
1/2-13
Close Fit
Drill 33/64
3/4 Ream
TITLE:
SIZE
A
Rec Tube 1
DWG. NO.
SCALE: 1:2
2
A
1
1
WEIGHT:
REV
SHEET 3 OF 11
1
0.750
0.500
0.250
0
2
0
B
B
1.000
0
78
0.313
0.20
Drill 10
4-40
Close Fit X2
Drill #34
0.375
0
1/4-20
Close Fit
Drill F
0.500
A
1.200
TITLE:
SIZE
A
Rec Tube 2
DWG. NO.
SCALE: 2:1
2
A
1
1
WEIGHT:
REV
SHEET 4 OF 11
1
0
1.201
50
1.969
2
0
0.625
Drill 5/8
0.288
B
B
0.788
1.288
1.288
40
1.575
0.788
0
79
0.288
4-40
Close Fit X2
Drill #34
0
X2
0.400
1.100
A
50
1.969
TITLE:
1/4-20
Close Fit X3
Drill F
L Bracket 50-50-40
Nut Vertical
SIZE
A
DWG. NO.
SCALE: 1:1
2
1
1
WEIGHT:
REV
SHEET 5 OF 11
A
0
1
0.951
50
1.969
2
0
0.625
Drill 5/8
0.288
B
B
0.788
1.288
1.288
40
1.575
0.788
0
80
0.288
4-40
Close Fit X2
Drill #34
0
X2
0.400
1.100
A
50
1.969
TITLE:
1/4-20
Close Fit X3
Drill F
L Bracket 50-50-40
Nut Horizontal
SIZE
A
DWG. NO.
SCALE: 1:1
2
1
1
WEIGHT:
REV
SHEET 6 OF 11
A
1
0
1.500
75
2.953
2
0
B
B
0.594
1.374
4-40
Close Fit X2
Drill #34
0
1.819
0
0.150
81
M6
Close Fit X2
Drill B
0.984
50
1.969
1.082
A
TITLE:
L Bracket 75-60-50
Vertical Motor
60
2.362
SIZE
1.00
A
DWG. NO.
SCALE: 1:1
2
1
1
WEIGHT:
REV
SHEET 7 OF 11
A
1
0
1.900
75
2.953
2
0
B
B
0.594
1.374
4-40
Close Fit X2
Drill #34
0
1.819
0
0.150
82
M6
Close Fit X2
Drill B
0.984
50
1.969
0.964
A
TITLE:
L Bracket 75-60-50
Vertical W/O Motor
60
2.362
SIZE
1.00
A
DWG. NO.
SCALE: 1:1
2
1
1
WEIGHT:
REV
SHEET 8 OF 11
A
1
0
1.000
75
2.953
2
0
B
B
0.484
1.484
4-40
Close Fit X2
Drill #34
0
1.082
A
1.819
0.984
0
0.150
83
1/4-20
Close Fit X2
Drill F
50
1.969
TITLE:
L Bracket 75-60-50
Horizontal Motor
60
2.362
2
SIZE
1.00
A
DWG. NO.
SCALE: 1:1
1
1
WEIGHT:
REV
SHEET 9 OF 11
A
1
0
1.000
75
2.953
2
0
B
B
0.484
1.484
4-40
Close Fit X2
Drill #34
0
1.819
0
0.150
84
1/4-20
Close Fit X2
Drill F
0.984
50
1.969
0.964
A
TITLE:
60
2.362
1.00
L Bracket 75-60-50
Horizontal W/O
SIZE DWG. NO. Motor
REV
1
A
SCALE: 1:1
2
1
WEIGHT:
SHEET 10 OF 11
A
1.700
0
1.306
1
0.306
2
0
0.222
B
B
0.505
0.597
0.800
1.300
M6
Close Fit
Drill B
0.906
0
85
0.306
2-56
Close Fit X4
Drill #43
0
0.222
A
0.505
0.597
0.800
1/4-20
Close Fit
Drill F
TITLE:
Limit Switch Plate
SIZE
A
DWG. NO.
SCALE: 2:1
2
1
1
WEIGHT:
REV
SHEET 11 OF 11
A
Appendix D
Part List
The parts used for this project are listed below.
86
Category
Spec
Name
Screw Size
Link
4ft
Rail
T-Slot
Aluminum
87
Electronics
Panel
Corner Brace
Corner Surface Bracket
Tee Surface Bracket
3 Way Outside Corner
Fasten Plate
Single
Fasten Plate
Dual
Dust Cover
L Bracket
L Bracket
Al Sheet
Al Sheet
Al Rod
75 * 60 * 50 mm
50 * 50 * 40 mm
2 * 24 * 1/8''
8 * 8 * 1/8''
1 1/4'' OD 1'' length
Manual Switch
Toggle - Monentary
Toggle - Maintained
Limit Switch
Standoff
Flat cable Signal
Flat cable Power
26 awg
18 awg
L to R
R to L
PVC 1/4'' thick
https://www.mcmaster.com/#47065t101/=1cbr8ec
2ft
1ft
1'' screw distance
Exit Switch
Pause and Wire switch
4 cable
4 cable
$10.57
https://www.mcmaster.com/#47065t216/=1cbr8mf
https://www.mcmaster.com/#47065t267/=1ct8pah
https://www.mcmaster.com/#47065t278/=1ct8qy1
https://www.mcmaster.com/#47065t244/=1cbra50
1/4''-20-1/2'' https://www.mcmaster.com/#47065t142/=1cbr7ot
1/4''-20-1/2'' https://www.mcmaster.com/#47065t147/=1cbr7xq
https://www.mcmaster.com/#47065t93/=1cbr627
$7.79
$5.84
$4.96
$7.62
$7.95
$9.86
$2.30
$4.29
$4.15
https://www.mcmaster.com/#2313n46/=1cby7fm
https://www.mcmaster.com/#2313n43/=1cttttv
https://www.mcmaster.com/#89015k231/=1ctty5m
https://www.mcmaster.com/#89015k239/=1ctu0cb
https://www.mcmaster.com/#1610t12/=1d2s65q
$13.60
$8.39
$10.46
$13.07
$2.96
8
4
2
3
1
https://www.mcmaster.com/#7343k29/=1ct8u34
https://www.mcmaster.com/#7343k184/=1ct8uci
https://www.mcmaster.com/#7193k3/=1cazszw
https://www.mcmaster.com/#90268a203/=1ccj61x
https://www.mcmaster.com/#9634t203/=1ctvn73
https://www.mcmaster.com/#9634t603/=1ct11kf
$9.14
$4.34
$7.17
$1.66
$2.08
$3.78
1
2
4
10
10
10
$2.31
$2.31
$92.78
5
5
1
1/2''
1/2''
2-56
2-56
Comment
X2 cut to 34'', X2 use
10 for cutting shorter
ones
5
2
38
8
10
8
10
10
3
Hole D 0.25''
Hole Spacing 0.5''
https://www.mcmaster.com/#1910a42/=1ct0b2b
https://www.mcmaster.com/#1910a22/=1ct0aul
https://www.mcmaster.com/#92985t52/=1ct8ij0
Constant-Force Spring 10.60 lbs
Sleeve Bearing
Sleeve Bearing
Width 1''
Length 1/2''
Length 1 1/2''
ID 1.2'', OD 1.52''
ID 1/4'', OD 3/8''
ID 1/2'', OD 3/4''
https://www.mcmaster.com/#9293k12/=1ctcaxk
https://www.mcmaster.com/#6391k136/=1cucsi1
https://www.mcmaster.com/#6391k413/=1ctcfzf
$10.83
$0.67
$4.71
1
1
1
Sleeve Bearing
Length 3/8''
ID 1/2'', OD 3/4''
https://www.mcmaster.com/#6391k521/=1ctsrf0
$1.50
0
Flanged Sleeve Bearing
One-way Bearing
Shaft
Shaft Collar
Rectangular Tube
Length 1''
Length 1/2''
Length 9''
ID 1/2'', OD 3/4''
ID 1/2'', OD 3/4''
D 1/2''
Length 12''
1.5*0.75''
https://www.mcmaster.com/#6338k424/=1ctsg38
https://www.mcmaster.com/#2489k24/=1ctsnot
https://www.mcmaster.com/#7398k6/=1cuchny
https://www.mcmaster.com/#9946k15/=1ctt7z4
https://www.mcmaster.com/#6546k54/=1cts37f
$2.28
$11.17
$19.40
$2.77
$9.12
2
1
1
4
1
Ruler
Perforated Sheet
Wire Retractor
3ft
1''
Amount for
Final Desgin
$12.31
4
Unit Price
No longer required in
final design
Category
Button Head Screw
Screw
Socket Head Screw
Nut
Shaft
2-56 1/4''
4-40 0.5''
4-40 1 3/8''
1/4-20 0.5''
1/4-20 1''
1/2-13 3.5''
M6 12mm
M6 20mm
https://www.mcmaster.com/#92196a077/=1cu00p8
https://www.mcmaster.com/#92949a110/=1ctzdks
https://www.mcmaster.com/#92949a813/=1ctzdgv
https://www.mcmaster.com/#97763a263/=1ctznzk
https://www.mcmaster.com/#97763a267/=1ctze0m
https://www.mcmaster.com/#90044a167/=1ctzj8m
https://www.mcmaster.com/#91292a134/=1ctzrd6
https://www.mcmaster.com/#91292a137/=1ctzorm
$5.97
$3.38
$5.19
$8.35
$6.72
$5.05
$7.44
$4.44
Amount for
Final Desgin
1
1
1
1
1
1
1
1
M6 30mm
https://www.mcmaster.com/#91292a139/=1ctzfq8
$9.41
0
1/4-20 1/2''
https://www.mcmaster.com/#94567a510/=1d2s6uf
https://www.mcmaster.com/#91841a005/=1ctzaex
https://www.mcmaster.com/#97149a100/=1ctzgtl
https://www.mcmaster.com/#97149a250/=1ctzjtn
https://www.mcmaster.com/#91828a251/=1cu0gf7
$2.65
$2.91
$7.24
$6.51
$8.73
24
1
1
1
1
Spec
Name
Thumb Screw
4-40 Nut
1/4-20 Nut
1/2-13 Nut
M6 Nut
Shaft
Screw Size
Link
Unit Price
20mm
1000mm
https://www.mcmaster.com/#6459k62/=1cagjsi
$95.82
20mm
600mm
https://www.mcmaster.com/#6459k59/=1cagjxv
$57.48
88
Shaft Support
Mounting Hole 45mm
Linear Bearings
40 mm spacing
1* M5 2*M7 https://www.mcmaster.com/#61815k36/=1cag4oi
$25.19
Comment
No longer required in
final design
X2 cut from previous
foamcutter
X4 cut from previous
4
foamcutter
X8 from previous
16
foamcutter
4
https://www.mcmaster.com/#2464k34/=1cbgsmi
$68.64
3 ft
OD 1.47''
304 Stainless
thinckness 1''
https://www.mcmaster.com/#98980a132/=1cbizut
https://www.mcmaster.com/#1343k134/=1cbj0f6
$36.59
$36.81
Collar
OD 1.3125''
thinckness 0.5''
https://www.mcmaster.com/#6698k13/=1cbj08y
$18.35
Bearing
OD 1.125''
thinckness 0.3125''
https://www.mcmaster.com/#60355k704/=1cbrell
$9.08
https://www.mcmaster.com/#91182a703/=1cbrlk2
$11.59
X8 from previous
foamcutter
X4 from previous
4
foamcutter
4
4
X4 from previous
8
foamcutter
No longer required in
0
final design
1
Shaft Coupler
Lead screw
Transmission Nut
10mm to 1/2 inch
1/2''-10
Shim
4* M6
https://www.mcmaster.com/#9338t54/=1cag46d
$68.20
12
Acrylic
24'' * 48'' *1/4''
https://www.mcmaster.com/#8589k84/=1cy43x1
$55.76
1
Acrylic
6'' * 12'' * 1/8''
https://www.mcmaster.com/#8560k275/=1cyln3f
$5.37
1
Delrin
6'' * 6'' * 1/4''
https://www.mcmaster.com/#8573k121/=1d2s6lb
$9.43
1
No longer required in
final design
Appendix E
Purchase History
The purchase history of this project are listed below.
89
Category
Spec
Name
Rail
T-Slot
Aluminum
Electronics
90
Panel
4ft
3ft
2ft
1ft
1''
Corner Brace
Corner Surface Bracket
Tee Surface Bracket
3 Way Outside Corner
Fasten Plate
Single
Fasten Plate
Dual
Dust Cover
$12.31
$10.57
$7.79
$5.84
$4.96
$7.62
$7.95
$9.86
$2.30
$4.29
$4.15
Amount for
Final Desgin
4
10
5
2
38
8
10
8
10
10
3
Unit Price
1'' screw distance
Constant-Force Spring 10.60 lbs
Sleeve Bearing
Sleeve Bearing
Sleeve Bearing
Wire Retractor Flanged Sleeve Bearing
One-way Bearing
Shaft
Shaft Collar
Rectangular Tube
Width 1''
Length 1/2''
Length 1 1/2''
Length 3/8''
Length 1''
Length 1/2''
Length 9''
Length 12''
---------------$37.80
1
2
4
10
10
10
$9.14
$8.68
$28.68
$16.60
$20.80
$37.80
-------------------
-------------------
-------------------
-------------------
----------------
$2.31
$2.31
$92.78
5
5
1
5
5
1
$11.55
$11.55
$92.78
----------
----------
----------
----------
----------
----------
$10.83
$0.67
$4.71
$1.50
$2.28
$11.17
$19.40
$2.77
$9.12
1
1
1
0
2
1
1
4
1
1
1
1
2
2
1
1
4
1
$10.83
$0.67
$4.71
$3.00
$4.56
$11.17
$19.40
$11.08
$9.12
----------------------------
----------------------------
----------------------------
----------------------------
----------------------------
----------------------------
$9.14
$4.34
$7.17
$1.66
$2.08
$3.78
Hole D 0.25''
----------------
1
2
4
10
10
10
Toggle - Monentary
Toggle - Maintained
Perforated Sheet
----------------
------------------$15.90
-------------
-------------
Manual Switch
L to R
R to L
PVC 1/4'' thick
------------$2.96
$53.70
----------------
8
4
2
3
1
Ruler
---------$11.68
---$60.96
----------------
Order4
Amount
------------------2
-------------
$148.63
----------------
$13.60
$8.39
$10.46
$13.07
$2.96
4 cable
4 cable
Order3
Amount
---------2
---8
----------------
$108.80
$33.56
$20.92
$39.21
----
75 * 60 * 50 mm
50 * 50 * 40 mm
2 * 24 * 1/8''
8 * 8 * 1/8''
1 1/4'' OD 1'' length
26 awg
18 awg
Order2
$1,256.92
Amount
------1
$10.57
1
$7.79
------6
$29.76
4
$30.48
-------------------------------
8
4
2
3
L Bracket
L Bracket
Al Sheet
Al Sheet
Al Rod
Limit Switch
Standoff
Flat cable Signal
Flat cable Power
Order1
$1,235.68
Amount
4
$49.24
9
$95.13
5
$38.95
------32
$158.72
8
$60.96
10
$79.50
8
$78.88
10
$23.00
10
$42.90
3
$12.45
----
1
10
Category
Button Head Screw
Screw
Socket Head Screw
Nut
Shaft
Spec
Name
Thumb Screw
4-40 Nut
1/4-20 Nut
1/2-13 Nut
M6 Nut
Shaft
Shaft Support
91
Linear Bearings
Shaft Coupler
Lead screw
Transmission Nut
Collar
Bearing
Shim
Acrylic
Acrylic
Delrin
2-56 1/4''
4-40 0.5''
4-40 1 3/8''
1/4-20 0.5''
1/4-20 1''
1/2-13 3.5''
M6 12mm
M6 20mm
M6 30mm
1/4-20 1/2''
20mm
20mm
10mm to 1/2 inch
1/2''-10
24'' * 48'' *1/4''
6'' * 12'' * 1/8''
6'' * 6'' * 1/4''
1000mm
600mm
3 ft
OD 1.47''
OD 1.3125''
OD 1.125''
$5.97
$3.38
$5.19
$8.35
$6.72
$5.05
$7.44
$4.44
$9.41
$2.65
$2.91
$7.24
$6.51
$8.73
Amount for
Final Desgin
1
1
1
1
1
1
1
1
0
24
1
1
1
1
$95.82
$57.48
$25.19
4
4
16
----------
----------
2
0
8
$191.64
$0.00
$201.52
----------
----------
----------
----------
$68.20
$68.64
$36.59
$36.81
$18.35
$9.08
$11.59
12
4
4
4
8
0
1
----------------------
----------------------
4
0
4
4
4
8
1
$272.80
$0.00
$146.36
$147.24
$73.40
$72.64
$11.59
----------------------
----------------------
----------------------
----------------------
$55.76
$5.37
$9.43
1
1
1
----------
----------
1
1
$55.76
$5.37
----
-------
------$9.43
----------
----------
Unit Price
Order1
$1,235.68
Amount
1
$5.97
1
$3.38
1
$5.19
1
$8.35
1
$6.72
1
$5.05
1
$7.44
1
$4.44
1
$9.41
------1
$2.91
1
$7.24
1
$6.51
1
$8.73
Order2
$1,256.92
Amount
-------------------------------------------------------------------------------------
----
Order3
Amount
---------------------------24
-------------
1
$148.63
---------------------------$63.60
-------------
Order4
Amount
-------------------------------------------
$53.70
-------------------------------------------
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