Table of Contents
Reference the Detailed Design Documents directory to view all files.
Team Vision for Detailed Design Phase
- Mechanically, the team planned to finish the CAD work for the support structure re-design. In addition, the team wanted to purchase an aluminum plate to machine into the DLP mount. Electronically, the team planned to finish the initial design, implementation, and integration of the custom photoconductor motor control system. The team also planned to integrate the DLP with the LabVIEW code. Finally, the team wanted to create a Bill of Materials to determine an approximate cost for the project.
- The MEs finished the CAD work for the support structure re-design and purchased the aluminum plate for the DLP mount. The mount has been submitted to the ME Machine Shop for machining. The EEs completed initial Arduino code and installed required LabVIEW drivers. Subsystem integration is nearing completion, but full system integration has not yet started.
Progress ReportProgress Report
- What does the team plan to accomplish by the Detailed
- Finish CAD mock-up of support structure
- Machine aluminum plate for DLP
- Attach the DLP to the mounting plate
- Create functional prototype photoconductor motor control system
- Begin integrating new motor control system into existing code and structure
- Integrate the DLP with LabVIEW or at least have some approach for the integration
- What tasks have been accomplished so far?
- Hinged doors chosen for the design
- Aluminum plate for top plate (cost approx. $400 for 1/2" thick)
- Sheet metal side panels for easy removal
- Started working on cover design, based off the design proposed by team P10503
- The first builds of the individual components of motor control system
- Subsystem integration (other than final debugging)
- Detailed design plans for Arduino code upgrades
- What tasks remain, and who is the owner of each?
- Finish CAD (Zach)
- Machine DLP mounting plate (Brandon)
- Finish debugging Arduino/LabVIEW interactions (Cameron)
- Integrate new LabVIEW motor control commands into existing LabVIEW code (Cameron)
- Retrofit Arduino code with timer based pulse control
- Implement magnetic sensing
- Work on LabVIEW integration with DLP. Met with Mr. Wellin and Prof. Kempski for some suggestions. Contacted the DLP company since the DLL driver connecting labVIEW with DLP isn't working.(Zeyar)
- What decisions have been made so far?
- We want to pursue an aluminum plate for the top plate
- Hinged doors that can be easily removed if necessary
- Replace existing photoconductor motor control system
- Use Arduino running custom code for control
- What questions does the team have for the customer
and/or guide in order to continue moving forward?
- Will we have enough money to purchase the aluminum plate and sheet metal sidings?
Prototyping, Engineering Analysis, Simulation
Custom Motor Controller
Arduino Controller Functional Diagram: The PC (LabVIEW) talks directly to both the Arduino and the DAQ. The Arduino controls the motor driver which controls the motor. The motor triggers both a rotary encoder (read by the DAQ) and a magnetic home sensor (read by the Arduino), which allows for detection of both absolute and relative position.
Timer Diagram: Timer0 is configured to oscillate pin 12 at a set frequency. Pin 12 is then fed directly to the motor driver to control the photoconductor motor. Pin 12 is also fed into pin 11, which acts as the clock source for Timer1. Timer1 is used as a counter, and will increment with every pulse. Once pin 12 has pulsed the desired number of times, Timer1 will trigger code to stop the motor. Pin 4 is used to read the magnetic home sensor and automatically stop the motor whenever it is triggered, even is a movement command is underway.
High Visibility Cover: Black portion blocks light for the light sensitive processes while the clear portion allows the transfer stage to be observed. A sheet of dark acrylic serves as the interface between the two "zones". The interface will have a small hinged door that allows the photoconductor to move through all of the processes.
High Isolation Cover: The whole cover is made of dark, low gloss acrylic. This eliminates the possibility of light inadvertently entering the light-sensitive processes through the interface that is present in the High Visibility Cover.
View of the structure without cover present.
Back view of the structure without cover present. The oval holes in the top plate for all of the wiring can be seen.
Structure with protective cover. Casters and levelers are also present on this view. The High Visibility cover may be swapped out for the High Isolation cover pending the results of the Detailed Design Review.
Assembled structure with open doors. All of the voltage generators and computer are stored underneath the test bed.
View of the assembled structure with the High Isolation cover present.
View of the assembled structure with the High Isolation cover present with doors open.
Exploded view of the assembled structure. The cover was not taken apart due to sub-assembly constraints in Solidworks.
Bill of Material (BOM)
Bill of Materials for the Electrical Components
Bill of Materials for the Mechanical Support Structure
Bill of Materials for the High Visibility Cover option
Bill of Materials for the High Isolation Cover option
Current Budget Projection - To be refined after Design Review