P20652: 3D Concrete Printer
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

This phase was focused on detailed design for low risk items such as the structure.

Prototyping, Engineering Analysis, Simulations

During this phase additional prototyping, analysis and simulation were performed by each team.

Mechanical

Prototyping of the extruder was continued. A successful extrusion example is shown below.
Extruder prototype.

Extruder prototype.

Extruder prototype testing.

Extruder prototype testing.

Extruder prototype test GIF

Extruder prototype test GIF

This auger iteration had a smaller diameter allowing it to turn more freely. Additionally, the mixture used was a derivative of the Portland Cement Mortar Mix which worked fairly well.

Structural analysis

A static bending analysis for the x- and y-axes was completed to facilitate selection of aluminum extrusion profile. The maximum deflection was calculated for 6 different profiles from FramingTech. Three loads were considered: our estimate of the extruder weight, 2x this estimate, and 3x this estimate.

In the y-axis, the beam was assumed to have pin supports at each end and the extruder was applied as a static point load at every 10mm along an assumed 1.5m long beam.

In the x-axis, the beam was considered as a cantilever beam from a fixed support at the vertical beam toward the extremities. A worst-case analysis was performed by approximating the applied load as the sum of the entire extruder load (with factors of safety) as well as the weight of the y-axis beam.

From this analysis, we conclude that 45x45 profile will be used for the machine. A maximum deflection of 0.00085m was calculated in the y-axis under the extruder load with a factor of safety of 3. A maximum deflection of 0.00057m was calculated in the x-axis under the extruder load with a factor of safety of 3.

The matlab file used for the analysis is found here.

Electrical

A table displaying all of the variables and results in the system wide power analysis. The results yield that a 200W power supply should suffice for all functionalities, with a built in safety factor. For in-depth description see the "System Wide Power Analysis" document below.
Fig. 1: Power Consumption Calculation Table.

Fig. 1: Power Consumption Calculation Table.

Fig. 2: Projected Total Power Consumption Graph.

Fig. 2: Projected Total Power Consumption Graph.

Fig. 3: Power Supply Selection Choices/Benchmarking.

Fig. 3: Power Supply Selection Choices/Benchmarking.

A few files are provided to show analysis for System Power, Power Consumption, and End-Stop Selection.

System Wide Power Analysis

Power Supply Consumption Calculation

Power Supply Proposal

End-Stop Selection Plan

Software

A Cura profile has been created for an example print of the RIT logo. The Cura settings are shown in the images below. The tool-path has been recorded and is shown in the video below.
Cura extruder settings.

Cura extruder settings.

Cura machine settings.

Cura machine settings.

Cura profile settings.

Cura profile settings.

Software Profile of Example Print.

Software Profile of Example Print.

Drawings, Schematics, Flow Charts, Simulations

Below are the schematics that are currently used to model the system.

Mechanical

Structure CAD diagrams are found below. Additionally, a GIF shows the movement paths for the structure assembly.
Structure Front Isometric View

Structure Front Isometric View

Structure Back Isometric View

Structure Back Isometric View

Structure GIF.

Structure GIF.

Isometric View of Current Auger Assembly, Transparent Shell.

Isometric View of Current Auger Assembly, Transparent Shell.

Isometric View of Current Auger Assembly.

Isometric View of Current Auger Assembly.

Isometric View of Current Auger Assembly, Section View.

Isometric View of Current Auger Assembly, Section View.

Current Auger Assembly.

Current Auger Assembly.

Electrical

Figures 1, 3, 5: Schematics of model specific motor simulations performed in MATLAB/Simulink.

Figures 2, 4, 6: Scope captures of the simulation results. From the results, model specific performance can be analyzed in the electrical environment of the project and under the mechanical loads that the motors may be presented with. The plots display: voltage per phase, current per phase, electromagnetic torque, angular velocity, and angular displacement.

Fig. 1: NEMA 23 Motor (Model: StepperOnline 23HS45-3504S) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Schematic.

Fig. 1: NEMA 23 Motor (Model: StepperOnline 23HS45-3504S) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Schematic.

Fig. 2: NEMA 23 Motor (Model: StepperOnline 23HS45-3504S) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Scope Capture.

Fig. 2: NEMA 23 Motor (Model: StepperOnline 23HS45-3504S) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Scope Capture.

Fig. 3: NEMA 17 Motor (Model: Schneider Electric M1713_15) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Schematic.

Fig. 3: NEMA 17 Motor (Model: Schneider Electric M1713_15) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Schematic.

Fig. 4: NEMA 17 Motor (Model: Schneider Electric M1713_15) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Scope Capture.

Fig. 4: NEMA 17 Motor (Model: Schneider Electric M1713_15) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Scope Capture.

Fig. 5: NEMA 17 Motor (Model: Makeblock 81042) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Schematic.

Fig. 5: NEMA 17 Motor (Model: Makeblock 81042) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Schematic.

Fig. 6: NEMA 17 Motor (Model: Makeblock 81042) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Scope Capture.

Fig. 6: NEMA 17 Motor (Model: Makeblock 81042) and Driver (Model: Trinamic TMC2662) Level 3 Simulation Scope Capture.

Software

The overall library of instructions to setup a new Duet 2 Wifi controller board are found here. Specifically, to setup the controller board from scratch, follow the instruction found here.

Bill of Material (BOM)

Structural & Mixture BOM.

Structural & Mixture BOM.

Structural & Mixture BOM

Electrical System BOM.

Electrical System BOM.

Electrical System BOM

Test Plans

Since the Preliminary Detailed Design review, the test plans have been updated to the excel sheet. Test Plans

Risk Assessment

The updated risk management document: Detailed Design Risk Assessment Chart. The previous phase risk assessment and new risk assessment preview PNG can be found below.
Risk Management Document for Preliminary Design Review.

Risk Management Document for Preliminary Design Review.

Preview of Risk Management Document for Detailed Design Review.

Preview of Risk Management Document for Detailed Design Review.

Design Review Materials

Pre-Read

Plans for next phase

The three week plans for the detailed design review are found below.

Alex K.

Alex P.

Amiee

Chad

Joe

Mary

Nick

Seth

This completes the MSDI phase of senior design. Moving forward, MSDII will begin with prototyping and testing of each axis (X, Y, Z) one by one. Preparation for MSDII included constructing a wooden extrusion prototype.


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