Autonomous Machine To Manufacture PCB and 3-D Design

Transcription

1 Volume 119 No , ISSN: (on-line version) url: Autonomous Machine To Manufacture PCB and 3-D Design Mrs. Archana Prasanthi. R Asst. Professor Department of ECE SRMIST Chennai, India archana.r@vdp.srmuniv.ac.in G.V. Rohit Final year Department of ECE SRMIST Chennai. India g.v.rohit01@gmail.com Rahul Final year Department of ECE SRMIST Chennai, India laposte.khachi@gmail.com Abstract The paper represents how we can manufacture PCB design and 3-D printing in a single setup. The entire system is divided into 3 interfaces: the hardware interfacing, controlling interface and software interface of all the modules. The hardware is interfaced like a mini CNC machine which will work on 3 axis which are controlled by 3 stepper motors. Out of the 3- axis the z- axis is equipped with a spindle motor and 3-D designer. Spindle motor is responsible for the cutting and drilling the copper plate in order to design the PCB plate. The 3-D designer is attached with a material for 3-D printing. The entire process will be controlled with the help of Arduino GRBL. The controller is executed with the help of GRBL software. The circuit to be designed is done with a software PCB layout which would give us the symmetric layout of the circuit board. G-Cam is used to design the required 3-D image to be printed. After the designing of the layout as per our requirements the design is converted into G-code with the help of FlatCam. The G-code of the layout will be the input for the entire process. The extracted G-code is 77and we would get the required output from the process. This way we can do PCB designing as well as 3-D printing in a single machine. Index Terms CNC, Stepper motor, Spindle Motor, G- code, Arduino GRBL. I. INTRODUCTION There are many ways by which we can make a Printed Circuited Board(PCB) and 3-D printed objects. A PCB is a board which supports mechanically and electrically by connecting electronic components or electronic components. These components basically soldered onto the PCB for both connecting the components and fastening them mechanically. These can be either single sided or double sided or multilayered. Multi layered PCB s contain high component density due to the inner layer which takes the space in between the components. Manufacturing of PCB includes two methods by which we can design a PCB. Mainly the design the of PCB is carried out with the help of chemicals which is Ammonium persulfate and Ferric chloride. Where at first, we have to make a layout of the schematic [4] With the help of permanent marker. That designed plate is then put into the chemical for etching of the copper from the remaining part of the board. This process usually takes ten hours to complete. Figure 1. PCB Process 3-D printing is a process by which a material is used in the construction of an object in a three-dimensional object. The objects formed by this process can of any structure and are made with the digital or electronic data[3]. The cost of a 3-D printer is very high but we can make an efficient printer which can construct any object by the data provided to it. For doing 961

2 2 this we are using software s i.e. FlatCam, Inkscape, PCBlayout. Initially Gerber file is created by designing the layout of the PCB in a software through PCB layout software for designing a PCB board whereas Inkscape is used for creating the 3-D printing. These Gerber files are then converted into G-code through FlatCam which is taken as an input for the entire process. CNC also known as computer numeric control is an automation of machines tools with means of pre-program sequences of machine control commands. In contracts there are machines that are control manually by hand, wheels, livers or by mechanically automated parts, CNC computer numeric control takes digital data, a computer program is used for the moments of machines. This paper describes about manufacturing of PCB board (both single side and double side) and manufacturing of 3D printing on a single setup [2]. For working on this idea, we are giving.nc codes to our setup. NC code is a special language that a CNC machine can understand and execute. This code is obtained by G-code or ISO code. G-code is heart of whole CNC router which control the moment of machine and with the help of Arduino Nano this code in.nc format is sent to CNC router The dimensions for our router hardware is described in the given figure. The overview of the entire system is where the user designs the circuit layout to be imprinted on the PCB. The layout is then changed into a machine language using Arduino GRBL. Sequence of pulses are generated which controls the motion of stepper motor i.e. clockwise or anticlockwise direction. Figure 3. Flow Chart for whole process II. Design and Working Open frame structures and closed frame structures are the most common machine structures in the industry. Strong structure loop having a good symmetry and good thermal stability which can provide better rigidity than open frame structure for ease to access to work with the same magnitude in size. In the other hand where large precision is required close frame structure is used. It is easier for moving the tool with a specified work piece. The structure is expensive to build as it requires more materials. It is commonly used in small machines. Even if the structure is asymmetrical, which leads to unnecessary thermal gradients with bending moments, it s an ideal structure for small machines. Small and light work pieces are taken so that the material removal rate is smaller to the large work pieces by a large machine, so the thermal effects causing errors is not a big problem. Figure 2. 3-D printer and PCB printing mechine 962

3 3 current is 1.3A. Spindle motor attached to the z-axis works on 24V with a 1000r/min. The entire machine works on a power supply of 24V and 5A current. A. Selection OF components B. Selection of motors Figure 4. Determining the axes After the evaluation of all the ups and downs we decide that for small machines an open frame structure can be used having different alterations on an open frame structure. Depending on the tool orientation they are divided into two categories i.e. vertical positioning and horizontal positioning tool[6].in the horizontal configuration, i.e. the XY plane the work piece is fixed and thework piece is to be light and compact. Along Z axis spindle is mounted horizontally for ensuring maximum rigidity to the machine which is an optimal structure in the micro-manufacturing of machine tools[5]. The length scale for the machine tools to be designed is be amidst 10mm and 70mm. The weight effect and the length scale cannot be discarded, as it s challenging to fix the work piece on the XY vertical plane. A bold try had been made during the designing stage by moving Z axis by transferring a milling machine to a lathe machine Figure 4.1. Circuitry of the machine. The Z axis helps us for the drilling, etching and engraving of the PCB board and 3-D designer is mounted on the Z axis for printing. The working area of the machine is 160X100X45 mm having a frame size of 260X240X220mm. The stepper motors are working on the basis of bipolar step motor between 9-12V and A. At first motor selection has to be carried out as it is related directly to the driving and control mechanism. There are basically four different types of motors i.e. Stepper Motor, Servo motor, Linear Motor and coil Motor. All having their own strengths and weakness making them suitable for particular operations. Rotary Motor should always contain a led screw for transforming rotary motion to linear motion which is not required for linear motors. B. Stepper Motor is used to convert electrical pulses into distinct mechanical movements. Stepper motor is equipped with spindle which rotates with distinct step increments when an electrical command is given to it in a proper manner.[3] There is a direct relation between the motor rotation and input pulses. Motor rotating speed is directly proportional to the frequency of input pulses and the rotating length is directly related to the applied number of input pulses. Servo motor is equipped with a feedback sensor which tells its current position.this is a basic difference between servo motor and stepper motor [6]. Servo motor contains 4 to 12 poles whereas stepper motor doesn t require this the condition of poles. Stepper motor move using the pulses whereas servo motor takesthe difference between the motors encoding and the commanding position and maintain the current movement as required. Precise control and angular position is maintained by the T. The input current level is proportional to the speed of servo motor. C. Arduino GRBL Arduino GRBL is a microcontroller which is integrated with Arduino Nano and motor driver circuit. This works on the basis of AtMega328P having the same specifications as of Arduino UNO and programming can be done using Arduino IDE. It can be operated with the help of GRBL software. The 963

4 2 input is given in the form of G-code making it simpler and programming is not required by Arduino IDE. D.PCB MAKING PROCESS The design of the schematic is drilled on the board. For making the schematic of the circuit board Dip Trace is used. This software is used in making the schematic and that schematic of the board is converted to G-code using FlatCam which is used as the input for the designing process[4]. Figure 4.5 Output Obtained for PCB E. 3-D Printing Process DIP TRACE Flat Cam Arduino CNC Board Figure4.2. PCB Making Process The 3-D printing process is done with the help of a software called G-cam. The object to be printed is opened in G-cam where the G-code of the object is created and is sent as an input to the GRBL[3]. Figure 4.3 Milling Process G-Cam Figure D Printing Process Arduino CNC Board Figure 4.4 Drilling Process Figure 4.7 G code for 3-D printing 964

5 5 [4] W. Bosshart, Printed circuit boards. New Delhi: Tata McGrawHill, [5] H. Kief, H. Roschiwal and J. Hood, CNC handbook. New York: McGraw-Hill, [6] J. Valentino and E. Goldenberg, Introduction to computer numerical control. Upper Saddle River, N.J.: Prentice Hall, Figure D printing process using GRBL III. Conclusion and Future Use The machine as described above is able to manufacture PCB boards and the 3-D object as per the given instructions. Thus, it can be interpreted that the interfacing and coordination of all the modules has correctly accepted the user data into proper outcomes as required by the stepper motor control module as well as spindle motor control module so that the smooth manufacturing of PCB boards and 3-D objects can be obtained. In the near future the PCB printing process will be applied in the field of broad cameras, auto placers, active system components. 3-D printing will be used in medical purposes, custom parts replacement. Researchers are experimenting of creating artificial bones in human body hence there is a sense of potential growth in the field of medical applications. REFERENCES [1] C. Y. Bing, A. A. Mohanan, T. Saha, R. N. Ramanan, R. Parthiban, and N. Ramakrishnan, Microfabrication of surface acoustic wave device using UV LED photolithography technique, Microelectronic Engineering, vol. 122, pp. 9 12, (2014). [2] K. Davitt, Y. K. Song, W. R. Patterson, A. V. Nurmikko, M. Gherasimova, J. Han, Y. L. Pan, and R. K. Chang, 290 and 340 nm UV LED arrays for fluorescence detection from single airborne particles, Optics Express, vol. 13, no. 23, pp , (2005). [3] P. Radhakrishnan, Computer numerical control machines and computer aided manufacture.2nd edition. New Academic Science Limited,

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