Difference between revisions of "3D PRINTING WITH ROBOTS"

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[[Category:Software]]
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[[Category:Machines]]
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[[File:4_End effector catalogue_FL_Kopie.jpg| thumb | End effector catalogue FL Kopie)]]
  
 
==Material Preparation==
 
==Material Preparation==
  
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*Locate the Rhinoceros 5 or Rhinoceros 6 shortcut on your desktop and double-click to launch the application.
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Testing material viscosity and printability before 3D printing with a robot is indeed a prudent step to ensure successful printing outcomes. Here's a breakdown of the recommended process:
 +
 
 +
 
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'''Manual Extrusion Test with a Closed Tube Mortar Gun:'''
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 +
- Use a closed tube mortar gun to manually extrude the material.  
  
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Alternatively, you can also click on the Windows Start button and select All Programs. Go to the program group containing Rhinoceros 5. (The name of this program group will usually be called Rhinoceros 5 or 6 unless you specified otherwise during setup). If the installation was successful, upon launching of Rhinoceros 5 you should observe a menu called RhinoCAM 2018 in the main menu bar of Rhino. If you do not see this menu entry then please check the On-Line Help document of the product (found in the installation folder) for help with troubleshooting the installation.
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- This allows you to assess how the material flows and how it behaves during extrusion.
  
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*Before we begin, let's talk a bit about the RhinoCAM display. When you run RhinoCAM for the very first time, your screen may look at this.
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- The closed tube design helps in maintaining consistent pressure and control over the extrusion process.
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These windows on the left belong to plug-in modules that are currently loaded. For now, let's close all of them.
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*Launch the MILL Module
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'''Mixing the Material:'''
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Now, let's begin by launching the RhinoCAM 2018 MILL module.
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1. From the Rhino main menu bar, you will see the RhinoCAM 2018 menu item.
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2. Drop-down the menu and pick MILL to load the MILL module.
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- Ensure thorough mixing of the material to achieve homogeneity.
  
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3. Docked on the left you will see the Machining Browser and the Machining Objects
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- Inadequate mixing can result in inconsistencies in material properties, affecting print quality.
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Browser. When you first run RhinoCAM 2018, these two browsers may be docked side
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by side. However, you can move them anywhere on the screen that feels comfortable
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for you.
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4. For example, let's move the Machining Objects Browser so that it displays under the
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- Avoid adding excessive water content, as it can cause shrinkage issues during printing.
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Machining Browser on the left. Simply left-click and hold the title bar of the browser
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and drag it around on your screen.
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[[File:RhinoCam interface.JPG|800px]]
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- Conversely, too little water content can lead to dry material, making it difficult to print.
  
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==Extruder Assembly==
 
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To set up the stock( the whole material to be milled) follow these instructions:
 
  
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Machine  
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==Machine Views==
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1. Define the Machine and Post-processor to use.
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2. Define the Machining Setup including Stock Geometry, Material and Work Zero.
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[[File:View.jpg| 700 × 402 pixels]]<br><br>
  
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3. Create and Select a Tool to use for machining.
 
  
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4. Create the Machining Operations including the Feeds and Speeds, the Clearance
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1- Motor
  
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Plane and other Cutting Parameters.
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2- Control system: Frequency converter with switch
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5. Generate the toolpath.
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elements, power supply inlet plug with undervoltage
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release to prevent re-start in case of voltage interuption
  
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6. Simulate the toolpath.
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3- Hopper for wet premixed material
  
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7. Post Process the toolpath.
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4- Housing with polyurethan inlet
  
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8. Generate Shop Documentation.
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5- Worm pump
  
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==Select the Post Processor==
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6- Pump outlet with pressure gauge
  
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[[File:Rhinocam 21.jpg|800px]]
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==Operating the machine==
  
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Next, we'll define the Post Processor.
 
  
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1. From the Program tab select, Post to display the dialogue.
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'''Connections Before Start-Up'''
  
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2. For the Current Post Processor, select Haas from the list of available posts.
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Connect the main power plug to the control cabinet
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with the cable to the construction 230V/1/N/PE/50Hz
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(3x1,5mm2).
  
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3. Then set the Posted File Extension to .nc.
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Make sure that all cables and safety devices are functioning properly.
  
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4. Pick OK and notice that the Post type now appears under Machining Job in the Machining Browser.
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'''Start-up in manual mode'''
  
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==Create Stock Geometry==
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- Before Operating the machine check the machine state. Switch rightwards for manual mode.
  
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[[File:Rhinocam stock.JPG|800px]]
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[[File:2_MAI_2PUMP_PICTOR_3D_B_Kopie.jpg| 700 × 402 pixels]]<br><br>
  
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In this step, we'll define the raw stock from which to cut the part.
 
  
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1. From the Program, tab select Stock and then select Box Stock from the menu to display the dialogue.
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- '''Step 1:''' Turn on the main switch
  
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2. Under Dimensions, set the Length L to 10.0, Width W to 6.0 and Height H to 0.125. Note that the stock dimensions you enter are measured from the corner of the bounding box selected in this dialogue.
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[[File:Onn_n_off_switch.jpg| 700 × 402 pixels]]<br><br>
  
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3. Pick OK and notice that the Stock type now appears under Machining Job in the Machining Browser.
 
  
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4. If the stock does not display on the screen, select the Stock Visibility icon located at the base of the Machining Browser.
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- '''Step 2:''' Fill the material-hopper with wet premixed material.
  
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==Create Tools==
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- '''Step 3:''' Turn the Forward/Reverse Switch to FWD (Start the machine by turning the mode switch from
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0 to FWD)
  
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[[File:Rhinocam 20.jpg|800px]]
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[[File:Speed_controlle.jpg| 700 × 402 pixels]]<br><br>
  
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[[File:Rhinocam 22.jpg|800px]]
 
  
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To machine the above part we will now create a ½ inch (0.5”) Flat End Mill.
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- '''Step 4:''' Turn the Speed control to the desired speed
  
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1. This will display the Create/Select Tool dialog.  Select Flat Mill from the Tool Type menu at the top of the dialog.
 
  
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2. Set tool Name to FlatMill-0.5 and Tool Diameter to 0.5.  Under the Properties tab set Material to HSS and Tool Number to 1.
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'''Stopping the pump:'''
  
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3. Switch to Feeds and Speeds tab and click Load from File.
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- '''Step 1:''' Turn the Forward/Reverse control to 0
  
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4. From the dialog that displays, set Stock Material to Wood and Tool Material to HSS.
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- '''Step 2:''' Turn off the main switch
  
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5. Now pick OK and the computed cut feedrate and spindle speed are transferred to the Feeds and Speeds tab of the Create/Select Tool dialog.
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==Termination of work and cleaning==
  
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6. Pick Save as New Tool to save the tool. The tool is now created and listed under Tools in Session on the left side of the dialog.
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After work is completed or in the event of longer inter-
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ruptions, run the machine until the material hopper is empty.
  
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7. Pick OK to close the dialog.
 
  
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==Cut Material Simulation==
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'''Step 1:''' Wash the hopper with clean water, rub the hopper with the sponge provided if it is necessary
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The new toolpath can now be Simulated to display the in-process stock model.
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1. Switch to the Simulate tab at the top of the Machining Browser.
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'''Important:''' 
  
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2. Select Preferences from the Simulate tab.
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Never use any cutter or any sharp/rough tools to clean the hopper, always use the rubber tool that is provided.
  
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3. From the Preferences dialog set the Simulation Model to Polygonal and the Simulation Accuracy to Fine and then pick OK.
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'''Step 3:''' Soak a sponge ball in water.
  
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4. Then from the Simulate tab, uncheck Simulate by Moves and adjust the slider to the left to slow down the simulation speed.
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'''Warning!'''
  
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5. Now, under Setup 1 in the Machining Job tree, select the 2½ Axis Profiling operation we just created and then pick Play to start the simulation.
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Never disconnect the hose when there is any pressure in the pressure gauge. Remove the remaining pressure gauge reaches 0.
  
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6. You can stop the simulation at anytime by selecting the Pause button from the Simulate tab.  Subsequent to pausing the simulation, you can either choose to continue the simulation by selecting the Play button again or exit the simulation by selecting the Stop button.
 
  
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7. To view the cut model with textures applied, select the Toggle Material Texture Visibility icon located at the base of the Machining Browser.
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'''Step 4:''' Open the hose coupling, insert the sponge ball into the hose.
  
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==Post G-Code==
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'''Step 5:''' Reconnect the hose coupling
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Now with the toolpaths complete we're ready to post-process to an output text file containing G-codes that can then be sent to the machine tool to actually machine the part.
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1. Select Setup 1 from the Machining Job, right-click and select Post.  This will postprocess all operations created under the Setup.
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'''Step 6:''' Start pumping and wait for the sponge ball to come out of the hose.
  
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2. The Post & Save As dialog is displayed.  By default, the Part file name and the Setup name are appended for the G-code File name.  Also by default, the posted G-code file is Saved in the folder where the part file is located.
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'''Step 7:''' Grease the pump after cleaning to ensure the pump gasket is residue free.
  
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3. Now pick Post and the G-code file is displayed in Notepad where it can be viewed or edited manually.  
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'''Step 8:''' Ensure that the grease is pushed out of the pump gasket.
  
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4. Now close Notepad.
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'''Warning!'''
  
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==Information Report==
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Never disconnect the hose when there is any pressure in the pressure gauge. Remove the remaining pressure gauge reaches 0.
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At any time, you can create a Report of your Machining Operations.  
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1. Switch to Program tab in the Machining Browser.
 
  
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2. Select Setup 1.
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If the machine is not required for a longer period, dismantle the rotor
 +
and stator and lubricate them with
 +
slide spray. Reassemble the
 +
components and put them into the
 +
machine again.
  
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3. Right-click and select Information to display and Print the report.
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==Troubleshooting==
  
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This dialog provides an estimate of the machining time required for the operations in the Setup.
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'''Pump not starting:'''
  
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Note (Professional & Premium configurations only): In the future, if your Machining Job contains multiple Setups, you can perform the same right-click sequence on the Machining Job to determine the estimated machining time for all Setups.  
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- Ensure that the remote control plug is properly installed.
  
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4. Now pick OK to close the Information dialog.
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[[File:Troubleshoot.jpg| 700 × 402 pixels]]<br><br>

Revision as of 14:57, 28 January 2024

File:4 End effector catalogue FL Kopie.jpg
End effector catalogue FL Kopie)

Material Preparation

Testing material viscosity and printability before 3D printing with a robot is indeed a prudent step to ensure successful printing outcomes. Here's a breakdown of the recommended process:


Manual Extrusion Test with a Closed Tube Mortar Gun:

- Use a closed tube mortar gun to manually extrude the material.

- This allows you to assess how the material flows and how it behaves during extrusion.

- The closed tube design helps in maintaining consistent pressure and control over the extrusion process.

Mixing the Material:

- Ensure thorough mixing of the material to achieve homogeneity.

- Inadequate mixing can result in inconsistencies in material properties, affecting print quality.

- Avoid adding excessive water content, as it can cause shrinkage issues during printing.

- Conversely, too little water content can lead to dry material, making it difficult to print.


Machine Views

700 × 402 pixels


1- Motor

2- Control system: Frequency converter with switch elements, power supply inlet plug with undervoltage release to prevent re-start in case of voltage interuption

3- Hopper for wet premixed material

4- Housing with polyurethan inlet

5- Worm pump

6- Pump outlet with pressure gauge

Operating the machine

Connections Before Start-Up

Connect the main power plug to the control cabinet with the cable to the construction 230V/1/N/PE/50Hz (3x1,5mm2).

Make sure that all cables and safety devices are functioning properly.

Start-up in manual mode

- Before Operating the machine check the machine state. Switch rightwards for manual mode.

700 × 402 pixels


- Step 1: Turn on the main switch

700 × 402 pixels


- Step 2: Fill the material-hopper with wet premixed material.

- Step 3: Turn the Forward/Reverse Switch to FWD (Start the machine by turning the mode switch from 0 to FWD)

700 × 402 pixels


- Step 4: Turn the Speed control to the desired speed


Stopping the pump:

- Step 1: Turn the Forward/Reverse control to 0

- Step 2: Turn off the main switch

Termination of work and cleaning

After work is completed or in the event of longer inter- ruptions, run the machine until the material hopper is empty.


Step 1: Wash the hopper with clean water, rub the hopper with the sponge provided if it is necessary

Important:

Never use any cutter or any sharp/rough tools to clean the hopper, always use the rubber tool that is provided.

Step 3: Soak a sponge ball in water.

Warning!

Never disconnect the hose when there is any pressure in the pressure gauge. Remove the remaining pressure gauge reaches 0.


Step 4: Open the hose coupling, insert the sponge ball into the hose.

Step 5: Reconnect the hose coupling

Step 6: Start pumping and wait for the sponge ball to come out of the hose.

Step 7: Grease the pump after cleaning to ensure the pump gasket is residue free.

Step 8: Ensure that the grease is pushed out of the pump gasket.

Warning!

Never disconnect the hose when there is any pressure in the pressure gauge. Remove the remaining pressure gauge reaches 0.


If the machine is not required for a longer period, dismantle the rotor and stator and lubricate them with slide spray. Reassemble the components and put them into the machine again.

Troubleshooting

Pump not starting:

- Ensure that the remote control plug is properly installed.

700 × 402 pixels

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