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MECHANTRON IIIfinal PRESENTATION

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TEAM MECHANTRON III :INTERNAL ADVISOR :

SIR FAHAD AHMED SIDDIQUI

GROUP MEMBERS :

M.WAQAS USMAN 2012-EE-113

DANISH JUSANI 2012-EE-077

M.HAMZA KHAN 2012-EE-070

JEHANZAIB SHAHAB 2012-EE-099

M.MUNIR ALAM 2012-EE-112

M.JEHANZAIB RAJ 2012-EE-107

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INTRODUCTION : The name of our project is MECHANTRON III

Consists of mechanical as well as electronic work

Named it after a word which is a combination of mechanical and electronics. 4

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What does it do? It carves :ShapesAlphabets Some sort of images on a wooden block .

It does so with the help of a CNC mechanism attached with it.5

BEFORE CNC :6 In the old days everything was done by human power and manually by humans Then men started doing many works by machines

Machines are controlled with motors mounted on them They are programmed tofollow specific instructions

Previously 10 to 15 men were needed to complete some sort of carving

After CNC only 1 man is able to do more than that work in less time with more accuracy and precision .

WHAT IS CNC ???7 CNC stands for Computer Numerical Control (CNC)

The functions and motions of a machine tool are controlled by means of a prepared program

CNC can control the motions of the workpiece or tool, the input parameters such as depth of cut, speed, and the functions such as turning spindle on/off,

ELEMENTS OF A CNC :

8 A CNC system consists of three basic components

1 . Part program

2 . Machine Control Unit (MCU)

3 . Machine tool (lathe, drill press, milling machine etc)

PART PROGRAM :9 The part program is a detailed set of commands to be followed by the machine tool.

Each command specifies a position in the Cartesian coordinate system (x,y,z) or motion (workpiece travel or cutting tool travel), machining parameters and on/off function.

Part programmers should be well versed with machine tools, machining processes, effects of process variables , and limitations of CNC controls.

Machine Control Unit (MCU)10 Machine Control Unit (MCU) holds all the electronic part of the project and that Control Unit controls everything that our hardware do.

Machine TOOL : The machine tool could be one of the following:

Lathe, milling machine, laser, coordinate measuring machine etc. to describe the motions of a machine tool .

There are three linear axes (x,y,z), three rotational axes (i,j,k), and other axes such as tilt (theta) are possible.

ENHANCEMENTS:11 Modifications to old project (Mechantron I ) & (Mechantron II) made by EE-08 and EE-10.

In 2008 was 3 axis CNC Wood Carver And in 2010 was a 5 axis CNC carver but was only modified mechanically.

Formerly having X, Y, Z axis movement.

Being modified to 5 axis movement CNC machine.

FORMER 3 AXES CNC :

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OUR 5 AXES CNC :13

METHODOLOGY :Implementation Phase :

Removing the rust from body Removing mechanical faults from hardwareReplacing the motors that were out of orderAligning the motors & sprockets Assembling it all together

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METHODOLOGY :15Testing Phase :

Checking and testing of stepper motors

Checking ball screws and chain gears are perfectly coupled together

Checking the breakout board by connecting it to the computer

METHODOLOGY :Testing Phase :

Sending Commands by Mach-3

Finally testing the assembled CNC machine for the first time

Making necessary alteration & modifications after testing16

PROBLEMS FACEDNo Electronic circuitry Alignment problems in motorsSprockets not properly alignedNo stiffness & rigidity in the frameDriver issuesMotor issues

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INTRODUCTION TO THE HARDWARE :18

Our hardware consists of an iron made structure whose dimensions are 3.5x3 foots.

It has a iron base , the thing that need to carves on will be placed on the base

The base is made very stronger to hold force applied by the beam and cutting tool

A beam fitted over base so that it can move over it and it will give the motion along Y axis

A router which fitted over beam and it can move back & forth and thus it will give the motion along X axis.

INTRODUCTION TO THE HARDWARE :19

The router will be able to move upward and downward direction thus giving the motion along Z axis.

The horizontal motion is called the motion along X axis.

The vertical motion is called and known as the motion along Y axis.

The motion in upward and downward direction is motion along Z axis direction.

There are 2 motors fitted on router, which will help the router to move giving angular axes ,thus making it a 5 axes machine.

STEPPER MOTOR SPECIFICATIONS :

20 NEMA 23 3000 rpm max speed 1.8 deg step angle Up to 12.1 N. m holding torque 200 counts/revolution resolution 6 wires Industrial construction

WHY WE ARE USING STEPPER MOTORS? 21

The motor has full torque at standstill ( if the windings are energized).

Excellent response to starting/ stopping/ reversing.

Stepper motors operate in an open loop configuration, unlike servo motors in which closed loop is a necessity

Very reliable since there are no contact brushes in the motor, the life of the motor is simply dependant on the life of the bearing.

Less expensive

22ELECTRONIC COMPONENTS :

STEPPER MOTOR DRIVERBREAKOUT BOARD

BLOCK DIAGRAM :23

SOFTWARE FLOW CHART :24

SOFTWARE DESCRIPTION :25MACH3:

Mach 3 will be used for carving and controlling.

Mach 3 was developed by ArtSoft in 2001

It is known to be as the best pc based CNC software on the internet claimed by thousands of its users.

The Mach series of software was originally developed for the home hobbyist, but has quickly turned into one of the most versatile controlpackages for industrial use as well.

Environment of Mach3

AFTER MID TARGETS ACHIEVED :Making the breakout boardGetting all the stepper drivers assembledConnecting all the circuitry with the power supply and assembling it in an enclosureWorked on remaining two axesFinally performing carving using all the axes by interfacing them with MACH 3.

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SOFTWARE DESCRIPTION :27USES OF MACH 3:

It is used in many applications for example: It is used in lathes

It is also used for milling purposes

It is also used in laser works

It is also used in gear cutting.

TIME ANALYSIS(1 Year)28

GANTT CHART :29MECHANTRON III ( 5 AXES)S No.TaskMARCHAPRILMAYJUNEJULYAUGUSTSEPTEMBEROCTOBERNOVEMEBERDECEMBERJANUARY1Arranging a place & Assembling Of Hardware2Mechanical adjustments3Survey to markets & purchasing of equipments4Electronic work 5Software evaluation6Testing & finalizing78

COST ANALYSIS :(SO FAR)30

CONCLUSIONThis project will be a change in the industries.

We are giving the basic principle of 5 axis CNC but if the research and development on this project continues it will soon be a revolution in the industrial growth of our country

As we are importing very small mechanical parts and components made on the 5 axis CNC at very high cost, This project is quite useful for our Industries. The successful completion of this project will allow us to manufacture precise components, which our industrial growth is lacking behind.

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