Difference between revisions of "LaserCutter"

From Technologia Incognita
Jump to: navigation, search
(→‎11-01-2023 - PC setup and Camera tests)
 
(15 intermediate revisions by 2 users not shown)
Line 4: Line 4:
 
|Model=HX-40A
 
|Model=HX-40A
 
|Category=Mechanics
 
|Category=Mechanics
−
|Operational Status=BROKEN
+
|Operational Status=Functional
−
|Super Users=Justa
+
|Super Users=Justa, beatskip
 
|Acquisition Details=On permanent loan from Justa
 
|Acquisition Details=On permanent loan from Justa
 
|Owner=User:Justa
 
|Owner=User:Justa
 
}}
 
}}
−
NOTE: THIS IS NOT THE CURRENTLY 'IN USE' LASERCUTTER.
+
NOTE: THIS IS THE "WHITE" LASERCUTTER. THE ONE THAT HAS BEEN IN PRODUCTION HAS BEEN THE "RED" LASERCUTTER
  
 
That one belongs to 'sawugo' and is documented here: https://wiki.techinc.nl/LAOSLaserCutter
 
That one belongs to 'sawugo' and is documented here: https://wiki.techinc.nl/LAOSLaserCutter
  
 +
== Change History ==
 +
- updated page with latest developments in Dec-2022 (Beatskip)
 +
- full rewrite of info on 2021-12-23
  
−
== tl;dr ==
+
== Short introduction ==
−
It works in it's current form, but insanely unhandy.
 
  
−
It's nonfunctional in the sense that it's a windows-box with two dongles required to run the software on XP; no import options for normal formats and ...well.. yeah, it's non-functional as I just remembered that it has a tendency to suddenly go awol and cut/engrave elsewhere than the program dictates, or suddenly change scales of vectors.
+
The lasercutter is a HX40A engraver/cutter, fitted with a 40Watt laser-tube, a small XY-table and originally comes with a controller-board for which only WinXP software exists that requires a PC with special USB-dongles for the license required by the software. The controller-board has all markings sanded off of all the chips and it is connected to the PC with the paralel-port like it is still 1989..
  
 +
That'd not be so bad, if the software even did a good job of controlling the laser; which it doesnt. It is a nightmare.
  
−
== Todo ==
+
The intention for the machine is to convert it to something modern. This work is in progress and is documented here.
  
−
In short:
+
== Modifications ==
−
* Cooling pump + heat-exchanger/radiator + fan + monitoring
 
−
* Plexiglass (or pertinax/epoxy) carrier-board for the laos-board
 
−
* Convertor-board for the flex-cable
 
−
* Refitting the original board for use with the convertor-board
 
−
* Testing with original board
 
−
* Removing all boards (inc PSU/etc)
 
−
* Drill required holes/etc for refitting for laos-board, cooling,etc and lighting
 
−
* Vacuum the machine
 
−
* Fit laos-board in
 
−
* Program and test board functions in machine
 
−
* Calibrate
 
−
* Use.
 
  
 +
* Replace driver-board with [[https://github.com/makerbase-mks/MKS-DLC32 Makerbase MKS-DLC32 board]] ESP32 based driver-board
 +
** {{Cbox}} Get optical end-stops to work.
 +
** {{Cbox}} Get LCD-module mounted on front-panel (requires bezel and/or longer cables)
 +
** {{Ucbox}} Test PWM-driving of laser-PSU via optocoupled 2-wire interface (see wiring-details)
  
−
That, in short, is what is still required for the laser-cutter to be used.
+
* Set up self-contained water-cooling arrangement using PC-cooling radiators.
 +
** {{Cbox}} Find suitable water-basin
 +
** {{Cbox}} Purchase submersible pump and wire it so it is on when machine is turned on.
 +
** {{Ucbox}} Design laser safety controller to prevent abuse of the laser [[LaserCutter: Laser Cooling Monitor]]
  
 +
* Re-work the laser-delivery head into one with Air-assist.
 +
** {{Ucbox}} Purchase air-assist laser-delivery head as a replacement OR modify current head
 +
** {{Ucbox}} Purchase and mount air-pump; create wiring for it . Consider 'turn on' when starting to cut, not 'always'
 +
** {{Ucbox}} Consider chain-link cable-guide for air-delivery tube
  
−
== Full story (Justa/Arnd) ==
+
Laminar flow Air-assist nozzle prototype design V1
  
−
There is a laser-cutter i have available for the space. It requires modification to be usable. It's a so-named 'cheap chinese lasercutter'. If you google for it you can read about the horror it is to use it with the supplied (windows-only, dongle-protected) software.
+
[[File:Airassistv1-alt.png|300px]]
 +
[[File:Airassistv1.png|300px]]
  
−
So, to make it usable it requires a brain transplant. The brain chosen is to be a laos-laser board from the Laos Laser project (thank you Jaap). The board itself is built and tested. The required micro-controller is present but requires programming and the testing and calibration, etc.
 
  
−
I reverse-engineered the current wiring of the laser-cutter as it is and have a good idea of how to get the new board to interact with the stuff that's not going to be replaced (PSU, Laser-PSU, control-panel, Steppers, Limit-switches).
+
* Align gantry after last modifications
 +
** {{Ucbox}} Gantry has been removed and might need another removal
 +
** {{Ucbox}} Align using the 'ABC' method, using painter-tape, or consider a 'reverse' method with laser pointing from 'head' back to tube
  
−
All of the components use pretty standard 2.5mm pitch connectors; no probs there. Except one...
+
* Look at Z-bed mechanics
−
One connector is one of those flex-cables typically used to connect LCD-screens to motherboards of laptops; it has a couple of blank copper-traces on the end that need to be pushed into the connector on the current controller-board.
+
** {{Cbox}} Look at bed mechanics and fix the problematic clearings
−
This flexible connector leads to the X/Y table and has signals for (at least one of) the stepperrs and limit-switches carried on it. I have the documentation for it somewhere but it shouldnt be too hard to figure out again..
+
** {{Ucbox}} Current bed is hard to adjust and is manual. Purchasing an extra stepper , some guide-pullies and a longer belt would allow for auto-adjust via software.
−
The connector is hard to find, however, in catalogs and such; unless you can figure out what the name for one of those things is and get exactly the right pitch, etc. I believe another person who had the same problem harvested one from a broken VCR.
 
  
−
My current idea was to de-solder the connector and make a small intermediate board that'll convert the pinout from the Laos-board (which has screw-terminals for all connections) to the flex-connector. Then, when replacing the current board with the laos-board i can keep the older board functional in case I need to re-fit it to test things if the laos-laser board refuses to work right out of the box... etc... The old board needs to be kept in a workable state for that reason.
+
* Consider FluidNC firmware instead of current firmware
 +
** This is very likely to work without problems; requires careful flashing.  
 +
** Might need patches to support LCD , if possible at all
  
−
What i HAVE done already is to fit the laser-cutter onto a specially-made table-surface with two small cabinets on wheels below it that'll contain all the accesories, etc. Also there's two LED-lights acquired that need to be fitted to the machine once the electronics have been taken out (so that no chaff falls on the PCB's and fucks things up). Also, a plexiglass carrier needs to be made to carry the laos-board with the same screw-footprint as the current board.
+
* Consider Web interface running on a Pi to simplify usage
 +
** Laserweb seems a good candidate [https://laserweb.yurl.ch/ Website] [https://laserweb.github.io/LaserWeb4/ Live Demo]
  
−
Also the laser requires cooling. The cooling in the current setup is done by sticking a small waterpump into a bucket and hooking it up to the tubing leading to/from the lasertube. No temperature-monitoring is present; if the pump malfunctions the laser will overheat and die. The pump , already, is malfunctioning. It needs to be replaced and pref. also monitored. My idea was to use the space between the two cabinets to put a heat-exchanger there with forced air (like watercooled PC) and keep a temp-monitor on it that'll cut off the power from the laser or somesuch. I'm rather sure that if this doesnt get done that someone will fry the lasertube for sure and cause a 300 euro repair.
+
== Usage/setup details==
 +
First of all, until the laser is fully operational and tested/validated. the laser is not yet freely useable, only when properly communicated with Justa or beatskip.
 +
It should be up and running relatively soon, so just hang tight a bit longer to laze your eyes out.
  
−
I'm planning to, in September, free up some weeks of my schedule to work on my house; i could put one or two days into work on the cutter , especially if someone's willing to help put in some work, too.. Esp. the carrier-board and convertor-pcb are nice things to have prepared before unscrewing anything on the machine as it is now.
+
the lasercutter uses a MKS DLC32 controller together with a Pi2 running laserweb.
 +
It is accessible over the network as: "https://laziemclazeface.local"
 +
user: lazie
 +
password: youllburnyoureyesout
  
−
Inquiries can be made to [[User:Justa|my address]] or on the [[Talk:LaserCutter|talkpage]].
+
please do not fiddle with the pi until everything is validated and safety features are added, for both the user and the machine itself.
  
−
== Suggestions ==
+
== Tasks/ToDo ==
−
20:45.51 <@Ikarus> btw, for anyone working on the laser, put the LAOS board in a metal box and put choke ferrules on all leads possible
+
Here is a short list of the tasks that have to be performed and which have been done already:
  
−
20:46.00 <@Ikarus> Revspace is still having interference problems
+
* {{Ucbox}} (T.B.D) Create user manual and usage guidelines
 +
* {{Ucbox}} (15-01-2023) Add Air Assist
 +
* {{Ucbox}} (15-01-2023) Install head camera
 +
* {{Cbox}} (13-01-2023) Purchase new Camera to attach to head
 +
* {{Cbox}} (12-01-2023) Add PC to run LaserWeb
 +
* {{Cbox}} (11-01-2023) Add additional end-stops to prevent any crashes (especially with Air-Assist)
 +
* {{Cbox}} (12-01-2023) Purchase LaseWeb License
 +
* {{Cbox}} (02-01-2023) Replaced 24V supply with 12V to stop motors skipping steps
 +
* {{Cbox}} (28-12-2022) Fine bed leveling
 +
* {{Cbox}} (28-12-2022) test PWM laser control
 +
* {{Cbox}} (21-12-2022) Collimate laser
 +
* {{Cbox}} (21-12-2022) Set up design plan for cooling system protection pcb
 +
* {{Cbox}} (21-12-2022) Wire up auxilary 12V supply to pump and fans
 +
* {{Cbox}} (18-12-2022) Added Project page for the cooling safety board [[LaserCutter: Laser Cooling Monitor]]
 +
* {{Cbox}} (17-12-2022) Mount additional 12V PSU for the cooling system and wire it up to share the main power connector
 +
* {{Cbox}} (14-12-2022) Fix Homing coordinates and general firmware config issues
 +
* {{Cbox}} (14-12-2022) Fix up stepper motor connection that occasionally doesn't work
 +
* {{Cbox}} (07-12-2022) Rough bed leveling
 +
* {{Cbox}} (07-12-2022) Fix Z-Bed clearances and fix it so it can move freely
 +
* {{Cbox}} (03-12-2022) Mount LCD housing
 +
* {{Cbox}} (01-12-2022) Design and print LCD housing
  
  
−
==Photos==
+
 
 +
== Status Log ==
 +
 
 +
==== 11-01-2023 - PC setup and Camera tests ====
 +
The laser control PC was set up with Ubuntu and Lightburn was set up to control the lasercutter.
 +
Endstops were added on both sides of the X-Axis. Since the MKS DLC32 does not accept separate endstops for the minimum and maximum of the axis, both were wired in series on the NC terminals. This will result in a trigger signal in the controller if either one of the two endstops is triggered.
 +
This seems to be working perfectly and will prevent the future air assist nozzle from being bumped off due to the frame edge. some additional testing was done to refine laser power settings.
 +
 
 +
[[File:engravingtests-20230111.jpg|300px]]
 +
 
 +
Lightburn has support for a head mounted camera to scan the working area and place designs on the right place. This will allow people to most effectively use the available materials with as little waste as possible.
 +
Also scanning the location of objects to be engraved is possible.
 +
 
 +
[[File:camera-test-setup.jpg|250px]]
 +
[[File:lightburn-test-cam-20230111.jpg|250px]]
 +
[[File:lightburn-align-test-20230111.jpg|250px]]
 +
 
 +
A new camera for this purpose was purchased, as the testing camera was way insufficient. the new camera is a 5MP OV5640 module with AutoFocus and usb 2.0. The resolution is 2592x1944 pixels.
 +
The result will be an approximate 0.03mm per pixel when mounted to the laser head. Tests will show if we can utilize the autofocus data to determine the bed height. If the autofocus data is not sufficient, a laser can be added in the view to triangulate the bed height.
 +
 
 +
[[File:5mp-head-camera-lightburn.jpg|350px]]
 +
 
 +
This camera will arrive the jan 14th 2023 and will be installed as soon as possible.
 +
the usb cable will be replaced with a flat flex cable that rolls over the axis and the camera itself will be mounted as close to the laser as possible to minimize the loss in working area.
 +
 
 +
== Latest Results / Photo gallery ==
 +
 
 +
Latest rastering tests by PIx13 and Beatskip
 +
 
 +
[[File:Spidey-by-pix13.jpg|600px]]
 +
 
 +
 
 +
[[File:LaseyMcLazeFaceMascotTest-01-2023.jpg|600px]]
 +
 
  
 
[[File:IMG_0970.JPG|320px]]
 
[[File:IMG_0970.JPG|320px]]
 +
 
[[File:IMG_0971.JPG|320px]]
 
[[File:IMG_0971.JPG|320px]]

Latest revision as of 20:47, 13 January 2023

TechInc Inventory
Description It cuts with lasers
Make Rabbit Laser
Model HX-40A
Category Mechanics
Operational Status Functional
Super Users Justa, beatskip
Received at
Acquisition Details On permanent loan from Justa
Owner User:Justa

NOTE: THIS IS THE "WHITE" LASERCUTTER. THE ONE THAT HAS BEEN IN PRODUCTION HAS BEEN THE "RED" LASERCUTTER

That one belongs to 'sawugo' and is documented here: https://wiki.techinc.nl/LAOSLaserCutter

Change History

- updated page with latest developments in Dec-2022 (Beatskip) - full rewrite of info on 2021-12-23

Short introduction

The lasercutter is a HX40A engraver/cutter, fitted with a 40Watt laser-tube, a small XY-table and originally comes with a controller-board for which only WinXP software exists that requires a PC with special USB-dongles for the license required by the software. The controller-board has all markings sanded off of all the chips and it is connected to the PC with the paralel-port like it is still 1989..

That'd not be so bad, if the software even did a good job of controlling the laser; which it doesnt. It is a nightmare.

The intention for the machine is to convert it to something modern. This work is in progress and is documented here.

Modifications

  • Replace driver-board with [Makerbase MKS-DLC32 board] ESP32 based driver-board
    • checked box Get optical end-stops to work.
    • checked box Get LCD-module mounted on front-panel (requires bezel and/or longer cables)
    • unchecked box Test PWM-driving of laser-PSU via optocoupled 2-wire interface (see wiring-details)
  • Set up self-contained water-cooling arrangement using PC-cooling radiators.
    • checked box Find suitable water-basin
    • checked box Purchase submersible pump and wire it so it is on when machine is turned on.
    • unchecked box Design laser safety controller to prevent abuse of the laser LaserCutter: Laser Cooling Monitor
  • Re-work the laser-delivery head into one with Air-assist.
    • unchecked box Purchase air-assist laser-delivery head as a replacement OR modify current head
    • unchecked box Purchase and mount air-pump; create wiring for it . Consider 'turn on' when starting to cut, not 'always'
    • unchecked box Consider chain-link cable-guide for air-delivery tube

Laminar flow Air-assist nozzle prototype design V1

Airassistv1-alt.png Airassistv1.png


  • Align gantry after last modifications
    • unchecked box Gantry has been removed and might need another removal
    • unchecked box Align using the 'ABC' method, using painter-tape, or consider a 'reverse' method with laser pointing from 'head' back to tube
  • Look at Z-bed mechanics
    • checked box Look at bed mechanics and fix the problematic clearings
    • unchecked box Current bed is hard to adjust and is manual. Purchasing an extra stepper , some guide-pullies and a longer belt would allow for auto-adjust via software.
  • Consider FluidNC firmware instead of current firmware
    • This is very likely to work without problems; requires careful flashing.
    • Might need patches to support LCD , if possible at all
  • Consider Web interface running on a Pi to simplify usage

Usage/setup details

First of all, until the laser is fully operational and tested/validated. the laser is not yet freely useable, only when properly communicated with Justa or beatskip. It should be up and running relatively soon, so just hang tight a bit longer to laze your eyes out.

the lasercutter uses a MKS DLC32 controller together with a Pi2 running laserweb. It is accessible over the network as: "https://laziemclazeface.local" user: lazie password: youllburnyoureyesout

please do not fiddle with the pi until everything is validated and safety features are added, for both the user and the machine itself.

Tasks/ToDo

Here is a short list of the tasks that have to be performed and which have been done already:

  • unchecked box (T.B.D) Create user manual and usage guidelines
  • unchecked box (15-01-2023) Add Air Assist
  • unchecked box (15-01-2023) Install head camera
  • checked box (13-01-2023) Purchase new Camera to attach to head
  • checked box (12-01-2023) Add PC to run LaserWeb
  • checked box (11-01-2023) Add additional end-stops to prevent any crashes (especially with Air-Assist)
  • checked box (12-01-2023) Purchase LaseWeb License
  • checked box (02-01-2023) Replaced 24V supply with 12V to stop motors skipping steps
  • checked box (28-12-2022) Fine bed leveling
  • checked box (28-12-2022) test PWM laser control
  • checked box (21-12-2022) Collimate laser
  • checked box (21-12-2022) Set up design plan for cooling system protection pcb
  • checked box (21-12-2022) Wire up auxilary 12V supply to pump and fans
  • checked box (18-12-2022) Added Project page for the cooling safety board LaserCutter: Laser Cooling Monitor
  • checked box (17-12-2022) Mount additional 12V PSU for the cooling system and wire it up to share the main power connector
  • checked box (14-12-2022) Fix Homing coordinates and general firmware config issues
  • checked box (14-12-2022) Fix up stepper motor connection that occasionally doesn't work
  • checked box (07-12-2022) Rough bed leveling
  • checked box (07-12-2022) Fix Z-Bed clearances and fix it so it can move freely
  • checked box (03-12-2022) Mount LCD housing
  • checked box (01-12-2022) Design and print LCD housing


Status Log

11-01-2023 - PC setup and Camera tests

The laser control PC was set up with Ubuntu and Lightburn was set up to control the lasercutter. Endstops were added on both sides of the X-Axis. Since the MKS DLC32 does not accept separate endstops for the minimum and maximum of the axis, both were wired in series on the NC terminals. This will result in a trigger signal in the controller if either one of the two endstops is triggered. This seems to be working perfectly and will prevent the future air assist nozzle from being bumped off due to the frame edge. some additional testing was done to refine laser power settings.

Engravingtests-20230111.jpg

Lightburn has support for a head mounted camera to scan the working area and place designs on the right place. This will allow people to most effectively use the available materials with as little waste as possible. Also scanning the location of objects to be engraved is possible.

Camera-test-setup.jpg Lightburn-test-cam-20230111.jpg Lightburn-align-test-20230111.jpg

A new camera for this purpose was purchased, as the testing camera was way insufficient. the new camera is a 5MP OV5640 module with AutoFocus and usb 2.0. The resolution is 2592x1944 pixels. The result will be an approximate 0.03mm per pixel when mounted to the laser head. Tests will show if we can utilize the autofocus data to determine the bed height. If the autofocus data is not sufficient, a laser can be added in the view to triangulate the bed height.

5mp-head-camera-lightburn.jpg

This camera will arrive the jan 14th 2023 and will be installed as soon as possible. the usb cable will be replaced with a flat flex cable that rolls over the axis and the camera itself will be mounted as close to the laser as possible to minimize the loss in working area.

Latest Results / Photo gallery

Latest rastering tests by PIx13 and Beatskip

Spidey-by-pix13.jpg


LaseyMcLazeFaceMascotTest-01-2023.jpg


IMG 0970.JPG

IMG 0971.JPG

Retrieved from "https://wiki.techinc.nl/index.php?title=LaserCutter&oldid=27059"