If you have spent any amount of time working with a laser cutter, At your local hack(er)space, makerspace or maybe in your line of work. Perhaps you are even fortunate to have one at home in your workshop? You will know that working with repeated tasks can come with its own challenges. Especially if you need continuity between cuts and you are cutting a lot of the same pieces. Clem, having experienced the same, decided to take matters into their own hands and produce a solution to help, watch the episode and read along and perhaps you will also find it useful!
Watch the Video:
For Clem, it quickly becomes tedious and frustrating to have to constantly swap pieces out when working on them in the laser cutter, not to mention error-prone to do the same task repeatedly and ensure that quality is maintained. Having to load and unload workpieces into their CO2 laser cutter, needing to deactivate the safety interlocks and ensure that each new material was played accurately to ensure that it was engraved correctly, this multi-step process requires a lot of concentration and time, which invites misalignment from a variety of factors.
The Problem with Traditional Jigs
Why not simply use a ‘jig’? If you are unfamiliar with the term, it is effectively a template or layout for the piece being worked on to sit securely in the same position and layout every time. Usually, you would do this when you need what you are working on not to move, but its shape is unconventional and this becomes difficult to use with clamps. A jig has its limitations:
- They usually depend on flat, mountable parts.
- Alignment tolerances are a concern with multiple items.
- The solution is either suitable for one component worked on regularly, or mass production, but is not adaptable for smaller-scale production/alterations.
Clem's Rotating Drum Solution
As Clem found that a traditional approach to a jig is not suitable for their needs, they sought a more adaptable solution that can work with different types of workpieces, permitting individual clamping and no special preparation. Considering when working with the laser cutter with the Lightburn software, it has a consistent origin point for the tooling to do its job, this means that Clem’s solution will offer significant flexibility.
Clem’s solution involves the ‘classic’ project parts that should be familiar to any maker:
- An Arduino Uno
- Trinamic TMC2100 stepper driver
- With Corresponding stepper motor
- Prototyped on a protoboard with hand-soldered wires.
Put together, this would develop into a four-sided rotating drum mechanism that uses interchangeable slides, designed for each type of workpiece. These slides are quick to 3D print, and they can be shaped to fit even the most unusually shaped workpieces, including those without flat sides.
Simplifying Stepper Motor Wiring
Using six leads, Clem demonstrates an easy method to identify the correct wires on a stepper motor. With the help of two wires and turning the motor, resistance can indicate the appropriate ends of the same coil. When no resistance is felt, the wires belong to different coils, this process which you can follow along with Clem in the video can take no time at all with a little practice.
Considerations when Designing the Drum Solution
Measure twice, design once. Clem quickly discovers that their design had a design flaw: it was too tall to fit inside the laser cutter. On reflection, this is due to deliberately leaving enough clearance for the mounting of thick workpieces, this revelation resulted in a clear design improvement. Clem switched to a rotary table design, allowing it to feature a switchable magnet system. This is like the design of magnet bases used in machining shops! This means that Clem’s 3D printed design aligns magnets to create a magnetic lock. Three magnet pairs have the north pole aligned upwards with one in the opposite direction, the plate can then be easily lifted off by rotating it ninety degrees which causes the magnets to repel one another.
Reaping the Rewards of Design Iteration and Automation
Clem demonstrates the final solution, recording it from inside the CO2 laser cutter which shows the entire process in all its glory. An external cable remote helps the process by allowing quarter turns of the turntable.
The project is a clear reminder of the importance of automation and identifying repetitive tasks and where time can be saved, or frustrations reduced, allowing you to focus on the task at hand where necessary. It helps to have multiple tooling solutions to aid with designing the solution. Clem’s innovative approach is a prime example of how automation can help and enhance your efficiency and accuracy.
Downloads & Links:
Parts and Bill of Materials
| Product Name | Manufacturer | Quantity | Buy Kit |
|---|---|---|---|
| Arduino UNO SMD Rev3, | ARDUINO | 1 | Buy Now |
| stepper Motor, Dual Shaft, 42 | Nanotec | 1 | Buy Now |
| TMC2100 Silentstepstick | Trinamic | 1 | Buy Now |
| MULTICOMP 3D Printer Filament, 1.75mm | Multicomp | 1 | Buy Now |
| BRAUER Toggle Clamp, Vertical, 70 N | Brauer | 4 | Buy Now |
| Black Rocker Switch, | Multicomp pro | 3 | Buy Now |
Additional Parts
| Product Name |
|---|
| Protoborad, 2,54mm pin headers. Wiring. |
| 4 pin “aviation connectors” |
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