New Perforator Head
Hi all
Thought you might be interested in this version of the perforator head that I've been working on.
My previous laser cut version 1.1 worked really well (still works after all these years !), but had a few annoying issues - mainly the software chain, the size of the thing - it takes up a whole 1200mm table, the amount of cabling involved - and finally the cost of the hardware - especially vee wheels and rails (at the time, they're a bit cheaper now).
The latest idea was to change from a marlin based RAMPS 1.4 3D printer controller - with all the annoying firmware changes to something GRBL based. It also had to have (like my RAMPS 1.4 setup) a display screen with an SD card interface - absolutely NO controller computer attached. I ended up using a CAMXTool v3,5 GRBL board (think they're used in some of the 3 axis el cheapo Chinese CNC machines) with an offline controller board to give the display/SD interface.
It was also destined to be cordless

)
Bearing in mind that we're not producing parts for the medical, military or space programs, there seems no need to go to the extent that some folks take their projects

) To that end, I've kept the parts count to a minimum - the addage being that the best engineering part is no part at all

)
The software chain
My previous chain was - Adobe Illustrator to SVG, the free Inventables web based Easel software to convert to the SVG to Gcode - then my own DIY post processor (written in Xojo) - really just to replace all the Z axis commands with servo commands for the RAMPS board. While that all worked well, it was a bit of a PITA. I wanted something a wee bit sleeker and went for Lightburn software as the main item. I do still use Adobe Illustrator for the main drawing as all my laser stuff is done in that anyway, but it can just as easily be done in lightburn - what a wonderful bit of software, I wish it had been available when I was building my own CO2 laser designs back in the day - the Chinese software stuff was (IS !) just awful and only runs in windoze and not Mac. All you need to do is tell lightburn that you're driving a diode laser and you're done - how easy is that ! You could drive the GRBL board directly from Lightburn I suppose if that's your thing.
The perforator head
It has a servo to move the whole internals up and down as a Z axis as before. An ESC to control the brushless motor and a brushless motor. However, rather than have all the connections and cabling to all these items, there are only three connections - 0V, +12V and a 0-100% PWM signal. This signal is derived from the 'laser' output connector on the GRBL board - there being no servo output like the RAMPS board. To this end, I had to write some arduino code for a nano that handled this. It takes the 0 to 100% signal from the laser output and converts that to the depth of cut for the foam - 0 to 100% = 0 to 8mm. The ESC signal is set to a single value to handle (in my case depron) the number of dots per millimetre that will be cut in the foam - ie, the speed of the brushless motor. The motor only comes on when there is a signal greater than 10% and switches off when the signal drops below this. I haven't bothered to do a full 0 to 100% depth in firmware as the foam only needs a full cut and a half cut - YMMV as they say and can easily be modified in the arduino code.
The needle cutter therefore emulates a diode laser I suppose

I guess you could just plug it in to one of those diode laser machines that I just hate LOL

))
It's been through a couple of iterations. My original v1.1 worked REALLY well - NEVER broke a needle - mainly due to the use of TWO bearings with a spacer washer rather than attempting to grind a slot around a bearing (why would you want to do that ???).
As folks found, there was a minor heat issue with this needle setup (caused by the side-to-side movement of the needle touching the MIG head), so they added a series of bearing to alleviate that and attempt to get the needle reciprocating rather than flailing about. Rather than go that route, I originally added a small heatsink to the MIG head - this fixed the problem, the temp was only around 30degC - fine for foam.
One issue however, was that a lot of folks used CNC machines to control the head - moving the whole thing up and down on the Z axis. This meant that the needle was at full extension when driving in to the foam and caused (still causes it seems

broken needles.
As my setup wasn't a CNC machine and used a servo to drive the whole NEEDLE driver up and down (within the confines of the MIG head), I didn't have this problem. I went one step further and added what in essence is the same as a sewing machine 'presser foot' - a foot that STAYS DOWN on the surface of the material permanently. It's just an end piece from a 28mm copper pipe 'stopped end' and is simply soldered to the MIG head. It gives a large heatsink area and also give a further BIG benefit - as it's down on the foam all the time, it keeps the foam level - you DON'T need to hold the foam down in any way - no vacuum beds/pins/nails/tape.
This setup has proven to work well and is the reason I stayed with it in v2.0.
I had originally wanted to use 'real' needles - ie, sewing machine needles (as that's what they were designed for

) - I ended up using a 'scotch yoke' setup on a pair of rails to drive the needle vertically - it DID work, but was rattling the house to bits as I couldn't get it balanced at all. The weight of the yoke was just too much (the pix show the original yoke which rode up and down on a pair of 3mm ground rods - the 3D printed yoke used 4 oilite bearings and a pair of 3mm rods as the yoke). The 'big end' just couldn't be balanced with enough weight to make it smooth.
I scratched that idea for v2,1 - and based on the parts count, dropped the rails and scotch yoke and simply bent a scotch yoke in a bit of 0.7mm (22SWG) piano wire (music wire USA) that the crank pin yanks up and down as the needle - in a linear fashion, NOT side to side as the restrained original in the bearing. The heatsink is under a lot less strain now and only gets barely warm. The 'scotch yoke' is held against the crank pin and can't move due to the 3D printed face of the wheel and the MIG head.
I haven't mentioned anything about the new XY framework for this setup as it's still incomplete - time is the issue (being retired means that you now have ZERO time to do anything

) Suffice to say that it's based on hardware store 20mm square section aluminium tubing and 3D printed 'bearings' - I say bearings in it's loosest sense - just PLA sliding tubes really with some added bits to hold the perforator head and the electronics together. The electronics and the two steppers ride on the Y axis 'bearing' in a setup similar to the ERC Timsav 'T' shaped layout (but move with the Y axis) - which is in essence the same as the old 'drawing machines' we used to build way back in the late 90's. There is an option to have it 'cordless' - just a 3S/2200 LiPo or plugged in to a 12V walwart. Having the cordless option is good as you can then take it anywhere - I mean, how many times do you cut foam planes ??? It's also foldable. I'll eventually get around to doing some drawings for this.
I'm sure I'll have missed some important bits of info, so just ask - the pix should be self explanatory 'though.
Cheers
Neil