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One project in the lab involved converting an industrial robot arm into a 6-DOF 3D printer capable of complex geometries. This printer manufactured parts of continuous carbon-fiber with PAEK matrix. This process required filament feeding, compaction, cutting, and bed heating.
In order to fulfill the requirements of the printer I created a programmable logic controller using a KUNBUS Revolution Pi. Using Python and C++, this controlled various components via serial communication from the robot arm. The PLC also had an 8 inch touchscreen with a simple GUI for current operations and a button to change tool heads.
The PLC featured M12 connectors, a USB port, six K-type thermal couple ports, power switch, and emergency stop button. The component panel designed to be replaceable as the project evolved, with DIN rails to mount internal parts.
Over the course of the project, many additions and changes took place. This photo is from testing the pneumatic system for semi-automated tool head changes.
Keyence LJ-V7080 laser line scanner used for in-situ inspection of manufactured parts.
The test apparatus for defect scanning
A – D638 test coupon
B – Keyence LJ-V7080 laser line scanner
C- Closed-loop motor and driver
Render of processed data from the Keyence LJ-V7080 laser line scanner. The specimen was a D638 Coupon.
Layer by layer analysis of processed data was used to reveal voids, layer shifting, and under/over extrusion.
A Keyence LS-9030M laser micrometer was used to measuring filament diameter in the extrusion process from recycled PLA pellets.
3D printer with a heated chamber for high performance thermoplastics. Responsible for upgrades and maintenance.
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