Gina
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Blog Comments posted by Gina
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Assembly top view showing box, X and Y rails plus crossed rods that carry the extruder and hotend etc.
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The piece of hardwood ply I bought for the job is 900mm x 900mm x 18mm. To allow room for motors, brackets etc. I reckon to add 50mm at each end of the XY rails. So that makes 400mm x 400mm inside and about 440mm x 440mm outside.
This is the sort of box I'm thinking of with a height of just under 450mm. This should give a print volume of 190mm x 190mm x 220mm approximately using 6 off 300mm MGN12 rails. The bottom front rail will come from the bottom panel and the top a piece of ply left over from my Concorde printer box.
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My first thoughts were to use the same type of rails and drives as my Concorde printer viz. V-Slot aluminium extrusion with Mini V wheels including C-Beam extrusion and gantry plate carriages for the Z axis. I am now looking into higher precision rail systems on a smaller scale. Home made linear bearings using tiny ball bearings arranged in threes around round rods is one option but this means using dozens of ball bearings with every third being adjustable. Although giving high precision, this is very labour intensive and time consuming, even with 3D printed parts. My thanks to @Chriske for this idea. Another possibility, apart from the ubiquitous cylindrical linear bearings on round rods, is these MGN12 rails. A combination approach is also a possibility. I shall be giving this a lot more thought before going ahead and ordering anything.
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Final sketch and IDE report.
// Filename :- Giant_Wall_Clock_v2_2019-11-15 // Software timing from RTC using polling // #include <DS3232RTC.h> //http://github.com/JChristensen/DS3232RTC #include <Wire.h> //http://arduino.cc/en/Reference/Wire (included with Arduino IDE) // boolean lastSqWave = 0; boolean ledON = 0; int sqwPin = A6; int dirPin = 5; // DIRECTION pin int stepPin = 6; // STEP pin int enPin = 12; // Enable pin int ledPin = 13; // Internal LED pin // void setup() { pinMode(dirPin, OUTPUT); pinMode(stepPin, OUTPUT); pinMode(enPin, OUTPUT); pinMode(ledPin, OUTPUT); digitalWrite(enPin, 0); // enable digitalWrite(dirPin, 1); // set on test pinMode(sqwPin,INPUT_PULLUP); // RTC timing pin RTC.squareWave(SQWAVE_1_HZ); // 4096Hz square wave } // // void runClock(void){ for (int i = 1600; i >= 1; i--) { // count 1600 pulaes in half second digitalWrite(stepPin, 1); delayMicroseconds(10); // Make STEP pulse 10μs long digitalWrite(stepPin, 0); delayMicroseconds(290); } // 1600×300 = 480ms **** 2019-11-17 ledON = !ledON; digitalWrite(ledPin, ledON); } // flash LED on & off // void loop(){ boolean val = ((analogRead(sqwPin) > 500)); // read logic level of 1Hz square wave if (val != lastSqWave) { lastSqWave = val; runClock(); } // Call runClock on rising edge of RTC square wave } // End
Sketch uses 3896 bytes (12%) of program storage space. Maximum is 30720 bytes. Global variables use 283 bytes (13%) of dynamic memory, leaving 1765 bytes for local variables. Maximum is 2048 bytes. /home/gina/arduino-1.8.10/hardware/tools/avr/bin/avrdude -C/home/gina/arduino-1.8.10/hardware/tools/avr/etc/avrdude.conf -v -patmega328p -carduino -P/dev/ttyUSB0 -b115200 -D -Uflash:w:/tmp/arduino_build_979028/Giant_Wall_Clock_I2C-control_2019-11-15.ino.hex:i avrdude: Version 6.3-20190619 Copyright (c) 2000-2005 Brian Dean, http://www.bdmicro.com/ Copyright (c) 2007-2014 Joerg Wunsch System wide configuration file is "/home/gina/arduino-1.8.10/hardware/tools/avr/etc/avrdude.conf" User configuration file is "/home/gina/.avrduderc" User configuration file does not exist or is not a regular file, skipping Using Port : /dev/ttyUSB0 Using Programmer : arduino Overriding Baud Rate : 115200 AVR Part : ATmega328P Chip Erase delay : 9000 us PAGEL : PD7 BS2 : PC2 RESET disposition : dedicated RETRY pulse : SCK serial program mode : yes parallel program mode : yes Timeout : 200 StabDelay : 100 CmdexeDelay : 25 SyncLoops : 32 ByteDelay : 0 PollIndex : 3 PollValue : 0x53 Memory Detail : Block Poll Page Polled Memory Type Mode Delay Size Indx Paged Size Size #Pages MinW MaxW ReadBack ----------- ---- ----- ----- ---- ------ ------ ---- ------ ----- ----- --------- eeprom 65 20 4 0 no 1024 4 0 3600 3600 0xff 0xff flash 65 6 128 0 yes 32768 128 256 4500 4500 0xff 0xff lfuse 0 0 0 0 no 1 0 0 4500 4500 0x00 0x00 hfuse 0 0 0 0 no 1 0 0 4500 4500 0x00 0x00 efuse 0 0 0 0 no 1 0 0 4500 4500 0x00 0x00 lock 0 0 0 0 no 1 0 0 4500 4500 0x00 0x00 calibration 0 0 0 0 no 1 0 0 0 0 0x00 0x00 signature 0 0 0 0 no 3 0 0 0 0 0x00 0x00 Programmer Type : Arduino Description : Arduino Hardware Version: 3 Firmware Version: 4.4 Vtarget : 0.3 V Varef : 0.3 V Oscillator : 28.800 kHz SCK period : 3.3 us avrdude: AVR device initialized and ready to accept instructions Reading | ################################################## | 100% 0.00s avrdude: Device signature = 0x1e950f (probably m328p) avrdude: reading input file "/tmp/arduino_build_979028/Giant_Wall_Clock_I2C-control_2019-11-15.ino.hex" avrdude: writing flash (3896 bytes): Writing | ################################################## | 100% 0.59s avrdude: 3896 bytes of flash written avrdude: verifying flash memory against /tmp/arduino_build_979028/Giant_Wall_Clock_I2C-control_2019-11-15.ino.hex: avrdude: load data flash data from input file /tmp/arduino_build_979028/Giant_Wall_Clock_I2C-control_2019-11-15.ino.hex: avrdude: input file /tmp/arduino_build_979028/Giant_Wall_Clock_I2C-control_2019-11-15.ino.hex contains 3896 bytes avrdude: reading on-chip flash data: Reading | ################################################## | 100% 0.44s avrdude: verifying ... avrdude: 3896 bytes of flash verified avrdude done. Thank you. -
Clock drive reinstalled and all working fire after a tiny tweak to the timing. Clock is now virtually silent - just a faint pulsating hum only audible if sitting quietly with no TV, radio or records. I can probably make that tiny hum quite inaudible with flexible mounting - the motor is currently fastened firmly to the partition wall (plasterboard).
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New assembly so far.
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New sketch compiled and uploaded to the Arduino Nano. Motor and control electronics board set up on table and all working fine. Turned the motor current down until the PSU showed 100mA at 9v and the NEMA17 motor still produced plenty of power. I could hear a faint hum if I put the motor to my ear.
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Taken the motor and gears unit off the living room wall and brought the electronics in from the cupboard for rewiring and installing replacement sketch into the Arduino Nano. On inspecting the TMC2100 driver module connections I've found a mistake. I have connected a pin to Gnd presumably to change from stealthChop to spreadCycle mode but I've connected Diag1 instead of Cfg1. This would have no effect so I've been running it in stealthChop mode quite happily. This is the silent mode with lower power but the clock has bee running quite happily on just 9v so I'll stay with this mode.
The wiring mod is simply connecting the Square Wave output from the RTC module to the Nano and an output from Nano to Step input of driver instead of a direct connection..
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Going back to basics :-
- The chain wheel rotates at 4x the centre wheel which rotates once an hour. So chain wheel takes 15m per revolution.
- The chain wheel (sprocket) has 18 teeth and the auto-winding sprocket has 8 teeth. So AW sprocket rotates at 15x8/18 m/rev = 15x60x8/18 = 400 s/rev
- Drive motor rotates at 2 s/rev so overall ratio required is 200:1
This could be achieved with a 40 tooth ratchet wheel and a 5:1 pair of spur gears. This seems a lot simpler than the epicyclic gear system. (OK so I've changed my mind again - my prerogative! 👩🤣 )
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Also, following from my Giant Wall Clock where the gears from the stepper motor that drives the seconds wheel produce a lot of noise from the teeth, it occurs to me that the motor gear and 64t epicyclic drive gear will probably also make a noise. This is pointing back to a ratchet system where any noise would be on a 2s cycle like the clock itself.
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To allow for the different timing the motor gear can have 16 teeth instead of 25 and drive the pendulum and strike auto-wind as well as the main clock.
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Might change the timing to the stepper motor to give a rotation speed of 2s per revolution and save a gear or two. I can do this with an Arduino sketch - here is a first attempt.
// Filename :- Pendulum_Longcase_Clock_v2_2019-11-14 // Software timing from RTC using polling // #include <DS3232RTC.h> //http://github.com/JChristensen/DS3232RTC #include <Time.h> //http://www.arduino.cc/playground/Code/Time #include <Wire.h> //http://arduino.cc/en/Reference/Wire (included with Arduino IDE) // boolean lastSqWave = 0; boolean ledON = 0; int sqwPin = A6; int stepPin = 6; // STEP pin int enPin = 12; // Enable pin int ledPin = 13; // Internal LED pin // void setup() { pinMode(stepPin, OUTPUT); pinMode(enPin, OUTPUT); pinMode(ledPin, OUTPUT); digitalWrite(enPin, 0); // enable pinMode(sqwPin,INPUT_PULLUP); // RTC timing pin RTC.squareWave(SQWAVE_1_HZ); // 1Hz square wave } // void runClock(void){ for (int i = 800; i >= 1; i--) { // count 800 pulses in half second ie. 3200 micro-steps per two seconds digitalWrite(stepPin, 1); delayMicroseconds(10); // Make STEP pulse 10μs long digitalWrite(stepPin, 0); delayMicroseconds(600); } // 1600×610 = 976ms ledON = !ledON; digitalWrite(ledPin, ledON); } // flash LED on & off (for testing) // void loop(){ boolean sqUp = ((analogRead(sqwPin) > 500)); // read logic level of 1Hz square wave if (sqUp != lastSqWave) { lastSqWave = sqUp; runClock(); } // Call runClock on both edges of RTC square wave } // End
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Here is an Arduino sketch.
// Filename :- Giant_Wall_Clock_v2_2019-11-14 // Software timing from RTC using polling // #include <DS3232RTC.h> //http://github.com/JChristensen/DS3232RTC #include <Time.h> //http://www.arduino.cc/playground/Code/Time #include <Wire.h> //http://arduino.cc/en/Reference/Wire (included with Arduino IDE) // boolean lastSqWave = 0; boolean ledON = 0; int sqwPin = A6; int stepPin = 6; // STEP pin int enPin = 12; // Enable pin int ledPin = 13; // Internal LED pin // void setup() { pinMode(stepPin, OUTPUT); pinMode(enPin, OUTPUT); pinMode(ledPin, OUTPUT); digitalWrite(enPin, 0); // enable pinMode(sqwPin,INPUT_PULLUP); // RTC timing pin RTC.squareWave(SQWAVE_1_HZ); // 1Hz square wave } // void runClock(void){ for (int i = 1600; i >= 1; i--) { // count 1600 pulaes in half second digitalWrite(stepPin, 1); delayMicroseconds(10); // Make STEP pulse 10μs long digitalWrite(stepPin, 0); delayMicroseconds(300); } // 1600×310 = 496ms ledON = !ledON; digitalWrite(ledPin, ledON); } // flash LED on & off // void loop(){ boolean sqUp = ((analogRead(sqwPin) > 500)); // read logic level of 1Hz square wave if (sqUp != lastSqWave) { lastSqWave = sqUp; runClock(); } // Call runClock on both edges of RTC square wave } // End
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One thought was to apply a time correction every so often to keep the clock in time. ie. using the 32KHz (actually 32768Hz) gives a ratio of 10.24 for 3200 microsteps per second so a correction of 24 counts per 1000 or 3 in 25.
Another thought is to generate pulses controlled by the Arduino clock such that a number of them finish just short of the fixed time. eg. produce 3200 pulses in just short of a second and use the 1Hz square wave to restart the sequence. The 1Hz is a symmetrical square wave so timing can be taken from both edges resulting in two smaller gaps in the pulse train to the motor rather than one larger one each second.
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Unfortunately, the 25:32 gears that provide the 1 second drive to the seconds wheel are far from quiet in spite of being accurately printed. There are possible ways of improving the gears such as helical teeth but this mainly applies to machined gears. Printed helical gears will be rough due to the layers. Consequently, I'm looking into the possibility of just using code in the Arduino sketch.
The RTC module is capable of producing square waves of 32kHz, 8192Hz, 4096Hz, 1024Hz and 1Hz. The stepper motor has 200 steps per revolution or 3200 steps/rev with 16x microstepping. The TMC2100 only does "quiet" in 16x or 4x microstepping.
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Oops - just realised the strike wheel and shaft rotates anti-clockwise when striking so the winding has to be clockwise.
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One idea is a 64 tooth ratchet wheel which is driven from the pendulum pushing system. This would be connected to the strike shaft through 6:1 gearing and a "free wheel" (like on a bicycle). A lever/pawl from the pendulum drive would be arranged to engage with the 64t ratchet wheel during the wind-up period - being started by a cam on the hour shaft and stopped by the weight being wound to the top of its travel.
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More calculations :-
- A ratchet wheel with 64 teeth and 160mm OD will fit nicely in the space
- This will need 13 revolutions so a total of 13x64 = 832 - comfortably below the 900.
- Total time to wind is therefore 832x2 = 1664s = 27.73m
This gives minimal force needed to wind the strike mechanism yet taking a reasonable time. The winding sequence can be started at 12:15 and will end just before 12:43. Seems like a plan - just need to design the parts now.
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A calculation for winding every 12 hours :-
- Weight would descent by 1+2+3+4+5+6+7+8+9+10+11+12 = 78 times the amount for one strike (revolution of the big wheel).
- Distance from bottom of hood/clockface to floor = 1.3m, less height of weight and pulley of 200mm give 1m clear so 2m travel of the cord.
- Amount of cord for one strike = 2000/78 = 25.64mm
- If this were on the same shaft as the strike wheel the drum diameter would be 25.64/π = 8.16mm - which is far too small.
- With a 4:1 gearing from the strike shaft this would become 32.7mm. 5:1 gives 40.8mm - better.
- 78 factorises into 2x3x13 so at 6:1 the drum would turn 13 times to wind up the strike system giving a 50mm diameter drum. Seems OK.
I will have a lever pushing the pendulum every 2 seconds and I think it could be used to wind up the strike mechanism. This could take half an hour or more giving up to 30x30 = 900 strokes.
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Every half hour seems logical. Three thoughts :-
- Maybe I could use a similar arrangement to the strike mechanism.
- A wheel that turns less than a revolution when the clock strikes 12 could be would back up until it's back to "square one".
No.2 seems simpler. It would want gearing of something over 12:1 as the striking shaft rotates 12 times for 12 o'clock.
OTOH for every 12 hours :-
- A knot in the cord that engages a lever when the weight is at the top to stop the winding. The winding could be started by a cam on the hour shaft.
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One possibility I have in mind is to use cord rather than chain unwinding from a drum (a common system in longcase clocks) with some mechanism for re-winding the drum between striking periods. Usually this would be manual but I want to design an automatic system. (I don't want to wind up the strike anymore than I want to wind up the main timepiece.)
The way manual winding works is to have a ratchet system between the drum and the strike mechanism. The motorised winding could drive the drum with another ratchet. This ratchet would only engage when winding (otherwise it would stop the drum driving the strike mechanism). I'm thinking the motor winding would take place either every half hour or when the weight had dropped a certain amount.
I'll continuing posting my ideas as the come into my head 😀
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This model of the clock assembly shows the strike mechanism as far as I've got with the design plus the AW for the timepiece. The large wheel on the left with blue cam turns once per ring of the gong/bell so a cam on the axle of this will operate a clapper lever. I was planing to drive the large wheel with step down gearing from a sprocket carrying chain and weight similarly to the timepiece but I wondering whether some lateral thinking can come up with something simpler.
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That print turned out to be perfect for the job and will be the final print. I've been printing more of the gears with good results. I now feel like a break from printing and looking at the design of the strike mechanism. The main parts are done but there remains an auto-winding system. With the main clock auto-winding gears taking up more than half the free space, the AW system for the strike needs something smaller. There is also the problem that the drive varies by 12 to 1 over the 12 hours unlike the timepiece which is constant.
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After a problem with the bed heater, I now have my 3D printer working again and printing the 64t gear. OK so it's not blue. 😄
"GinaRep Mini Mk.2" 3D Printer
in A Range of DIY 3D Printers
A blog by Gina in General
Posted · Edited by Gina
Sliders for X and Y rails added. So far this is just a small number of the many parts involved in this 3D printer but I think a CAD model is worth drawing to fit all the parts together.