Dosing Final Report
Dosing Final Report
By Josh Frew
Contents
Problem definition: ....................................................................................................................................... 3
Primary Objectives .................................................................................................................................... 3
Secondary Objectives ................................................................................................................................ 3
Constraints ................................................................................................................................................ 3
Bill of Materials (NZD) ................................................................................................................................... 4
Functionality ................................................................................................................................................. 5
Operational Flow chart ............................................................................................................................. 6
Safety and Standards .................................................................................................................................... 6
Environmental Impact................................................................................................................................... 7
Ethical issues ................................................................................................................................................. 7
Conclusion ..................................................................................................................................................... 7
Appendix ....................................................................................................................................................... 8
Calculations ............................................................................................................................................... 8
Driver..................................................................................................................................................... 8
Linear Actuator Speed........................................................................................................................... 8
Bought Parts.............................................................................................................................................. 9
R.U.M.B.A Control Board ...................................................................................................................... 9
DRV8825 Driver ..................................................................................................................................... 9
Photo Interrupter ................................................................................................................................ 10
Linear Actuators .................................................................................................................................. 10
Servo ................................................................................................................................................... 10
Tweezers ............................................................................................................................................. 10
Designed Parts ........................................................................................................................................ 11
X-Z connection .................................................................................................................................... 11
Gripper Module................................................................................................................................... 11
Photo Interrupter holders ................................................................................................................... 11
Test Rack ............................................................................................................................................. 12
Power supply and control board housing ........................................................................................... 12
Construction............................................................................................................................................ 13
3D print ............................................................................................................................................... 13
Photo Interrupters .............................................................................................................................. 14
Body .................................................................................................................................................... 15
Project Contract ...................................................................................................................................... 19
Category of Ethics ................................................................................................................................... 21
Tailgates .................................................................................................................................................. 22
Problem definition:
Isotrace is a forensics lab that spends a lot of time and money paying wages for samples to be
weighed out. This process requires the movement of small, delicate cups to be weighed and
filled with 400µg of powder. Due to the repetitive nature of the job, it is a perfect opportunity
to create a robot to do this, saving Isotrace time and money from wages.
Primary Objectives
- Design a system that will automatically move sample cups to be weighed and filled with
sample powder then put on an 8x12 rack.
- Arduino coding – mapping of positions.
- Develop a method to pick up the cups and move them.
Secondary Objectives
- As little spillage of powder as possible (~5%) while robot is moving.
- Have process be completed as quickly as possible, <5 min per cup.
Constraints
- Time: One semester.
- Size: Must fit on a benchtop 500mm x 1500mm.
- Cup is limited to Elemental Microanalysis, Tin Capsules, 5 x 3.5mm.
- Opening to balance is 50mm wide x 55mm high.
Bill of Materials (NZD)
Unit Cost Total
Item Supply Part # Company
(#@NZD) (NZD)
Linear actuator, Stepper Motor Drive Kit, AliExpress – YUN
1@
Mini Slide Table. 1mm Lead 100mm N/A DUAN Industrial 39.89
39.89
Stroke Store
Linear actuator, Stepper Motor Drive Kit, AliExpress – YUN
1@
Mini Slide Table. 1mm Lead 200mm N/A DUAN Industrial 47.57
47.57
Stroke Store
Linear actuator, Stepper Motor Drive Kit, AliExpress – YUN
1@
Mini Slide Table. 1mm Lead 300mm N/A DUAN Industrial 70.64
70.64
Stroke Store
620pcs Dupont Connector 2.54mm
Dupont Cable Jumper Wire Pin Header AliExpress – Tassa 1@
N/A 12.77
Housing Kit Male Crimp Pins + Female Pin Store 12.77
Terminal Connector
Photo Interrupter ZD1901 Jaycar 3 @ 5.90 17.20
5m @
Wire 25AGW WH3017 Jaycar 2.40
0.48/m
Gifted for this 0.24m @
Wire 18AGW 0.48
project 2/m
Multicore Cable, Flexible Mains, 15A, Per Gifted for this 0.06m @
0.46
Metre, Unscreened, 3 Core, 13AGW project 7.60/m
Arduino Compatible 9G Micro Servo 1@
Motor YM2758 Jaycar 18.90 18.90
1@
Mean Well 150 W 24V 6.5A Power Supply MP3292 Jaycar 99.90
99.90
1k Ohm 0.5-Watt Metal Film Resistors -
RR0572 Jaycar 1 @ 1.00 1.00
Pack of 8
470 Ohm 0.5-Watt Metal Film Resistors -
RR0564 Jaycar 1 @ 1.00 1.00
Pack of 8
Rocker Switch SK0979 Jaycar 1 @ 4.70 4.70
Snap-In IEC C13 Mains Socket PP4009 Jaycar 1 @ 7.20 7.20
1@
3pin Mains Plug to IEC C13 Female - 1.8m PS4106 Jaycar 14.90 14.90
1@
eSUN Black PLA+ Filament 1kg 1.75mm TL4454 Jaycar 46.90
46.90
Narva Heat Shrink Tubing 3.2-6.4mm Black 1@
463426 Mitre 10 10.58
& Red - pack 10.58
Autoline 4@
20x40 Slotpro 500mm 1.0204.6.SPRS 83.52
Automation 22.88
Autoline 2@
20x20 Slotpro 500mm 1.0202.4.SPSS 25.88
Automation 12.94
Autoline 30 @
Threaded T nut 3.02.T.SP5 36.90
Automation 1.23
Autoline 15 @
2 Series Angle Bracket for Extrusion 6.02.SPB20 110.10
Automation 7.34
6@
Stepstick Stepper Driver DRV8825 Makershop.co.nz 133.86
22.31
1@
Control Board RUMBA Makershop.co.nz 149.95
149.95
M5x6mm Pan head screw - 100 Pack MP006601 Element14.co.nz 1 @ 5.12 5.12
Zenith M6 x 20mm Zinc Plated Round
ECA1320 Bunnings 1 @ 6.76 6.76
Head Bolt And Nut - 12 Pack
Pinnacle M3 x 20mm Black Round Head
SFA504 Bunnings 1 @ 4.23 4.23
Bolts and Nuts - 12 Pack
Pinnacle M3 x 10mm Black Round Head
SFA502 Bunnings 1 @ 4.23 4.23
Bolts And Nuts - 12 Pack
Pinnacle M3 x 10mm Black Round Head
SFA501 Bunnings 1 @ 4.23 4.23
Bolts And Nuts - 12 Pack
(Isotrace has not placed a budget cap as the savings produced once this robot is complete
960.33
will be significant)
Functionality
The steppers are zeroed with the use of photo interrupters positioned at one end of the
actuator. Tabs have been placed so that when the table of the actuator is in place it breaks the
light between the LED and the light dependent transistor. The stepper is then zeroed.
Once all steppers are zeroed, Y stepper motor will move to the first rack Y position. Then X
stepper will move to the first rack X position. The Z stepper then lowers the tweezers to rack
height. The servo will then close the tweezers allowing a cup to be picked up before Z stepper
will retract to moving height. Once at moving height the X stepper moves into the balance
placing the cup on the scale’s plate and moving out of the way so that the balance can operate.
When the balance has operated the robot moves back into the balance, picks up the cup and
moves it to the dispenser’s position. Places the cup onto the dispenser before moving out of
the way for the dispenser to operate.
When the dispenser has finished the robot will pick up the cup again, move it to the balance so
that the balance can confirm the weight of the sample within the cup. Once the balance has
confirmed the weight, the robot will then move the cup back to the rack.
All the X coordinate positions will then repeat the process before the Y stepper moves to the
next position The X coordinate is then reset and repeated. This process will repeat until all Y
coordinates have been completed.
Ethical issues
Some groups think that robots are out to steal their jobs. When talking to the lab technicians at
Isotrace, they couldn’t be happier that there will be a robot to take this monotonous task off
their daily duties.
Conclusion
The gripper module could do with some improvements. As it is there is potential for deformed
cups to cause issues. The customer recently informed me that once the sample is in the cup,
the tops of the cups get pinched closed. There is a potential for the gripper to do this as it
moves the cup back to the rack.
The robot moves very slow at this stage, taking almost a minute to move from the rack to the
balance. Investing in leadscrews with a longer lead would improve this while the loss of
positional accuracy will be negligible. Since the leadscrews need upgrading anyway, getting a
shorter stroke, 50mm instead of 100mm, for the Z axis would be recommended. This will
slightly lower the cost of the robot with a cheaper linear actuator and reducing the height
needed, meaning less aluminium will be needed. An alternative method could be to look at
using a robotic arm instead of the linear XYZ setup. This would get rid of the need for a frame
however, the cost of a robotic arm is significantly more than the method that has been chosen.
The next stage of the project is to create a method of dispensing 400µg of powder into the cups
and having the balance communicate with the robot to confirm the weight. With a weight that
is within tolerances the cup can be placed on the rack. If it’s bellow tolerance the robot will try
adding more in. If it’s above tolerance the cup will be rejected.
Appendix
Calculations
Driver
The DRV8825 needs to have its potentiometer adjusted so that the driver does
not produce too much current to the motor causing it to overheat. This
requires the VREF to be calculated. The VREF is the voltage difference between
the Potentiometer and Ground and can be calculated with:
Imax 0.6
VREF = = = 0.3𝑉
2 2
Where Imax is the maximum current the stepper motor can handle as stated in
Linear Actuators. Figure 1 Pot and
GND Labeled
DRV8825.
• Arduino Programmable.
• 135mm x 75mm.
• Can handle 12VDC-35VDC.
• Capable of driving 6 stepper motors.
• 6 position switch pins.
• 5 PWM pins.
• 5 analogue pins
• Display and SD-card reader capable
• USB connected.
• Can run off just power supplied.
Figure 2 RUMBA control The RUMBA user’s manual has been included in the Zip file. There you can find
Board.
details on pin uses and positioning.
The user’s manual doesn’t cover everything here is a useful website, https://reprap.org/wiki/RUMBA
Ed’s 3d Tech
Special thanks to Ed for the very helpful tutorials on YouTube about the Rumba control board
and the stepper motor driver DRV8825. He also has videos about connecting other devices
which the user’s manual and the producer’s website does not cover.
https://www.youtube.com/watch?v=_V96Meo-VQU&list=PLP-
VDZmS6bForVRid2bjnGAlXNSE9tVv7&ab_channel=Ed%27s3dTech
DRV8825 Driver
• Built in microstepping Indexer.
• Up to 1/32 microstepps.
• 8.2VDC-45VDC operating supply Voltage.
• 2.5A Maximum Drive Current at 24VDC.
• Simple Step/Direction interface.
• Built in 3.3V Reference Output
• Protection features:
o Overcurrent Protection
o Thermal Shutdown
Figure 3 DRV8825. o Undervoltage Lockout
o Fault Condition Indication Pin
Data Sheet
https://www.ti.com/lit/ds/symlink/drv8825.pdf
Photo Interrupter
The ZD-1901 was advised to me as being a better option than a limiting
switch due to it having no moving parts and can react very quickly.
Figure 4 Photo
Interrupter ZD-1901.
Linear Actuators
• Bipolar stepper motor driven.
• CNC sliding rail table.
• Available in 1, 2, 4, 6, and 12mm lead screw.
• Available in 50-300mm stroke at 50mm intervals.
Figure 5 Linear Actuators. • 6.7 Ω, 24VDC, 0.6A, 1.8o per step.
Servo
• 30mm x 30mm x 10mm W x H x D.
• 20 grams.
• 3.5VDC-6VDC.
• Speed; 500 degrees/second at 6V.
• Turque; 1.6kg.cm at 4.8V.
Tweezers
• 124mm end to end.
• Curved.
Figure 7 Curved tweezers with hole drilled.
• 19 grams.
Gripper Module
The gripper module is attached to the Z linear actuator with bolts through the
green holes. The tweezer is then placed in the yellow section with a bolt that
goes through a drilled hole in the tweezer and into a threaded hole on the Z
actuator table. The blue area houses the servo motor which slides in and held
by friction. There is a cutout at the bottom of the servo housing to make way
for the servo’s wires, and a hole at the back for the wires to be threaded
through. The red tab is for when the X actuator is zeroing.
Figure 10 Gripper
module coloured
for section
referencing.
red.
Figure 15 Control
board housing lid.
Coloured for section
referencing.
Power Supply Housing
The yellow power supply housing has been designed to take the
Mean Well 150 W 24V 6.5A Power Supply. The front has two
square cutouts the red for the IEC plug and the pink for the
switch. The back has two extrusions these are to slide down the
back of the control board housing. When everything id in place a
screw can be installed through the notch cutout at the top of
the power supply housing, locking everything in place.
Construction
3D print
File Name Body Name Number of copies
Short Slot Connection 4
Linear actuator connections Long Slot Connection 2
X-Z connection 1
Gripper Module 1
Gripper Saddle
Servo Paddle 1
X Interrupter 1
Photo Interrupter Holder Y Interrupter 1
Z Interrupter 1
Test Rack Test Rack 3x3 1
Control Board Housing 1
Control Box Control Board Lid 1
Power Supply Housing 1
Note, the orientation of each component is not always suitable for printing. Change orientation
to suit.
Photo Interrupters
1) Cut wires to length:
Red) 2x20mm for all interrupters, X interrupter 350mm, Y interrupter 450mm, Z interrupter
350mm.
Black) 2x20mm for all interrupters, X interrupter 350mm, Y interrupter 450mm, Z
interrupter 350mm.
White) X interrupter 380mm, Y interrupter 480mm, Z interrupter 380mm.
2) Strip 5mm of insulation off both ends of all wires
3) Take note of what leg is what, found at pin base, before placing photo interrupter into its
saddle.
4) Put nuts for an M3 thread in nut shaped hole. Screw M3x10mm bolts through photo
interrupter and through nut until firm. Do not over tighten.
5) Solder the 470Ω resister to pin A.
6) Solder the 1kΩ and white wire to the C pin.
7) Solder a 20mm red wire to the 1kΩ resister.
8) Solder the other 20mm red wire to the 470Ω resister.
9) Put heat shrink over resisters and soldering.
10) Twist ends of red wires together with the long red wire and
solder together.
11) Heat shrink solder. Figure 18 Photo interrupter wiring
schematic.
12) Solder one 20mm black wire to E pin
13) Solder one 20mm black wire to K pin
14) Heat shrink black wires and solder.
15) Twist black wires together with long black wire and solder
16) Heat shrink solder.
17) Connect female Dupont connectors to ends and orientate the wire in the 3-
pin housing: red, black, white.
Figure 19 Photo
interrupter Dupont
connector
orientation.
Body
1. Cut the Slotpro 20x40 into lengths; (A) 1 @ 315mm.
(B) 2 @ 235mm.
(G) 1 @ 140mm.
3. With bar ‘A’, two ⌀6mm holes need to be drilled through at each end (4 in total). These
holes are to be 9mm and 30mm from the ends.
4. At the same positions, each hole needs a ⌀11mm counterbored hole 5mm deep.
5. Both ‘C’ bars require the two existing holes that run the length of the bar to be threaded to
take an M6 bolt. Only one end needs to be done.
6. Bar ‘A’ can be attached to both ‘C’ bars by using M6x20mm bolts through the drilled holes,
making sire the head rests within the counterbored hole, and into the new threads.
7. With the two ‘long slot connections’, place nuts with M3 thread into the nut
shaped housing.
8. Slide both down a channel on bars ‘B’, one for each bar.
9. One bar ‘B’ (B1) can be attached flush to the end of bars ‘D’ and ‘F’ using the
angle brackets, T-nuts, and M5x6mm Pan head screws. Making sure that Figure 21 Long slot
connector -
‘long slot connection’ is on the upward facing face. Ref Figure 20 Completed underside
Robot body.
10. The second bar ‘B’ (B2) is to be attached at 176mm centres of the first bar using the angle
brackets, T-nuts, and M5x6mm Pan head screws. Making sure that the ‘long slot
connection’ is the same orientation as B1.
11. The linear actuator with a 200mm stroke can now be screwed into the ‘long slot
connections’ using M3x10mm bolts. Leave loose for adjustment later.
12. Place a nut for an M3 thread into the nut shaped hole for all 4 Short Slot
Connections.
13. Slide two of the ‘Short Slot Connections’ down the side channel ‘A’ bar. With
the same face orientation, the ‘C’ bars need a ‘Short Slot Connection’ Figure 22 Short Slot
Connection -
inserted on the right most channel for both bars. underside
14. Attach the Linear Actuator with a 300mm stroke to these components by
using four M3x10mm bolts through the existing holes in the actuator and into the nuts of
the components slotted into railing.
15. Using two angle brackets, T-nuts, and M5x6mm Pan head screws on each side, bars ‘C’ can
be attached to bars ‘D’ and ‘F’ 180mm from the end where B1 is attached. Having the linear
actuator facing towards the end where B1 is attached.
16. Using M3x6mm bolts, screw on the ‘X-Z connection’ onto the X linear actuator’s table. This
should be oriented so that the longer side is pointing down.
17. Place M3 nuts in the housings found on the top-backside of the ‘X-Z connection’.
18. Push the Linear Actuator with a 100mm stroke onto the ‘X-Z connection’ and secure it using
M3x6mm bolts.
19. Attach photo interrupter housings onto their respected actuator axes. This requires
removing the existing screws from the lower end wall of the actuator, pressing the
interrupter holder into the holes, and replacing the screws with M3x20mm bolts.
Note: sometimes the bolts need 2-3mm filed off the end.
20. Drill a ⌀3.5mm hole through the curved tweezers. This hole needs to be 6.5mm from the
fulcrum point end of the tweezers to the centre of the hole and centred from the edges.
21. Position the tweezers into its housed position then attach the gripper module to the Z
actuator table using an M3x10mm bolt through the tweezers and 3 M3x6mm bolts through
the other holes.
22. Feed the servo wire through the servo housing and press the servo into its housing. Press
the wire into the slot on the side of the Z photo interrupter housing, making sure there is
enough slack so the table can reach the bottom.
23. Attach the Servo Paddle with screws provided in servo pack and the single
arm Figure 23 Servo arm and screw.
24. Cut a red, a brown, and a yellow AGW25 wire to 350mm and strip 5mm of
insulation off the ends of all the wires. Attach male Dupont connectors to
one end and push them into a 3-pin housing in order of brown, yellow,
orange. At the other end attach female Dupont connectors and push them
Figure 23 Servo
into a 3-pin housing in order yellow, brown, orange. arm and screw
25. Push M3 nuts into the back of the Control Board housing. Place the control
board onto the square pads, lining the holes up and screwing together using M3x6mm
bolts.
26. Slide the two tabs on the back, see Control Board housing, along the inside face of ‘D’ bar.
27. Cut the multicore 13AWG to 60mm length. Strip off the outer black insulation and strip
5mm of the inner insulation off both ends of all 3 wires. Solder these wires at 90o to the IEC
pins on the back taking note on which pin is L, N, and Earth (written on the back of the IEC
plug).
28. Feed the wires into the IEC hole. Ref: Power Supply Housing. Making sure the wires are
sticking up and attach each wire to their respected L, N, and Earth terminals with the screw
clamps provided with the power supply unit.
29. Cut a black 18AWG wire to 120mm and strip 5mm of insulation off both ends. Twist the
wires.
30. Cut a red 18AWG wire in two lengths, 50mm and 70mm and strip 5mm of insulation off
both ends. Twist the wires.
31. Solder the 50mm red wire at 90o to the rocker switch pin 1.
32. Soder the 70mm red wire parallel to pin 2.
33. Attach the black wire to the –’ve DC output terminal and feed the other end through the
hole in the back of the Power supply housing.
34. Feed the red wires through the swich hole. Feed the 70mm wire through the hole in the
back of the power supply housing and attach the 50mm red wire to
the +’ve DC output terminal.
35. Press all components together. The IEC plug and switch will snap
together, the power supply will finish flush with the top of the
housing.
36. Attach the power supply housing to the control board base as seen
in Figure 24 Power supply, Control board housing base and lid
interconnectfeeding the black and red wires into the control board
bases power supply hole as you go.
37. Screw an M3x6mm bolt through the notch on top of the power
supply and into the robot body.
38. Attach power supply wires to their respected +’ve and –’ve terminals on the control board.
39. Attach female Dupont connections on all the stepper motor wires Figure 24 Power supply,
and insert them into a 4-pin housing with the orientation of Control board housing base
and lid interconnect
1A, 1B, 2A, 2B. (Black, Green, Red, Blue).
40. Install the drivers with the orientation as in Figure 25 X and
41. Feed all the component wires through the large hole on the control
board housing.
42. Attach wiring as per Figure 26 Wiring schematic.
43. Upload code onto board
44. Tune the drivers to 0.3V. Follow this video for instructions on how to
do this https://www.youtube.com/watch?v=BV-
ouxhZamI&ab_channel=ZerotoHeroEngineering