Embedded Files
Process map
Process map
BACKGROUND (introduction about the project )
BACKGROUND (introduction about the project )
final.mp4 HockeyBoard
HockeyBoard
At the second module in Advanced maker diploma, we will go through a different way of working from the last module, we will work on this project through a group, we are three colleges at Advanced maker diploma (Mohamed Abdel-Samie, Ahmed Sami Mostafa, Bassant Youssef ), we will explain the different stages that we went through in order to create the Air hockey board.
Ideation:
We tried to think out of the box and not create a cnc machine already existed, so we think of 3 ideas:
1_ Air hockey table with 3 axis
2_ Lifter Robot.
Which is a wheeled robot and have a 3 axis lifter to move in 3 dimensions . it can move from production line to another one and collect or put the products in its places.
3_ Tea bag dipper machine.
in my perspective (bassant), i was more interested to make the Tea bag dipper machine as for me is more cool and simple to start with but the others don`t agree with this idea, so we rethink again of creating the air hockey with three axes ( x, y axes for the hand hockey_ z axis to put the ball after finishing the game in a box at the top), but at the end ,we all agreed to create an Air hockey table but with 2 Axis as we have a limited time to do this project.
Objective :
The objective of this module is to create a CNC machine that does a function different from the machines that already exist (laser cutting,....), controlled by PCB and haS two axes at least.
OBJECTIVE #1: Design and Fabrication of the PCB stage
OBJECTIVE #1: Design and Fabrication of the PCB stage
Schema design and determine the functionality
Schema design and determine the functionality
In this stage we determined the functionality needed from the pcb and determined the components of the pcb at first.
In this pcb we needed a microcontroller to be the brain of the board, power jack, pinheaders for jumpers and steper driver, leds, Joystick for motors contrles, LCD , IR sensors to make a goals detector and voltage regulator to get 5V DC for the microcontroller.
Electronics Components:
Electronics Components:
Atmega328p
Atmega328p housing
Power Jack
Wires
2x LED
2x cap 100 uf
3x Steper motor Nema17
2x Motor Driver A4988
crystal oscillator16 MHz
Serial I2C LCD
LCD
2x IR Sensors
2x cap 22pf
PinHeader Male-Male
Joystick
PinHeader Male-Femal
Terminal Block
Adaptor 12V, 2A
Tools that we used at design PCB stage
Tools that we used at design PCB stage
Eagle software
Gimp software
gerbv. software
Schema Design
Schema Design
We use Eagle for PCB design to design our schema and export the 3d model to Fusion 360.
Our schema contains the main four blocks brain of the board (Microcontroller), Power circuit, Motor drivers, and Connectors as shown in the schema.
PCB Layout and Fabrication
PCB Layout and Fabrication
Tools that we used at fabrication stage
copper
Drill and bits
Double face tape
Tape
Milling machine
Tool to change the bits
After we determined the functionality and finished the schema design we converted it to a PCB layout design.
So we replaced the components with suitable places on the board and put the routing rules to make sure all paths and pages will be as we want then make routing and finally determine the board profile and extend the Gerber files.
The air wire for the Pcb
Preparing the copper for the fabrication
After fabrication
OBJECTIVE #2: Soldering and coding
OBJECTIVE #2: Soldering and coding
Tools we used at soldering stage
soldering wire and soldering machine
Sponge for soldering
Avo meter
after testing.mp4After testing with Avo meter
After soldering the whole components and wired it
Soldering the electronics Components
Soldering the electronics Components
The board is ready now to put all components on it and solder them so we get each component and put it in its place and take care with polarised components.
It is now ready to burn the board loader and upload our code to fit out functionality and get the remaining elements like the drivers and the motors.
Coding Stage
Coding Stage
Coding overall we want to control on hockey hand by using a joystick in 2 axes (X, Y) and count the goals through the IR sensors then show it on the screen.
So let's divide our code into blocks and show each one.
1- At first, we defined and imported "LiquidCrystal_I2C" library to use the I2C protocol with the LCD then define the LCD and give it the address "0x27".
2- Defined IR sensors pins and give initial values to players' goals which are shown on the LCD screen.
3- Then defined the joystick pins and X, Y-axis stepper motors which that each stepper motor needs a step pin and direction pin.
4-The setup function:
we determined all pinMode for all pins for motors, Joystick, and IR sensor.
5- We read analog values from the joystick and set condition to control the motion in the for direction.
6- We have two main function to control the stepper motors at the x and y axis.
7- Finally, we create two functions to control the screen and show a welcome message and show the players' scores.
Joystick axis values
We want to mention that joystick has 2 axes x,y give a difference values between 0 to 1023 (as analog values) so we get the values that define each direction and put a condition for it.
video_20220327_071004.mp4
OBJECTIVE #3: Mechanical design
OBJECTIVE #3: Mechanical design
Mechanical Components
Mechanical Components
Timing Belt Pulley 5mm
Belt (4 meter)
OpenBuilds Mini V Wheel
Idler Pulley 5mm
T-Nut Hammer 5mm
V_Profile 20*20
Steper motor Nema17
Scrowa 5mm
Tools that we used at mechanical design stage
Tools that we used at mechanical design stage
Fusion software
Hammer
Plywood sheets
Nails
rocket saw
glue
Pencil and ruler
Dril
This stage was mixed of three steps:
Step1: Manual step
_we went through the manual process as we want to make the table of the hockey board big but the space for cutting at the laser cutter machine in the fab lab was too small, the machine cut plywood with dimensions 50x30, and we want our table 70x 100, so we went through the manual process, and started to be open to gain carpentry skills, so we started to glue three sheets with each other in order to create the main part of the table table with 100x 70 dimension, then glue a long piece of wood at the back to be a supporter, we already prepared it to the diminision by using the rocket saw, as we want to make sure that the parts are quit fixed, then we hammer nails.
_in order to fix the side parts, we cut a thick 90 degrees parts and add a glue between it and the back of the table, we found that hammer nails was consuming our time and was not saficenit, till Mohamed suggested to use the drill instead of using the hammer, it was a pretty idea.
the supporter parts on the three sheet
add the glue
the 90 degree`s part
top of the table
20220313_190436.gif
the back of the table
work in progress
preparing the supported parts
Step 2: design on fusion 360 for laser cutter machine
en-closer box for components:
As the dimensions of the laser cutter machine at the fab lab have the dimension of 50x 35 cm, we were confused if we designed the encloser box with a width of 50 cm, it will not cut in a fine way and the joints will not be accurate, so we decided to create the width of the encloser box smaller than the machine by 47 cm, we started to create the main sides with those dimensions, then adding the tabs and the t slot joints.
_then download the components from the grab cad website (the LCD, iR sensor, joystick), after downloading the components, we have to upload the files to fusion 360, right click then choose the rigid group icon for each component, so you could move and assembly the component without missing any part in it, the last step is to use the projection icon for each component, to copy the holes of the component on the place that we want in the box, so we could assembly it after fabrication.
_As the encloser box will contain the components, also it will have the place for the goal, so we need to adda hole in the side of the box so the ball could pass from the begging point till the end.
Rigid group icon
assembly the lcd
Assembly the joystick
without using the rigid group
use projection icon for the holes of the lcd on another sketch
assembly the tabs
Step 3: design on fusion 360 for 3d parts
_when we started to think about the mechanism of the CNC machine, and how to make this mechanism be applicable for the hockey board, we faced some troubles, as we need the motion to be faster and smooth to play, so Ahmed Ibrahim the instructor`s suggested for us to use the mechanism of (Core x and y), but he talked is that`s will not be easy to make as it will need more time and test to make sure that the mechanism will be accurate, and that`s the first time for all of us to go through this process, so we all agreed to make the belt mechanism, and see how we could figure this out.........
First we start with table design (30cm x 90cm) and this dimension is the same as 3 sheet of plywood are putting side by side...
then start importing the mechanical parts one by one... first of them is the stepper motor, then we design an enclosure for it and fix it to the table.
Here I started with Y-Axis as it will be fixed directly to the table...
After Finishing one side of Y axis I mirrored it to the other side then I start designing the X-Axis
Hand hockey and the ball :
Failed trial
successful trial
OBJECTIVE #4: Digital fabrication (laser cutting + 3d printing)
OBJECTIVE #4: Digital fabrication (laser cutting + 3d printing)
Tools that we used at this stage
Tools that we used at this stage
3D Printer
Pla filament
Plywood
Laser cutting machine
Step 1: fabrication for laser cutting machine and assembly the parts
Assembly the lcd
the goal part
assembly the goal part with the box
assembly the IR sensor
Step2 : printing on 3d printer and assembly the parts
Problems:
there was a small problem in the X-Axis parts in the Yalow color... I designed the V-Wheel carriage for wheels of 15mm in diameter but the wheel we are using are 24mm in diameter. So, after fixing the wheel in the carriage the carriage wasn't able to ran in the Aluminum profile as the distance between the 4 wheel become smaller than the Aluminum profile width...
Solution:
To solve this problem, Mina in team 2 suggest to make the right dimensions in acrylic and connect the wheels in acrylic part the connect the acrylic part to the 3D printed part...
I design in fusion with approximate dimensions and try to cut in plywood at the beginning and I used 2 layers foe one carriage as each layer has 3mm thickness and the 3D printed part thickness was 5mm
fortunately trial 2 succeeded so I try to to cut in acrylic...
Then we Assemble the rest of the parts together and with the mechanical components
tying to make the holes more widen
Failed trial: we faced some trouble after printing the joints parts, some holes for the nails were too small to add the nail, so we tried to use sandpaper to make the holes widen
The ball in cura software
The supported part for for the hockey hand
Final touch
Give the table cool appearance using spray to give the table black color, and using Vinyl cutter machine to make the playground shape
Assembly the hockey board
Vinyl cutter machine
Vinyl cutter machine
creating the vinyl sticker on fusion 360
After adding vinyl to the board
CONCLUSION: The project Almost done......
CONCLUSION: The project Almost done......
What we Learned in this module.........
What we Learned in this module.........
alsi_ we consumed lots of time at the manual stage as we make it too big, we could do it through the laser cutter instead of this hassle, to be more focused on the mechanism of the Axes.
_Although because the the table was made manually so the places to fix the mechanical mechanicem was unstablie so the axes was not 100% fine in the moving.
_we faced some trouble, but as we were a group in one project, the problems was easy to figure out to search for solutions, as there were three thinking instead of one.
_ we also faced some trouble during dowloding the components from grabcad, as it were not identical to the one who were with us, and that's take a lot of time to recovere.
_although we faced some trouble when we tried to make the axes more faster so we could play, still did not fix.
Our Hockey board game
videoDemo.mp4Demo Playing Game
Small hockey board game
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