Power Core for feeders

[DoTheDIY (Apoorv Chaudhary)]

I have started work on a compact and easy-to-make feeder core that can be incorporated in feeder design. I am finding it difficult to source right angle n20 motor. So i have used a straight shaft n20 motor, biggest problem is the worm gear design how to desin such a small gear that can be reliable and be printed. So i am betting on drywall screw.

I have access to MJF and SLS 3d printing if someone can help with the design of the gear i can go that path as well. This core has a magnetic encoder and will be closed-loop. I will have additional I/O and an additional motor driver for peeling tape if required.

I will keep this fully Open source and will setup a repo one i do initial testing so others can use and improve.

[DoTheDIY (Apoorv Chaudhary)]

Thickness currently is 12.5mm this includes the 0.6mm pcb as well

[Michael Anton]

You could probably use off the shelf nylon worm gears with regular spur gears: https://www.aliexpress.com/item/1005005256932043.html.  These are available from many suppliers, and are very inexpensive.  This combination will have some backlash, but will probably work well enough, without having to make gears.

This is what I was planning to use when I was working on my feeder design.  I've attached a rough version of it.  You can hide various pieces of it to see what I had in mind.  Total feeder thickness was planned to be 10mm, which included a 1.6mm PCB used as the feeder baseplate.

[miciwan]

I used this combo in my setup and it works really well:

https://www.aliexpress.us/item/2261800158972077.html

Not the cheapest option (but I was only making a bunch of feeders for myself), but it's very solid and has very little backlash. And it's relatively thin compared to other bronze gears - the wheel is 5mm thick, the worm is 6.7mm in diameter, so it fits nicely into slim feeder assembly.

[DoTheDIY (Apoorv Chaudhary)]

In India I do not have access to AliExpress anymore. And importing stuff from China is complicated.

[DoTheDIY (Apoorv Chaudhary)]

Slowly getting there :)

[Jonathan Oxer]

Good progress Apoorv :-)

Where did you source the drive sprocket?

I'm in decision paralysis right now about feeders, because I need a heap of them and I've been betting on Rapid Feeders being released by the time I needed them, but I can't wait any longer so it looks like I'll have to go down a different path. If your feeder design will be released soon it could be a good candidate.

Jon

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[Mike Menci]

Well for a price you pay for worm and gear you can get here:

- a motor with worm + gear = https://www.aliexpress.com/item/1005005470868749.html?spm=a2g0o.order_list.order_list_main.490.40fc18021920H3

Apoo - how will you remove cover tape ? 

Mike

[DoTheDIY (Apoorv Chaudhary)]

all gears will be 3d printed in-house. The worm gear and shaft will be professionally printed using SLA. The sprocket is pretty strong if i print in PETG. I am trying to insource as much as possible

FYI the encoder magnet is inbuild into the worm gear which you will not get in off the shelf gears and this allows me to compensate for all the issues i may end up like backlash etc.

I am betting on wireless design for feeders

[Mike Menci]

I am looking forward to see see the development updates! 

[DoTheDIY (Apoorv Chaudhary)]

Design is done time to order parts and start testing. 

[DoTheDIY (Apoorv Chaudhary)]

The encoder ic used is AS5600. Had used the same ic in solder paste dispenser that I had designed sometime back 

https://youtu.be/3NOdC94tskk will be reusing the code from that project. Had manager to make it closed loop with stall detection 

[bing luo]

From your video, it can be seen that the accuracy of this encoder is sufficient.   This is a very low-cost solution. 

My plan is different from yours. I need the worm to rotate 360 degrees accurately.

[Apoorv Chaudhary]

Clever feeder by alan0131 uses similar encoder setup as you have shared. His design is not open but i have spent lot of time analyzing his design from the videos.

My design is somewhat influenced from it

https://alandesign.cn/en/pages/cleverfeeder

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Apoorv Chaudhary

9743055919

[bing luo]

I just finished testing this encoding motor（AB biphase incremental magnetic encoder）. In its program, there is a closed-loop control of speed and position. After it rotates for 10 cycles, it is no longer able to return to the same position. As the number of cycles increases, the error increases，So it is not usable.  

Someone told me that you should use an absolute value encoder, so I bought three pcs   AS5600  and   will test them.  

If this solution is feasible, then it doesn't matter whether it's open source or not, because the program is not complex and many people can write it.

[DoTheDIY (Apoorv Chaudhary)]

I had initially evaluated the design to put magnet in worm gear.

But putting the magnet in warm weel/ sprocket I do not have to worry about backlash and I know exactly wher the teeth of sprocket are once I set them in the controller, this way I can compensate for most of the errors. 

[bing luo]

If its error is within the allowable range, there is no problem.   because its error will not accumulate.  Whether it rotates 100 or 1 turn, its error is fixed.

[DoTheDIY (Apoorv Chaudhary)]

Laser cut 1mm SS vs PETG sprocket. Both will work. 

[DoTheDIY (Apoorv Chaudhary)]

testing different materials/processes for gear

[DoTheDIY (Apoorv Chaudhary)]

New gearbox design with improved gear ratio, more torque and different gear design. Have to reduce friction further and experiment with more materials. Printed fully in fdm now.
https://youtube.com/watch?v=weYLRCeDlDo&feature=sha anre

[DoTheDIY (Apoorv Chaudhary)]

Had to refine the design, a Single N20 motor was not enough. Waiting on the PCB now.

[DoTheDIY (Apoorv Chaudhary)]

[DoTheDIY (Apoorv Chaudhary)]

https://youtu.be/Tf3laZ8ykSQ

Implementing PID closed loop

[DoTheDIY (Apoorv Chaudhary)]

https://youtu.be/IeZcGXMZzIo?si=cbckul_TqqKejrbe 

wireless communication implemented. Working on firmware. Can be controlled my ReferenceAutoFeeder. It supports full configuration via GCODE command but not sure how do setup in openpnp for advance features. Now the master node will do it or I can write a pc application which will do.

[Marshall S. (Alakuu)]

How goes this?

Debating grabbing some cleverfeeders, but I like the layout of your work already better. Any chance I could talk you into sharing files? Heck I'd buy them!

[DoTheDIY (Apoorv Chaudhary)]

update 

https://www.youtube.com/watch?v=f_tQa3UI4Yo