[Hardware] Cyclone Control V2

[Samuel Kranz]

Hey,

since Robert never finished his controller board, I will try to design a new one compatible with marlin AND grbl.

Specs:

- Atmega 1284p (arduino compatible)

- 4 Steppermotor drivers (Stepstick compatible)

- USB serial (CH340G)

- Bluetooth (HC05/HC06)

- micro SD

- z-probe, 3axis endstops

- Spindle Driver (Relay or mosfet)

- All unused pins available over headers

I will try to avoid:

- traces under 16mil

- double sided

- smd components 

hopefully the finished boards will be "millable" on our cyclone :D

Samuel

[Iceflow]

That would be so great :D

One con i see, the sdcard, i always think that its better to have it in the LCD panel... so if you plan to left some pins for the LCD, you should :P you might left some too for the sdcard, and use a similar arrangement as the LCD panels used in ramps boards, that are cheap and easy to get ;)

Think too, that most people like to "hide" the electronics to have a neat construction, so maybe the sdcard port would not be easy accesible... :S

Also, to have both relay and mosfet would be great, so you can use AC switch with the relay or DC switch with the mosfet... to use either AC or DC spindle, or AC for the vacum cleaner and DC for the spindle :P

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[Samuel Kranz]

unfortunately the normal lcd sd boards are using rx1 and tx1 for the rotary encoder so these boards would not work with bluetooth :S

Maybe there is chance to use an i2c panel.. 

[Daniel "yOPERO" Garrido]

+Samuel Kranz

Have you already tested the edge branch of GRBL that supports the 1284?

Unfortunately I do not have that mC at hand.

[Samuel Kranz]

Hi,

Nope I've never tested GRBL on an 1284 by myself, but I've seen some projects with some sanguinololu running grbl (here). Due to the bad portmapping of the sanguinololu (which does not allow a direct pin mapping for grbl) I' wve designed a sanguinololu like board.

Hopefully i can just adapt the cpu_map.h so future versions of grbl will also work with no code adaption.

Current state: Prototype 1 (SMD Version)

 - Atmega 1284 - y

 - 4 stepper driver - y

 - usbserial w/ cheap CH340G - y

 - micro SD - n

 - bluetooth - n

 - i2c pins (portexpander/display/...) - n

 - probe/endstops - n

 - onboard dc spindle driver (12V/100W) w/ mosfet - y

 - onboard ac/dc spindle driver w/ relay - n

 - tht components - n

 - single sided - n

board dimensions: 45x100mm

I will work on the missing features this week (yay holidays ^^).

Some Pics:

  

I am going to etch this board today so maybe I can tell you more about the grbl-m1284 compatibility in the evening.

[Yiannis Mandravellos]

Nice job Samuel!

The only thing I don't like is the fact that, with the components selection, you 're limited to using 12 volts for the motors...

[Yiannis Mandravellos]

And more importantly, 12 volts for the spindle?

[Samuel Kranz]

Hi Yiannis,

if you replace the capacitors (eg 25V..) you can use the circuit with 24V motors/spindle. 

The circuit voltage is limited to the Stepsticks(eg 24V for the allegros) and the voltage regulator (35V for lm7805)

If you dont want an 12V/24V spindle you can use  the onboard relay (in future versions) to drive your 48V/110V/230V spindle

[Yiannis Mandravellos]

Hi Samuel,

yes, changing the capacitors rating will allow for higher voltages but then again, if you feed 24V at the input, the 7805 won't really like it :)

I know it's rated for 35V but the heat dissipation will be too much, imho...

Keep up the good work :)

[Carlos García]

Hi Samuel, the board looks awesome!

I'd only advise you to make the diameter of the vias larger, in order to simplify alignment/soldering when manufacturing the board "at home" (what technique do you use for vias when etching?)

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[Samuel Kranz]

Hi Yiannis,

of course the 7805 wont like those high voltages (efficency factor ~20%) but the avr does not consume that much current so the power dissipation would be quite small. Actually I also dont like that component but its easy to solder (compared to a buck converter) and its highly available. But maybe i will change that part in future version.

Thanks :D

Hi Carlos,

Thanks, the vias are 0.6mm/1.5mm (the smallest diameter i can manufature at home xD). I will increase the diameter in the final versions ;).

I align the top and the bottom like thomas (here) but unfortunately my laminator broke today :( so i couldnt manufature the boards. I will try to fix it tomorrow.

Thanks for the feedback :)

Samuel 

[Yiannis Mandravellos]

Hi Samuel,

one other thing I noticed is that you 're using one common ground both for logic and power (motors/spindle) levels.

Ideally, you should split it in two separate grounds to avoid interference from electrical noise from the motors/spindle.

But then you 'd have to have a separate power source (USB?) for the two voltage levels...

I hope you don't mind me nitpicking. I just want this to be a great board :)

Cheers,

Yiannis.

[Samuel Kranz]

thanks :D 

Please keep giving me feedback. I also want this to be a great board :D

[Samuel Kranz]

Hi,

a little update on the spindle driver and power management :D

let me know what you think.

[Alessandro Incalza]

Hi Samuel,

I'm following the steps of your design. About the latest update and in particular over the spindle driver, I'd not connect both PWM driven mosfet (DC spindle) and the one for the relay at same IO pin. Probably you could foresee the use of a jumper if two different pins are not free for splitting the two driving options.

[Samuel Kranz]

Hi Alessandro,

thanks for your reply. The idea of the dual spindle driver was to support both variants. its not intended that the user solders both (probably also not possible due to the layout) . just giving the option to use a low power dc spindle driven by powersupply used for the motors (support for pwm) OR using an higher voltage ac or dc spindle

[Yiannis Mandravellos]

Hi Samuel,

The general design looks ok for the average use.

Keep in mind though that the rest of my comments stem from the fact that my setup is not exactly common. Yet it'd be super cool if your design would cater for cases such as mine too ;)

My cyclone runs on three different power levels: 5V for the controller, 24V for he motors and 48V for the spindle.

The controller runs on 5V from USB. For 24V and 48V I use two different power supplies (I got them at different times; maybe I could find a single one providing both power levels).

So, with this setup in mind, my comments would be:

* I like the two driving options for the spindle (relay+pwm). I would use separate power connectors for spindle and motors power though. Users that use the same power level for the spindle and the motors, could just wire the same power supply to both connectors.

* I like the idea of  using an LC fliter to further reduce power supply noise.

* For power management I 'd go with variant 2 or 4, just because I don't use 12V anywhere and anything more than that level is really not suitable for a linear regulator to provide 5V...

Keep up the good work :)

Yiannis.

[Samuel Kranz]

Hi Yiannis,

the option with separate spindle power connector definitely makes sense. For power management I intended to use variant 3, which supports the buck converter for higher voltages and an 7805 for 12V (which would be cheaper and easier to solder). The option to power the electronics over the USB bus would also be supported by removing (or not soldering) the power management.

Maybe you noticed the 4th motor driver which is intended to support a dual motor axis (like the y-axis of the shapeoko) or just for adding an extruder / 4th axis? :D. I want to say that my goal is to support a lot of variations of the Cyclone (like yours) and multiple firmwares like grbl and marlin.

[Cory Kinnunen]

Heya, just finished printing my 2.1 cyclone! I'll be using a ramps1.4 for the time being with a dremel as the tool.
Would love to mill this board on the cyclone so i can use the ramps in another printer project.
Keep up the great work!