User:Mcmaster/Brainscope

Mitutoyo / Micromanipulator probe station with EZLAZE laser

Condition

The following issues have been noted:

• • EZLAZE: PS missing
  • XY stage: missing X motor and maybe some related brackets
  • FS-60: possibly missing part…fine focusing knob?
  • FS-60: focusing knob fell off (during shipping I think)
  • Broken e-stop wire (from dissassembly?)
  • Misc rusted screws. Rust has not been found on anything critical

EZLAZE

Head

NEW WAVE RESEARCH MODEL EZLAZE 532/355 SER NO XXX DATE OCTOBER 2000 MADE IN USA US Patent 5,611,946

Power supply

Power supply missing

Above: power supply this unit should take [eBay ntxsupply item 151675355993]

Console

Camera

Genwac GW-202B

Microscope

Mituotyo Finescope, likely FS-60

Above: focus knob

Above: likely motorized stage power/control connector

Hood

For doing optical emission analysis. Also good to block out dust in my dusty garage

Above: misc cables hanging out of the hood going to the various electronics inside

2015-08-16

Removed hood to move to proper table and overhaul control system. Notes:

• • ezlaze is not water cooled
  • water cooling is for chuck
  • BNC connector bent
  • From move?
  • CPC for thermal chuck (not motors)
  • Motors are synchronous stepping
  • Replacing with IMS NEMA 23

Motor

IMS MDM1FSD23A7

NEMA 23

"These are 90 oz/in"

Closest match: step/direction input version

• • Datasheet]]
  • Spec sheet]]
  • MDMXXX174
  • MDrive 17 Plus step and direction input
  • SPI

Y axis test

Color	Signal	To
White	Optocoupler reference	BBB P9.5-6 5V Red
Orange	Step	BBB P8.15 Blue
Blue	Direction	BBB P8.14 White
Brown	Output bridge enable	N/C
Black	Ground	Ground Black
Red	Power 12-75 VDC	24V

Open question: do I need the programming cable?

• • I think I have one

Initial current draw 50 mA. Holding torque is not very good; slightly above off level. Spikes to around 80 mA at startup

BBB: mk-test. Verified powers up

changes 10 mA (min PS resolution) when try to move. Time to play with settings cable

Cable: MD-CC4 USB to RS422 Comm Converter

Unfortunately:

The MDrive microstepping integrated motor and driver use the Serial Peripheral Interface (SPI) to configure the setup parameters.

Use bus pirate or beagle

2015-08-17

Decided to try one last time to see if I could move motors before messing with programming cables.

Hooked up a test motor without any shaft load. Spins fine and has reasonable torque.

Hooked Y2 axis back up and was able to move it just fine. Issues yesterday evidently were just due to shoddy wiring

Conclusion: don't need programming cable. Default settings seem to be good enough for now

Also validates that motors are good enough. Need to get 1-2 more for XY1. Wait until I take it apart to verify clearances etc?

X2 motor won't fit:

• • original: 2.0"
  • max: 2.2"
  • mine: 2.7" (official IMS docs list Lmax: 2.65")

Looked around and it looks like its going to be difficult to find any motors with integrated drivers at this constrained size. Min length from vendors:

• • IMS: 2.65"
  • linengineering: 2.69"
  • anaheimautomation: 2.98"

Time to see if I can make these motors work. I have some reasonably compact standalone IMS drivers (by coincidence also IMS) I can try to use

http://www.cnczone.com/forums/stepper-motors-drives/15273-slo-syn-motor-wiring-info.html]]

• • 4 wire motors are bipolar
  • 5 wire motors are unipolar
  • 6 or 8 wire motors can be wired either way

Mine: 6 wire

• • Red
  • White-red
  • Green
  • White-green
  • White
  • Black

In stock:

• • 3x IMS INT-481]]
  • 4x Compumotor OEM650]]

2015-08-20

Briefly poked at things. Current plan:

• • Try to use original motors. This is combination of tight clearance in X2 combined with advantages of using existing wiring harness in X1/Y1
  • See if I can get INT-481 to work with the slo-syn motors?
  • A fourth INT-481 may cost $100
  • This makes OEM650 more attractive since I have more of them
  • They are slightly bigger but also easier to mount
  • Z1 axis is a NEMA 34 motor. Does not appear to be a slo-syn. Maybe compumotor
  • Low priority
  • Make a schematic
  • Fix e-stop loose wire (after schematic to better understand where it should go)

2015-08-21

Working on schematic

Back connectors

Electrical:

• • (STAGE): 25×2 0.1" male IDC
  • T/C: type K thermocouple plug
  • HEATER: 4 pin CPC twist lock

Pnematic:

• • VACUUM
  • STAGE IN
  • STAGE OUT
  • RING IN
  • RING OUT

What is RING?

X1 ribbon cable

Main board: J2

Breakout board: Y

Y1 pin	50 pin	Function	Notes
1	28
2	21
3	N/C
4	N/C
5	22
6	19
7	27 etc
8	N/C
9	N/C
10	5
11	2
12	3
13	6
14	4

Main board

I did not pin this out directly since I don't need to interface it directly

Connectors:

J	Label	Notes
1
2	X	X1 motor, limit
3	Y	Y1 motor, limit
4	Z-ROT	N/C
5	Z-LIM	Into chassis
6	Z-MOT	Directly to NEMA 34 motor
7	THETA	N/C
8	-	X1 limit?
9	-	estop

Y1 ribbon cable

Main board: J3

Breakout board: Y

X1 pin	50 pin	Function	Notes
1	29
2	23
3	N/C
4	N/C
5	24
6	19
7	20 27 29
8	N/C
9	7
10	11
11	8
12	9
13	12
14	10

Y1 motor

Dataplate:

Superior Electric

SLO-SYN

SYNCHRONOUS/STEPPING MOTOR

TYPE: M061-LS02

OZ. IN: HOLD 60

RPM: SPEC BM101025

STEPS: 200

V: 5.0

A: 1.0

HZ: DC

CLASS A INSULATION

IMPEDANCE PROTECTED

X1 is probably identical

With breakout board rightside up pin 1 is at P2 right (on silkscreen)

P2 pin	Color	Function	Notes
1	Green		A1
2	White		AC
3	White-red		B1
4	Black		BC
5	Red		B2
6	White-green		A2

X1, Y1 breakout board

ASSY A1003958

has following connectors:

• • Y : "Y ribbon cable"
  • Upper right pin 1: on silkscreen and agrees with convention I was already using
  • Both X and Y board have label Y
  • P1: N/C. Ignore for now?
  • P2: motor. Has thicker traces
  • P3: limit switches?

Y pin	To	Function	Notes
1	P1.2
2	P3.3
3	P3.4
4	P3.6
5	P3.5
6	P1.4 P3.1
7	P1.3 P3.2
8	N/C
9	P2.1
10	P2.6
11	P2.2
12	P2.5
13	P2.3
14	P2.4

e-stop (white, black)

All are N/C

Pin	50 pin	Color	Function	Notes
1	47	White		Broken button side
2	48	Black
3	49	N/C
4	50	N/C

e-stop (green, blue)

to heater connector

HEATER

Pin	Color	Function	Notes
	Green	e-stop
	Blue	e-stop
	Black	chuck power
	White	chuck power

Goes to large loose brown connector near wafer chuck

VACUUM

Goes to t junction near front panel

• • To vacuum gauge
  • To switch

Not sure where goes from switch

I don't currently need the vacuum system but have no reason to rip it out. Leave it for now

Hoses could potentially tangle into Z1 drive but I could secure them if I eventually use Z1

THETA

Main board: J7

Pin	50 pin	Function	Notes
1	N/C
2	43
3	19
4	44
5	20 27 31
6	N/C
7	N/C
8	N/C
9	35
10	39
11	36
12	37
13	40
14	38

Z-LIM

Main board: J5

Pin	50 pin	Color	Function	Notes
1	26	Orange
2	19	Red
3	27 etc	Black
4	25	Blue
5	19	Red
6	27 etc	Black

X2?

Main board: J8

Pin	50 pin	Color	Function	Notes
1	25	Green
2	27 etc	Black
3	31	Yellow
4	19	Red
5	27 etc	Black
6	32	Orange

Z-ROT

Main board: J4

Pin	50 pin	Function	Notes
1	N/C
2	30
3	27 etc
4	19

Z-MOT

Main board: J6

Pin	50 pin	Color	Function	Notes
1	13	Green
2	17	White
3	14	White-green
4	15	Red
5	18	Black
6	16	White-red

2015-08-22

collating data

STAGE

Back 50 pin connector. Its not labeled but it is on the back of the hood enclosure

Per breakout board, pin 1 lower left, pin 2 upper left

Pin	Main Board	To	Function	Notes
1		X1.9 P2.1?	X1 motor? Opto: 5V	Missing from table but pattern indicates it should be here
2		X1.11 P2.2	X1 motor Step clock
3		X1.12 P2.5	X1 motor Ground
4		X1.14 P2.4	X1 motor Enable: N/C
5		X1.10 P2.6	X1 motor V+
6		X1.13 P2.3	X1 motor Direction
7		Y1.9 P2.1	Y1 motor Opto: 5V
8		Y1.11 P2.2	Y1 motor Step clock
9		Y1.12 P2.5	Y1 motor Ground
10		Y1.14 P2.4	Y1 motor Enable: N/C
11		Y1.10 P2.6	Y1 motor V+
12		Y1.13 P2.3	Y1 motor Direction
13				Z1 motor?
14		Z1-MOT.3	Z1 motor
15		Z1-MOT.4	Z1 motor
16		Z1-MOT.6	Z1 motor
17		Z1-MOT.2	Z1 motor
18		Z1-MOT.5	Z1 motor
19		X1.6 Y1.6 THETA.3 Z1-LIM.19 (red) X2?.4 Z1-ROT.4	+5V?
20		*	Ground
21		X1.2 P3.3	X1 limit switch?
22		X1.5 P3.5	X1 limit switch?
23		Y1.2 P3.3	Y1 limit switch?
24		Y1.5 P3.5
25		Z1-LIM.19 X2?.1
26		Z1-LIM.1
27		*	Ground
28		X1.1
29		*	Ground?	Y1.1?
30		Z1-ROT.2
31		% * X2?.3	Ground?
32		X2?.6
33
34
35		THETA.9
36		THETA.11
37		THETA.12
38		THETA.14
39		THETA.10
40		THETA.13
41
42
43		THETA.2
44		THETA.4
45
46
47		e-stop.1	e-stop
48		e-stop.2	e-stop
49		e-stop.3	N/C
50		e-stop.4	N/C

V+

What would it take to determine this?

• • Can I make a schematic of any of the opto boards?

Likely 5V

OEM650 motor test

Materials:

• • Benchtop power supply (want current monitoring)
  • Slo-syn motor
  • OEM650 driver
  • Sparkfun level shifter?
  • TODO: verify that OEM650 actually can't take 3.3V

Resistor config?

• • "V: 5.0, A: 1.0"
  • Series configuration
  • Jumper 1 removed
  • 1.0A: 18.2k
  • 2.0A: 3.57k

Wiring?

• • pg 13
  • Figure 2-2. NEMA 23 Size OEM Motor Wiring—Series & Parallel
  • LCR meter (old)
  • Single: 9.5 mH
  • Series: 36 mH

2015-08-23

Waiting for LCR meter to replace questionable 875B

Wiring up in preparation though

2015-09-17

Testing rewired OEM-650's

Using half motor to favor speed over torque (lower inductance but doesn't use the entire coil). if its not enough power I'll switch to using full motor. In part this should be lower power consumption

Microstepping: I was using 10,000 on pr0nscope. Start with that? pg 27 says default (reccomended?) 25,000?

Jumper config:

Jumper	Function	Pos Test	Pos Final	Notes
JU1	Motor current range	Off	Off	pg 15 Off low range (0.83-2.5A)
JU2	Resolution	On	On	pg 27
JU3	…	On	On
JU4	…	On	On
JU5	…	On	On
JU6	Waveform shape	Off	Off	pg 27 Sine wave
JU7	…	Off	Off
JU8	…	On	On
JU9	Auto standby	On	On	Full current
JU10	…	On	On
JU11	Auto test	Off	On

Quick disconnect power connector:

Pin	Function	Connect	Notes
1	REMOTE	N/C	pg 32 Can be used to disable motor by connecting to CURRENT
2	REF	…
3	CURRENT	18.2k 1/4W to REF	pg 15 18.2k 1.0A (w/ jumper #1 removed) Have 21.6k approx 0.87A
4	DUMP	N/C?	Least expensive resistor]] I could find ]
5	VDC+	+75V
6	VDC-	Ground
7	A+	Motor A1-green
8	A-	Motor AC-white
9	B+	Motor B1-white-red
10	B-	Motor BC-black

DB25 signal connector:

Pin	Function	Connect	Notes
1	Step+	BBB 5V buffer	pg 32 Minimum high-level output: 4.26V (Source 24mA)
2	Dir+	BBB 5V buffer	Maximum low-level output: 0.44V (Sinks 12 mA)
9	Fault+	N/C	pg 32 Not needed at this time long term connect to EMC e-stop?
11	Gear+	N/C	pg 33 Advanced usage
14	Step-	…
15	Dir-	…
16	Remote+	N/C	Pg 32 See above
17	Remote-	…
21	Fault-	…
23	Gear-	…

Successfully ran motor in test mode

BBB voltage boost

Need to convert from 3.3V to 5V per above spec

BBB breakout: https://www.adafruit.com/products/572]]

Logic level converter: https://www.sparkfun.com/products/12009]]

2015-09-10

Successfully tested BBB voltage boost X channel on standalone motor

Tested OEM650 drives and discovered only 2/4 are functional. Unclear if I broke these last time I used them or they were always broken. Discarded defective drives

Current strategy: use MDrive23 for X1, Y1. Use original motors with OEM650 for X2, Y2. Z1 will not be hooked up at this time but will still be accessible on connector if required. Only X1 and Y1 will be used in initial testing since stock BBB configuration only supports 3 axes

Working on polishing earlier tables to verify its safe to rewire X1, Y1 for completely different purpose signals. I'll then have to cut wires and solder in the MDrive23's.

X1, Y1 motor rewire

P2 pin	Orig color	New color	Function
1	Green	White	Opto
2	White	Orange	Step clock
3	White-red	Blue	Direction
4	Black	Brown	Enable
5	Red	Black	GND
6	White-green	Red	V+

50 pin table updated with this in mind

2015-09-13

Both X1 and Y1 MDrive23 motors have been integrated and tested

Made a second BBB 5V cape and tested X and Y successfully. Z pinout non-intuitive and made bad assumption. Need to make a more custom config and/or review CRAMPS config

CRAMPS pinout

P8

Pin	CPU GPIO	CNC function	I/O	Note
07	gpio2[2]	X max	I
08	gpio2[3]	X min	I
09	gpio2[5]	Y max	I
10	gpio2[4]	Y min	I
11	gpio1[13]	FET 1 : heated bed
12	gpio1[12]	X dir	O
13	gpio0[23]	X step	O
14	gpio0[26]	Y dir	O
15	gpio1[15]	Y step	O
16	gpio1[14]	eMMC Enable	O
17	gpio0[27]	estop	I
18	gpio2[1]	Z dir	O
19	gpio0[22]	Z step	O
26	gpio1[29]	estop out

P9

Pin	CPU GPIO	CNC function	I/O	Note
11		Z max
12		E0 dir
13		Z min
14		Axis enable
15		FET 2
16		E0 step
17		E1 step
18		E1 dir
21		FET 4
22		FET 6
23		Machine power
24		E2 step
25		LED
26		E2 dir
27		FET 3

Seems relatively complete with the notable issue that only XYZ have limit switches (E0/E1 do not). Probably not worth it to diverge from this where not needed. E0 and E1 will become X2 and Y2. TODO: figure out where limit switches should go

Limit switches

Confirm that limit switches take 5V. Is there a part or something I can read to confirm this?

Test them

Boards have a single part:

IUGN

3140U

230

http://pdf1.alldatasheet.com/datasheet-pdf/view/168545/ALLEGRO/3140U/+0WJ55JVYIK.HTS+YtCNd+/datasheet.pdf]]

• • 4.5 - 24V
  • 20 mA max open collector

Successfully fired laser!

2015-09-14

Step calibration

1000 steps = 0.001" 1,000,000 steps per inch…

20 TPI, assume 200 step steppers 4,000 real steps per inch 250 microstepping?

• • 250 * 200 = 50,000 steps per rev
  • This is a legal stepping value

What is the fastest step rate the BBB can generate? Is this going to be problematic?

BBB stepgen limits

latency-test by itself will just report soft stepping. How can I measure the PRUs?

Figure 6.1 Step /direction signal timing……………………………………………6-3

• • Step high: >= 100 ns
  • Step low: >= 100 ns
  • Dir: 50 ns setup time to step rise
  • Dir: 100 ns hold time to step (must be held during entire step?)

http://linuxcnc.org/docs/html/man/man9/stepgen.9.html]]

• • stepgen.N.steplen u32 rw: The length of the step pulses, in nanoseconds. Measured from rising edge to falling edge.
  • stepgen.N.stepspace u32 rw (step types 0 and 1 only) The minimum space between step pulses, in nanoseconds. Measured from falling edge to rising edge. The actual time depends on the step rate and can be much longer. If stepspace is 0, then step can be asserted every period. This can be used in conjunction with hal_parport’s auto-resetting pins to output one step pulse per period. In this mode, steplen must be set for one period or less

Calibration test: https://www.youtube.com/watch?v=6010s7QhAiw]]

Laser ablation tests

Material	Wavelength	Power	Objective	Result	Notes
Anodized Al (black)	532	Max	Mit20x	No noticible result unntil ~8 shots
Anodized Al (black)	532	Max	MitNUV50x	First shot

2015-09-17

Yesterday's cnc_microscope tests significantly increased BBB step rates (possibly to unreliability). Use those results to make a reasonable speed first cut at brainscope XY configuration

Do I need to order a power supply or can I use the Compumotor 75V supply for both the OEM650 and the MDrive 23?

• • The MDrive 23 accepts a broad input voltage range from +12 to +75 VDC
  • Conclusion: use the 75V supply for both
  • 5V will be generated from BBB

About 300 mA per MDrive23 when moving

X axis not moving…what happened?

• • Most likely cause appears to be poor X1 ground wire between 50 pin ribbon cable and breakout board
  • Connector is a bit stressed…should I try to get another breakout board? Cost?

X and Y axis are now moving

X axis tests:

• • Cannot move very far left off center…not nearly the leadscrew length. Why?
  • When I move to crash position on right it cannot by itself get moving again
  • Right now I can cheat by reaching under and moving it slightly to unstick it
  • This may be a good reason to up priority on supporting the limit switches
  • Should be sufficient for an initial laser bitmap

Next objective: get laser under Python control

• • Good place to start: [1]

Open issues:

• • Fine focus knob still falling off. Need to figure out how to torque it better, using locktite if necessary
  • Laser aperature alignment poor at 50x: only cuts lower left half of unmaked area. Perfect at 20x
  • Monitor 50 pin ribbon cable reliability

2018-06-05

motor M061-LS02 [2] type: LEADS typical step time: 2.5 ms nominal volts: 5 V bipolar series A per winding: 0.7 A H per winding: 38.3 mH Hold torque: 60

Rorze RD-021M8 resistor value Ir = 0.7 A Full step: I = Ir = 0.7 A Microstep: I = 1.414 * Ir 1.414 * 0.7 = 0.9898 = 1.0 A

X ={I/(0.1108×Ir+0.66)} 0.7 / (0.1108* 0.7 + 0.66) = 0.949075329 = 0.95 1.0 / (0.1108* 1.0 + 0.66) = 1.3 R = 8.2×X/(8.2-X) 8.2 * 0.95 / (8.2 - 0.95) = 1.074482759 = 1.1 8.2 * 1.3 / (8.2 - 1.3) = 1.5

2018-06-27

Effort to overhaul control system, especially for upper XY

Rorze RD-021M8 resistor value: 1.5 ohm?