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Controller Board for DIY Pick place Project
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Please be positive and constructive with your questions and comments.

Controller Board for DIY Pick place Project

by alphatronique on Sat Oct 30, 2010 11:35 am

Hi all

just for let us knot i doing now a hardware controller board for pick place
it primary designed for drop in upgrade of Zevatech 360/460
but it may used as well on DIY project or other machine upgrade
Hardware design + some of firmware driver will available as opensource

this was board description

Cortex-M3 based cpu LM3S9b96 ,LM3S808 (20 TTL input ,8 TTL out ,8 coil-driver)
1-)Conaxsat Wi-Fi module
1-)Eternet Port
1-) SD card socket
1-) RS485
1-) Canbus

Board will control low level state machine and communication
and pc side will only send feeder no. /final placement X,Y position / moving speed
all other will handled by controller board

first prototype batch will available sometime next week

also i still looking for a pc side vision (part centering) solution

Best regard
Marc L.
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Wed Nov 03, 2010 10:45 am

HI all some news on the project

first batch of PCB will come from PCB shop late this week ;-)
so i will able to test the beta firmware

and i finally find suitable and reliable vision solution it based
on congex system just like some of manncop ,aps-gold ,essemtech, etc etc ....
ok most of that system use it end end product that way to much for diy
but it have self contained camera/cpu the sell for 2500$ (got for 600$ on e-bay)
it come whit limited function but it have the essesial for what need
like find fiducial , and measure part dimension ,rotation (some model not have measure tool)

update: 8/11/2011
just got on ebay a used cognex 3400 system for 450$
i have play whit simulator and this system was good for fiducial
it not got confuse whit near via ;-) next step was to calibrate from pixel to millimeter
result output was send over RS-232 to PC or direct to Pick place controller

note that in this test i use 2 different algo 1 was "find circle" ,and 1 was "trained image"
result was close to +/- 5 pixel i planing to use trained image for start then "find circle" for fine position

Best regard
Attachments
vision_test.JPG
Vision Test on cognex simulator
vision_test.JPG (63.52 KiB) Viewed 9006 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Sun Nov 21, 2010 5:59 pm

Hi

ok i got some time for assemble board and take some more picture

next step was firmware Test but it may have some delay i really busy now

on picture it have original board that contain only buffer since "Brain" was on the PC
on the new one big part of brain was now on the machine itself

you may notice that on new board lot of wire was no more used since it was for drive conveyor
and i not have pass-troug option on any of my machine so it not implemet it

Best regard
Marc L.
Attachments
zeva_isnt.jpg
board nistalled on machine
zeva_isnt.jpg (254.53 KiB) Viewed 8922 times
zeva__juki_board.jpg
old board whit new one
zeva__juki_board.jpg (329.88 KiB) Viewed 8922 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Fri Nov 26, 2010 9:19 pm

Hi

ok i receive the vision system the good news is that real hardware was better that simulator ;-)

this was quick test for fiducial finding and report position ,it also dump screen shot to a ftp

valid via have score of > 70

next big step whit vision was to make a switch box for handle 2 camera
cable have gnd ,vcc, bias ,and 2 diff pair (clock ,data) so my idea was to put all in parallel
and switch only the data pair so one camera will serve for fiducial and second one for bottom vision

next step ,next week
Attachments
cognex_vision.gif
fiducial test V1.0
cognex_vision.gif (542.13 KiB) Viewed 8869 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Wed Dec 22, 2010 4:27 pm

Hi

vision system programing was done for bottom vision /top vision
and all camera fitted on machine

after long reflection we found a way to locate part center by averaging all pin x,y cordinate
this solution need only to train for pin type not part type
on some part like so-23 will need some hard-coded ofset since it odd pin number

controller pcb was finis to debog and version 1.02 was on the way for add/move some function

during Xmas holiday we will begin test the labview PC side software
Attachments
center.JPG
center.JPG (31.3 KiB) Viewed 8766 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by adafruit on Wed Dec 22, 2010 5:15 pm

this is very nice!

adafruit
 
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Location: nyc

Re: Controller Board for DIY Pick place Project

by dandumit on Thu Dec 23, 2010 6:00 am

Very interesting. I have tried to do the same. But it seems that I have started on a wrong path.
I was trying to use a webcam and some dedicated libraries for this matter. I am progressing very slow.
Could you please give us some more details about software used to detect parts ? I mean finding position , rotation.
It's the SDK from Cognex ?

Kind regards,
Daniel
dandumit
 
Posts: 1
Joined: Thu Dec 23, 2010 5:55 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Thu Dec 23, 2010 11:02 am

Hi

i must agree that since i use that pick place for commercial job i have try to use short patch possible whit a good budget
buy a manncorp will cost me over 22k$ and i will end up whit machine that was more delicate that my "tank" zevatech
and i will lost all my feeder and not to forgot that i may buy zevatech feeder for under 100$ so i chose to put the money
of the manncorp into major rebuild of my 3 zevatech :mrgreen:

i use cognex in-sight 3400 vision controller cognex will used on most modern machine (it use same base for pc hosted solution)
it a fully hardware solution so no pc need since it display on vga monitor and use game pad as keyboard
a pc interface is also aviable
as programing it excel like spread sheet whit added vision component
new that box cost > 2000$ but i was easy to find on ebay under 600$ ,local cognex office quoted me 3500$ for current model
not all model have same feature so look for model 1000 ,3400, 4000 (patmax option was not mandatory)
keep away of model 1010 and 4100 it very low cost but it will not work for sure in pick & place

it also have a pc simulator for program off line ,look in archive for explorer version 3.3.3
http://www.cognexsensors.com/support/Do ... D=45,46,47

in simulator you able to bitmap or jpeg and test programing i put on ATTACHMENTS the image and programing
for bottom vision centering of fine pitch component up to 100 pin
plase note that on above image i have used 2 different algo one by finding corner pin and draw line and the new one by averaging cordinate
also the .job was text based except for pin image ,so it will help you to see how program it but it really easy

on the last you may already notice that English was not native for me ;-)

Best regard
and have ton of electronic goddie for Christmas
Attachments
botom_vision_V1.01.zip
(183.75 KiB) Downloaded 355 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Mon Jan 10, 2011 5:43 pm

hi

this week we have made working the motion controller firmware and test it
and hardware modification for the 0.18deg hear rotation was head rotation complete
all part was here and tester it just whait for firmware

Best regard
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by adafruit on Mon Jan 10, 2011 9:16 pm

we cant wait to see more video. this is the best thread on the forums!

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Posts: 12151
Joined: Thu Apr 06, 2006 4:21 pm
Location: nyc

Re: Controller Board for DIY Pick place Project

by alphatronique on Tue Jan 11, 2011 12:11 pm

HI

nice to knot that this tread was not boring :mrgreen:

this was original machine 3 year back before any modification
now it used as test stand for my modification
http://www.alphatronique.com\DSCF2338.banned

that was my second machine doing one of my product
you may notice the nice Text based GUI in dos :lol:
and that it quite really fast for a totally obsolete machine
http://www.alphatronique.com/labrie_assy.wmv

Best regard
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Tue Jan 11, 2011 12:51 pm

Hi

this was modification of placement head for precise rotation

original air actuator cylinder was removed whit associated air hose
and mechanical stopper was also removed
then custom bracket was made for hold HS-5085MG digital servo
whit a gear 48 pitch gear (PN:RSA48-HMG-24 from servo city)
please note that servo must ordered whit for 180 deg rotation
and i have removed 80mil of the original gear thinkness

this was link for the bracket cad data
http://www.alphatronique.com\Servo_bracket_gerber.rar

best regard
Attachments
Picture 026.jpg
Picture 026.jpg (32.16 KiB) Viewed 8552 times
Picture 025.jpg
Picture 025.jpg (21.51 KiB) Viewed 8552 times
Picture 023.jpg
Picture 023.jpg (30.81 KiB) Viewed 8552 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by glennsky on Wed Jan 12, 2011 6:54 pm

Are your hardware design files available for the LM3S9B96 based controller board? are they in Eagle or another format?
I have been considering what is possible for doing a DIY pick+place machine and have used the Luminary microcontrollers extensively.

Keep up the good work.

Merçi d'avance!
glennsky
 
Posts: 1
Joined: Wed Jan 12, 2011 6:46 pm

Re: Controller Board for DIY Pick place Project

by alphatronique on Wed Jan 12, 2011 7:31 pm

Hi

my design was make in p-cad 2002 and code was in #C on keil whit Freertos

i will made complete/tested /supported board available and really good price for sure
gerber/schematic.pdf and some low level start code available for free for all beta version
as for final .pcb /.sch and full source code i not knot yet
since i estimate that project will cost me at the end ~10K$ i will unhappy to see it
become part of commercial product and ppl make money from what i put free.

but i what to share as much as possible whiteout have complete turn key solution for free
and provide a field proven and solid starting base for diyer that what to do similar project

as for limited source code that come from it the most expensive part since i hire third party for made it
and some part of code was reused from other commercial project that have some license associated to it ..

also if your good at firmware dev i will happy to trade/work whit you

p.s. reset pin 5 of LM3S628 need to be tie to pin 6 ,and 9B96 replaced by 5749 since "no stock" status of b96

Best regard
et mercit baucoup
Attachments
ALPH1105.ZIP
Gerber + Schematic of beta 1.0
(370 KiB) Downloaded 347 times
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Re: Controller Board for DIY Pick place Project

by alphatronique on Tue Jan 18, 2011 9:14 pm

HI

ok the big part of Project was started so now we work on the pc side interface in Delphi
whit cad import etc etc so normally if all go good i will be able to place a part in ~4 week
the Test/Debog on motor motion controller was near done

and now it have guy on 4 country that work on that project USA,Canada,Indonesia,Vietnam :mrgreen:

the good thing is that also mean that i will release compiled firmware of the current version
probably next week

Best regard
Best regard
Marc Lalonde CID.
IPC Certified PCB Designer.
Alphatroniqe inc.
www.alphatronique.com
http://ca.groups.yahoo.com/group/MyData_Group

alphatronique
 
Posts: 231
Joined: Fri Jun 25, 2010 8:30 am

Please be positive and constructive with your questions and comments.