v4.0.0 - REV05 Motherboard, Control Box, Dual Drag Chain

v4.0.0 is an overhaul release with tons of new features and improvements.

Summary

All of the pneumatic and electronic components have been removed from the staging plate, and moved into a control box on the side of the machine. This makes mounting PCBs and strip feeders much easier, and the enclosed pneumatics make operation much quieter.

The control box now houses the all new REV05 motherboard. Almost completely SMT, this controller now has a dedicated driver for the second Y motor, meaning that v4 can move over 300% faster than v3.0. It also has dedicated stepper motor drivers, meaning better control over thermals and current sensing. All power electronics have been overhauled for much higher and stable current capacity.

We've switched back to limit switches for X and Y homing, now on a custom board near the X motor. The Z limit switch is also custom now, with an AUX port for extra peripherals. There's a dedicated cable chain for both the X and Y axis. Cable management is greatly improved for the machine as well.

CAD Updates

• Control Box
  • Almost all mounting hardware for electronics and pneumatics have been integrated into a single control box.
  • Tool-free valve and pump mounting
  • Complete vibration isolation for both pumps
  • Cover has flexure buttons that allow much easier BOOT and RESET operation
• Cabling
  • Both the X and Y axis now have dedicated drag chains
  • X drag chain has a dedicated structural PCB for reducing sag across the build area
  • All moving cabling are now full silicone-sheathed
  • The new cable-splay print cleanly distributes cabling and pneumatics to both nozzles
• Bottom Camera
  • The bottom camera is completely new, with a wider field of view, and improved driver chip
  • The bottom camera mount has been shifted to accommodate the new wide-angle lens for the bottom camera
  • The staging plate foot is now attached with two thumbscrews, removing the chance of the foot falling off
  • The staging plate foot now comes to more of a point, removing the chance that it gets caught at an angle.
  • The bottom light diffusion has been greatly reworked to allow for better printing, even diffusion, and minimal occlusion of the bottom camera.
• Top Camera
  • The top camera is completely new, with a wider field of view, and improved driver chip
  • The top camera and top ring light are now held into x-gantry-back with a single print, making them much more rigidly integrated into the head
  • Improved thermals for the top camera, allowing better airflow during head movement
• Misc
  • The X and Y axis are now homed with the XY limit switch board, removing sensorless homing
  • The Z limit switch has been replaced with a custom PCB that also breaks out an AUX port
  • Nozzle masks are now included on both nozzles, helping isolate the background during machine vision operations

REV05 Motherboard

• Second driver dedicated to the Y axis
• Full test point coverage on the bottom side of the PCB
• Full XYZ limit switch support
• Almost fully SMT (closes #696 )(closes #703 )
• DIAG pins from all stepper drivers are still attached to the STM32 for future software updates that allow for stall detection
• Complete redesign of power electronics providing a much higher current capability on the 5v rail for future applications (closes #708 )(closes #665 )
• Voltage indicator LEDs are now present for all three bus voltages
• BOOT and RESET pins on the STM32 are broken out for external firmware flashing
• Full ESD protection on all exposed pins (closes #698 )
• Fully integrated stepper motor drivers for better thermals, reliability, and current sensing capability (closes #697 )(closes #704)
• Refined AUX port on the motherboard for additions and modifications
• Aux pin broken out to the Z limit switch PCB
• An optional fan port has been added, although not needed in operation
• A buzzer has been added
• "Chimera" jumper allows software to determine via GCode if the LumenPnP it's controlling is stock, or needs more customized configuration
• Hardware ID pullup resistors allow software to determine LumenPnP hardware version via GCode (closes #707 )
• Solenoid valve control pins have been moved to hardware PWM pins on the STM32 to allow for lower current operation (closes #701)
• The diode that allows USB VBUS to power the STM32 is now DNP by default, as this caused issues with boot sequence in the REV04 motherboard (closes #719 )(closes #666)

This machine is the result of hundreds of talented and enthusiastic folks, both at Opulo and within our community. Thank you to everyone that has contributed to making the LumenPnP v4 the incredible machine that it is. In particular, I'd like to thank all members of the review-squad that helped with the REV05 motherboard design, Thea Flowers, Justin Nesselrotte, Gonçalo Pereira, Stuart Pittaway, and David Smith.

v3.2.2 - Mobo D1 DNP and CAD Tweaks

What's Changed

• The motherboard now has D1 set to DNP (do not populate) for the following reason:
  • D1 allows the 3v3 rail to be powered from USB VBUS. However, the stepper motor drivers are not powered by VBUS.
  • If USB power is applied before main power, the STM32 will boot and send configuration data to the steppers, but the steppers are not powered to receive it. When the stepper drivers are eventually powered, they are incorrectly configured.
  • Removing D1 prevents this problem, and requires barrel jack power for communication to the machine.
• The nozzle rack has been adjusted to be slightly shorter to provide more clearance for the top camera lens.
• Nut pockets have been slightly adjusted to facilitate a better press fit.
• As of v3.2.1 the LumenPnP's CP40 nozzle holder is now an open source part known to Opulo as nozzle-holder that is compatible with the CP40 nozzle standard.
  

CI Improvements

• Update FreeCAD to 0.21.2 by @G-Pereira in #713
• FIx STL artifacts zip inside zip by @G-Pereira in #682

Additional Notes

• This release intentionally skips v3.2.1
  • v3.2.1 was nothing more than the results of #721, so a public release of this version was skipped while we awaited more publically relevant design changes to land.

Full Changelog: v3.2.0...v3.2.2

v3.2.0 - Introduces Feeder Slot Blades and Improves Software Configs

What's Changed

Improvements:

• FDM part changes:

  • x-gantry-front
    • switched to using M3x12-self-tapping-screw for installing z-axis linear rail and z-limit-switch
  • y-gantry
    • tightened M5 hex nut pocket fit
  • nozzle-rack
    • removed top ribs to improve z-clearance
    • updated mounting bolt channels to reduce likelihood of M3x10-hex-head free-spinning during installation
  • static-camera-foot
    • added bumps mounting socket for tightening fit to bottom-camera-mount
  • mobo-top-cover
    • Added detents to boot and reset button to improve UX
  • feeder-slot-bracket
    • See below

• OpenPnP Config

  • Certain settings are changed to make setup smoother
    • Nozzle tips N045 and N24 are set to not auto calibrate after homing to not confuse first time users
    • Homing fiducial is not set to scan after homing to simplify setup process
    • Both nozzles do not have tips installed by default
    • Docs are updated to reflect these changes, and walk the user through configuring these settings
  • GCode macros are updated to reflect new speed, acceleration, and homing settings

• Feeder slot overhaul:

  • Consolidates the 50x individual feeder slot pieces into 4x subassemblies to reduce assembly time
  • These subassemblies are made from 2x unique 3D prints and 4x unique PCBs
  • Adds design files for new slot blade PCBs to source
  • This new version of the feeder slot is fully backwards compatible with all existing feeders

Bug Fixes:

• Changes sensorless homing settings in Marlin release for much more consistent homing
• Updates method of polling vacuum sensors for quicker response

Full Changelog: v3.1.2...v3.2.0

v3.1.2 - Introduces Standardized Strip Feeders & Misc Improvements

What's Changed

Improvements:

• Strip Feeder Standardization by @lucian151 in #685
• Updates front-left-leg to Use M5 square nut by @lucian151 in #687
• Introduces x-cable-chain-guide-alt by @lucian151 in #690

Bug Fixes:

• Closes #688 with commit b62a0df
• Partially addresses #686 by adding a note in BOM.CSV with commit b62a0df

Additional Notes:

• This release intentionally skips v3.1.1
  • v3.1.1 was nothing more than the results of #687, so a public release of this version was skipped while we awaited a machine version that shipped with the new strip feeder design

Full Changelog: v3.1.0...v3.1.2

v3.1.0 - Introduces Linear Rails

Adds linear rails to LumenPnP x-gantry and y-gantries

Merges @theacodes's linear rail mod with the following improvements:

• Consolidates toolhead 3D prints by merging the x-gantry-block design into x-gantry-back
  - x-gantry-front now attaches directly to x-gantry-back with 4x M5x40mm-socket-head bolts to greatly improve rigidity
• Adds insertion clearance for installing m5-hex-nut into y-gantry

Extends height of machine by 50mm

This change was made to improve tape clearance when exiting auto feeders. Affects the following parts

• aux-staging-plate-foot
• static camera foot
• front-leg-extension (new)
• back-leg-extension (new)
• front-left-leg / front-right-leg
• back-leg

Improves machine toolhead

• Rotates toolhead motors 90º to improve cable routing
• Adds zip-tie channel in z-gantry for toolhead cable strain-relief
• Updates pneumatic coupler to rotary-pneumatic-adapter to support continuous toolhead rotation

Improves top-camera assembly

• Adds a tunnel around the focus-adjustment-screw for ease of use

• Adds air flow vents to top-camera-mount to improve cooling

• Adds top-camera-cover to better protect top-camera

• Adds new region to top-light-cover to cover top-ring-light THT pins

  

Additional changes

• Updates nozzle-rack to support tool-free removal from staging-plate with use of 2x m3-wing-nut
• Adds mid-air hole print optimizations wherever needed
• Adjusted various component tolerances for ease of assembly
• Smoothed out many parts in this assembly where possible to better unify design language
• Update mobo schematic with part numbers and ratings by @theacodes in #664

Full Changelog: v3.0.5...v3.1.0

v3.0.5 - Feeder Support, Improved OpenPnP Configs

This release is the first LumenPnP release with Photon feeder support! The OpenPnP config files included in this release assume an OpenPnP build that supports Photon feeders. The attached LumenPnP firmware files also have Photon feeder support.

More information about Photon Firmware can be found here.

Full Changelog: v3.0.3...v3.0.5

v3.0.4

What's Changed

• Updates LumenPnP to include rubber-feet attachment features for the two styles of staging plate feet by @lucian151 in #657
  • Added flat bottom static-camera-foot w/divot for rubber-feet
  • Added flat bottom aux-staging-plate-foot w/divot for rubber-feet
  • Converts aux-staging-plate-foot to use a side-inserted m3-square-nut, rather than an m3-hex-nut
  • Updates BOM accordingly

Full Changelog: v3.0.3...v3.0.4

v3.0.3

What's Changed

Improvements:

• Switches to M3 square nuts in 12 locations to improve the LumenPnP assembly process
• Updates the pump-mount design to support using m3-square-nut
• Rotates the tensioner-arm's M5 hex nut pocket on front-left-leg and front-right-leg to improve strength
• Introduces rubber-feet to the machine design
• Adds recesses to all legs to locate the rubber-feet properly
• Updates mobo-top-cover to improve legibility of the Boot and Reset text
• Updates mobo-top-cover to eliminate the tiny slots TMC2209 aux pin headers used to pass through
• Adds white PLA to BOM to reduce usage of PETG

Bug Fixes:

• Updates fastener counts after performing an audit

Full Changelog: v3.0.2...v3.0.3

v3.0.2

What's Changed

Improvements:

• Updates extrusion-cable-clip to work with a 0.6mm nozzle
• Updates toolhead top-camera-mount and top-light-mount to create access to focus adjustment screw on top-camera, closing issue #600
• Flips LH/RH letters found on y-coupler-bracket
  • This was done so that the vacuum lines don't need to twist before passing into the motherboard strain relief notches

Bug Fixes:

• Fixes BOM and assembly to use M3x10 rather than M3x8 for mounting the nozzle-rack
• Fixes BOM to have correct length of pneumatic-tubing-6mmOD

Full Changelog: v3.0.1...v3.0.2

v3.0.1

What's Changed

• Updated toolhead assembly to allow for adjustable z-limit switch position
• Updated tolerances of various FDM parts
• Implemented minor DFM improvements for y-gantry to create additional clearance between components

Full Changelog: v3.0.0...v3.0.1