DEVELOPMENT OF 3D PRINTING

FRAMEWORK USING PC-BASED PLC

VINCENT HOONG YONG SHENG

A project report submitted in partial fulfilment of the

requirements for the award of Bachelor of Engineering
(Hons.) Mechatronics Engineering

Lee Kong Chian Faculty of Engineering and Science

Universiti Tunku Abdul Rahman

May 2018
 ii

DECLARATION

I hereby declare that this project report is based on my original work except for
citations and quotations which have been duly acknowledged. I also declare that it has
not been previously and concurrently submitted for any other degree or award at
UTAR or other institutions.

Signature :

Name : Vincent Hoong Yong Sheng

ID No. : 13UEB03027

Date : 15/04/2018
 iii

APPROVAL FOR SUBMISSION

I certify that this project report entitled “DEVELOPMENT OF 3D PRINTING

FRAMEWORK USING PC-BASED PLC” was prepared by VINCENT HOONG
YONG SHENG has met the required standard for submission in partial fulfilment of
the requirements for the award of Bachelor of Engineering (Hons.) Mechatronics
Engineering at Universiti Tunku Abdul Rahman.

Approved by,

Signature :

Supervisor : Dr. Tey Jing Yuen

Date :

Signature :

Co-Supervisor : Mr. Chong Yu Zheng

Date :
 iv

The copyright of this report belongs to the author under the terms of the
copyright Act 1987 as qualified by Intellectual Property Policy of Universiti Tunku
Abdul Rahman. Due acknowledgement shall always be made of the use of any material
contained in, or derived from, this report.

© 2018 Year, Vincent Hoong Yong Sheng. All right reserved.

 v

ACKNOWLEDGEMENTS

I would like to thank everyone who had contributed to the successful completion of
this project. I would like to express my gratitude to my research supervisor, Dr.
Yogeswaran a/l Mohan, Dr. Tey Jing Yuen and Mr. Chong Yu Zheng for his invaluable
advice, guidance and his enormous patience throughout the development of the
research.

In addition, I would also like to express my gratitude to my loving parents and

friends who had helped and given me encouragement and great support throughout my
process of undertaking the project research. More of that, I would also like to express
my appreciation towards Mr. Lim Kok Teong from JKS Engineering (M) Sdn. Bhd.,
Mr. Johnny Poh from Beckhoff Automation Sdn. Bhd. and Mr. Ren and Mr. Kevin
from Iconix Technology Sdn. Bhd. for providing professional advises in terms of PLC
programming knowledge throughout the project.
 vi

ABSTRACT

3D printing denotes to processes which material is fused and solidified under computer
control to construct a three dimensional object. It can produce complex objects directly
by using computer aided design. This technology has traditionally been applied by
large companies to perform rapid prototyping before production. Moreover, there has
also been a change to adopt the technology as customise printing solution in the recent
years. The advent of 3D printers that are capable of multi-material printing such as
ProJet MJP 5600 from 3D Systems has create a breakthrough that enables the users to
create product with different mechanical properties over its structure. However,
current multi-material printing solution only offers up to discrete selection of printed
material matrix in a single printing process. Therefore, this project intends to develop
a multi-material composite 3D printer that is capable in selecting wide variation of
material matrix for printing through a single extruder. The framework for interpreting
G-code generated and performing 3D printing process is designed and developed in
this project. To ensure accurate and reliable system, configurations and
experimentations are performed to measure the performance of the system. Accuracy
and reliability of the system are determined and proven based on the experimental
results obtained. Low accuracy and performance system will be calibrated based on
the system behaviour. Furthermore, this project also covers the techniques to link user
interface with system framework. System framework will have certain level of
flexibility of controls by the non-technical users via user interface. Critical status of
the system will also be linked from the system framework to user interface for users
to understand the system condition.
 vii

TABLE OF CONTENTS

DECLARATION ii
APPROVAL FOR SUBMISSION iii
ACKNOWLEDGEMENTS v
ABSTRACT vi
TABLE OF CONTENTS vii
LIST OF TABLES x
LIST OF FIGURES xi
LIST OF SYMBOLS / ABBREVIATIONS xiii
LIST OF APPENDICES xv

CHAPTER

1 INTRODUCTION 1
1.1 General Introduction 1
1.2 Importance of the Study 2
1.3 Problem Statement 2
1.4 Aims and Objectives 3
1.5 Scope and Limitation of the Study 3
1.6 Contribution of the Study 4
1.7 Outline of the Report 4

2 LITERATURE REVIEW 6
2.1 Introduction 6
2.2 Additive Manufacturing 7
2.3 Working Principle of 3D Printer 10
2.4 Temperature Sensor 14
2.5 Extrusion Process 17
2.6 System Controller 19
 viii

2.6.1 Programmable Logic Controller (PLC) 19

2.6.2 Microcontroller 21
2.7 Modular Programming 23
2.8 Human Machine Interface 23

3 METHODOLOGY AND WORK PLAN 25

3.1 Introduction 25
3.2 Applied Theories 26
3.2.1 Program Flow 26
3.2.2 Pre-processing Technique 27
3.2.3 Process Framework 29
3.3 Hardware Configuration 32
3.3.1 Circuit Wiring 32
3.3.2 Selection of Relay 34
3.3.3 Selection of Temperature Sensor 34
3.3.4 Thermocouple Cable Extension 35
3.4 Control Configuration 36
3.4.1 Motion and Scale Factor Configuration 36
3.4.2 Thermocouple Configuration 39
3.5 Human Machine Interface (HMI) 40

4 RESULTS AND DISCUSSIONS 44

4.1 Introduction 44
4.2 G-code Interpreter 44
4.3 G-code Functions 48
4.4 Hardware Configuration 49
4.5 Electrical Wiring 50
4.6 Human Machine Interface (HMI) 51
4.7 Motion Control 52
4.8 Temperature Control 53

5 CONCLUSIONS AND RECOMMENDATIONS 56

5.1 Conclusions 56
 ix

5.2 Recommendations for future work 58

REFERENCES 59

APPENDICES 63
 x

LIST OF TABLES

Table 2.1 Comparison between NTC thermistors, thermocouples

and RTDs 16

Table 3.1 G-code Description 29

Table 3.2 M-code Description 29

Table 4.1 “testpieces1.txt” extracted G-code at 11th & 12th

command 46

Table 4.2 “testpieces2.txt” extracted G-code at 11th & 12th

command 47

Table 4.3 Progress of Code Completion 48

 xi

LIST OF FIGURES

Figure 2.1 Fused Deposition Modelling 8

Figure 2.2 Stereolithography 9

Figure 2.3 Selective Laser Sintering 10

Figure 2.4 Simple Stepper Control 11

Figure 2.5 ‘Hybrid’ Stepper Control 11

Figure 2.6 Difference between Multi-axis Synchronisation and

Non-Synchronisation Motion 12

Figure 2.7 Linear Interpolation 13

Figure 2.8 Circular Interpolation 14

Figure 2.9 Graph of resistance against temperature for RTD and

various thermistors 16

Figure 2.10 Cross-section of a Single Screw Extruder 18

Figure 2.11 Extrusion Screw 19

Figure 2.12 Internal Architecture of PLC 20

Figure 2.13 Internal Program Flow of PLCs 21

Figure 2.14 Microcontroller Architecture 22

Figure 2.15 Model-View-Controller Setting and Message

Sending 24

Figure 3.1 General Program Flowchart 26

Figure 3.2 Program Flow of G-code Interpreter 28

Figure 3.3 G28 Program Flow 31

Figure 3.4 Control Panel Layout 33

Figure 3.5 Stepper Motor Electrical Schematic 36

Figure 3.6 Power Transmission Schematic of Axis Motion 37

Figure 3.7 Overview Architecture of HMI 40

 xii

Figure 3.8 Program Flow of File Reading Operation Interfaced

with HMI 42

Figure 3.9 Program Flow of Temperature Control Interfaced with

HMI 43

Figure 4.1 Hardware Structure of 3D Printer 49

Figure 4.2 Schematic Flow of End-Stop Limit Switch 49

Figure 4.3 Schematic Flow of Temperature Control 50

Figure 4.4 Circuit Connection of Control Panel 51

Figure 4.5 Human Machine Interface with ABS Temperature

Configuration 52
 xiii

LIST OF SYMBOLS / ABBREVIATIONS

3D Three dimensional
e.m.f Electromagnetic force
AM Additive Manufacturing
FDM Fused Depostion Modelling
SLA Stereolithography Apparatus
SLS Selective Laser Sintering
RAM Random Access Memory
HMI Human Machine Interface
SSR Solid State Relay
EMR Electromechanical Relay
AC Alternating Current
DC Direct Current
BJT Bipolar Junction Transistor
IC Integrated Circuit
CNC Computer Numerical Control
CPU Central Processing Unit
Gr Pinion to gear ratio, 1
𝑇𝑃 Number of teeth of pinion
𝑇𝐺 Number of teeth of gear
d Distance travelled by the pinion per rotation, mm/rad
dpp Pitch-to-pitch distance of the screw/auger, mm/rad
SF Scaling factor
𝑑𝑟𝑒𝑣 Distance travelled per revolution
RMSE Root Mean Square Error
n Number of readings
𝑦𝑖 Measured reading
𝑦̂𝑖 Actual reading
𝜔𝑚𝑎𝑥𝑝𝑖𝑛𝑖𝑜𝑛 Maximum angular velocity of pinion
𝑣𝑚𝑎𝑥𝑔𝑒𝑎𝑟 Maximum velocity of gear
𝑓𝑏𝑎𝑠𝑒 Base frequency
𝑓𝑚𝑜𝑡𝑜𝑟 Motor frequency
 xiv

𝑇𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 Measured temperature

𝑇𝑡ℎ𝑒𝑟𝑚𝑜𝑐𝑜𝑢𝑝𝑙𝑒 Thermocouple temperature
𝑇𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 Calibrated temperature
𝑒𝑎𝑐𝑡𝑢𝑎𝑙 Actual percentage error
𝑒𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 Calibrated percentage error
 xv

LIST OF APPENDICES

APPENDIX A : “testpieces1.txt” G-code sample 63

APPENDIX B : “testpieces2.txt” G-code sample 64

APPENDIX C: Part 1 Gantt Chart 65

APPENDIX D : Part 2 Gantt Chart 66

APPENDIX E : Z Axis Spacer Design 67

APPENDIX F : Experimental data of the translated motion

with 1.5625x10-4 scale factor 69

APPENDIX G : Experimental and Actual Data of the

Temperature Measured 70

APPENDIX H : Electrical Schematic Diagram 73

 1

CHAPTER 1

1 INTRODUCTION

1.1 General Introduction

There is an increasing demand for customising products to fragment the market

in the middle of the 1950’s (Kaplan & Haenlein, 2006). Consequently, in order to
facilitate the demand of more tailored products, business decisions were directed
towards a certain degree of customisation. The unprecedented 3D shaping abilities of
additive manufacturing have lately influenced areas as diverse as medicine,
anthropology and design (Kokkinis, Schaffner and Studart, 2015). To fulfil the need
of customisation, inventors have sought new fabrication techniques to increase the
flexibility in structure of an output product. One such emerging technique is 3D
printing. 3D printing is a process used to create a customised three dimensional objects
via extruding molten materials, cooling and solidifying it. It is often known as additive
manufacturing (AM) process.

Depending on the physical and chemical properties of the final printed products,
the materials used for 3D printing is selected. In some occasions, there are a need to
create product with varying physical or chemical properties over the product. Current
multi-material additive manufacturing systems have encountered severe shortcomings
of technology in achieving this condition (Sitthi-Amorn et al., 2015). The current 3D
printer technology can concurrently use, at most, only three different materials (Sitthi-
Amorn et al., 2015). More of that, the ideas of using multiple extruders can only
produce a discrete selection on the material properties. The hardware and software
architectures of the current multi-material 3D printers are exclusive and inextensible.
Therefore, this project intends to develop a 3D printers that is capable of printing
product with varying local chemical composition over the product. The general
methodology of the stated idea is by controlling the mixing ratio of two types of
materials with different matrix properties. Accuracy and reliability of the framework
are two important criteria to be considered before performing investigation and study
on the chemical fusion of the materials.
 2

1.2 Importance of the Study

The importance of the undertaking project is to propose and develop a new method of
3D printing where the mechanical, electrical, chemical and optical properties of the
output product can be controlled. This is achieved by modifying the mother matrix of
a material with different proportion of additive added. Depending on the mixing ratio,
a product with different properties can be produced. With a success in the respective
proposed method, a complex structure like badminton racquet which require a softer
texture on the gripper but rigid structure on the other parts can be easily produced.
Furthermore, this idea can also create a gradient transition over the mechanical
structure to reduce the maximum concentrated stress applied on the structure. Due to
time limitation, the project only be focusing on the framework development. In
summary, the importance of this project is to act as a stepping stone in the future
progress of constructing a 3D printer which allows variable material properties
printing with a single extruder.

1.3 Problem Statement

In the current 3D printing technology, the outcome of the printed products is almost
impossible to be possessed with different material properties over the products. This
often creates an issue especially on complicated products which requires to have mild
flexibility and soft texture over its product. A solution to this problem can be applied
by using a multi-material feeding 3D printer that is capable of multi-material mixing.
With the ability to print products that contained the composition of multiple materials,
the printer can provide an additional control over the local chemical composition of
the printed material.

However, a question remains on whether the multi-material feeding 3D printer

is capable of printing desired output products with different composition of material
over the product. To resolve this problem, the framework of the printer with close
consideration on the performance of the machine is developed. Electrical control
system of the printer is designed and constructed to ensure proper and stable
 3

connections for system to perform command and control operation. In addition, the
accuracy and reliability of the system are also investigated to ensure proper printing
operation. The parameters are fine-tuned to produce a machine with better accuracy.
Human Machine Interface is developed to interface the users with machine’s command
and response.

1.4 Aims and Objectives

The main aim of pursuing this development project is to construct a 3D printer

framework to innovate new techniques in producing a product with variable material
properties over its body. With a success in the respective research, a 3D printer
framework that is capable of perform correct motion positioning and temperature
measurement is created. In order to achieve this, three objectives had been clearly
stated out to achieve and extend the capabilities of the stated goal.

 Develop 3D printing framework and electrical system controls of the machine.

 Improve the reliability and accuracy of the printer prototype by performing

calibration on the machine.

 Integrate 3D printing framework with Human Machine Interface.

1.5 Scope and Limitation of the Study

The physical and chemical behaviour of the plastic pellets are the aspect of the 3D
printing which is essential in ensuring expected quality products. It is to be highlighted
that to understand chemical behaviour especially the chemical fusion of the two plastic
materials required high level of chemical fusion knowledge and many chemical
experiments to be done. All properties including the fluidity and the fusion rate must
be considered properly in order to ensure that the particular mixing ratio can be printed
out at the right moment.
 4

Therefore, the inadequate knowledge of material fusion behaviour became one

of the limitation for the study. The study of thermoplastic material is not involved in
the scope of this project. Other than that, with an open-loop control system of stepper
motor used, there will also be a slight inaccuracy being generated. In other words, there
can be tolerance on the distance travelled by the stepper motor as compare with the
expected distance.

1.6 Contribution of the Study

With the completion of this project, one essential contribution is the limitation of the
variety in printing material of a 3D printer. From the view of engineering, it helps by
providing information on the integrating process of the structure and the factor on the
printer that needs to be to be closely considered. From the view of end-users, this
technology paves a new and better ways of printing product. End-users without
professional technical knowledge will be able to print a high quality product with ease.

Furthermore, 3D printing technology can also be expanded to more fields with

the breakthrough on the limitation. For instance, the base of the shoes can be printed
with a harder bottom base and softer upper base to deal with floor impact while at the
same time provide comfort for users.

1.7 Outline of the Report

The main chapters that will be covered in this report will be the literature review and
methodology. Literature review summarises the relevant researches that had been done
on the 3D printing concepts, technology and their limitations. Fundamental 3D
printing concepts such as the control system, components required and the processing
techniques will be discussed in literature review.

The methodology will be discussed on the techniques used in constructing the

3D printer using the information that had been gathered through reviewing the
literature. Detailed plan of the designing and constructing of the physical structure and
 5

framework will be included. Electronics components selection and its arrangement

will also be considered in methodology chapter.
 6

CHAPTER 2

2 LITERATURE REVIEW

2.1 Introduction

Additive manufacturing (AM), colloquially recognised as 3D printing, is currently

being introduced as the spark of an innovative industrial revolution. The technology
permits one to make customised products without acquiring any cost penalties in
manufacturing as neither molds nor tools required (Weller, Kleer and Piller, 2015).
Many techniques has been proposed based on the AM technologies to extend the
capabilities to customised products. Fused Deposition Modelling (FDM),
Stereolithography (SLA) and Selective Laser Sintering (SLS) are methods that are
commonly used in current society to perform AM.

Each of the AM techniques have their unique specifications and pros and cons
in terms of cost, printing speed and structure of printed products. However, among all
the AM techniques mentioned, FDM is one of the most recommended method used
for rapid prototyping. One of the main factor leading to this conclusion is due to the
cost-effective printing operations and high speed printing. FDM perform its 3D
printing operation by heating up production-grade thermoplastics to glass transition
phase and extrude it on a platform known as heat bed according to the commands given
to the machine.

The temperature is set by using an electrically, usually pulse width modulated,

controlled heater to heat up the extruder for plastic to melt. Sensors are used to control
the temperature of the system by controlling the modulation sent to the heater based
on the temperature configured. It uses motors to move the extruder around a 3D
platform to print an object. To be more precise, depending on the situation, stepper
motors are usually used in FDM 3D printing due to its accurate motion. To further
enhance the motion accuracy of the printer, a higher step angle stepper motor or a
stepper motor with encoder closed-loop feedback controller is equipped.
 7

As mentioned in importance of this study, this project aims to develop a 3D

printer which is capable of printing product with varying chemical composition along
the product. The direction to achieve this is by feeding two different materials into an
extruder barrel to melt and fuse it based on the mixing ratio. In other words, the
extruder barrel acts as a path for fusing a new blend of material with different
composition to printed out. Temperature is increased along the extruder barrel towards
the nozzle to safeguard printed output quality.

Finally, controls and commands display are another important aspects to study
before proceeding into practical hands-on. Important information should be summarise
and displayed to speed up printing configuration and process. Data presentation is a
key focus when designing the user interface. Furthermore, techniques to interface
between back-end configuration and front-end user display is to be study. In conclude,
the data presentation and interfacing methods are to be reviewed.

2.2 Additive Manufacturing

AM is a manufacturing method which involves the fusing of materials, usually layer-

upon-layer, to construct objects from 3D model data (Mellor, Hao and Zhang, 2014).
The advantages of this methodology include removal of tooling requirements, new
design freedom and economically low volumes (Weller, Kleer and Piller, 2015). AM
was mostly used for fabrication of conceptual and functional prototypes which is also
known as rapid prototyping during its early years of invention. It suggested that AM
production can reduce waste, offers design customisation, has shorter lead times and
allows economical custom products (Holmström et al., 2010). There are several
technologies which employ this method of manufacturing such as fused deposition
modelling, stereolithography and selective laser sintering. However, AM technologies
are commonly limited to rapid prototyping as they do not allow matrix of the
engineering materials to be processed (Holmström et al., 2010).

One of the most commonly used methods of AM in nowadays 3D printing

technology is the FDM. This method builds parts with production-grade
 8

thermoplastics which are equipped with excellent mechanical, thermal and chemical
qualities as shown in Figure 2.1 (Sidambe, 2014). FDM technology produces 3D
object by heating and extruding thermoplastic filament over a platform from bottom
up, layer by layer ("Types of 3D printers or 3D printing technologies overview | 3D
Printing from scratch", 2018). Thermoplastic is heated to its glass transition
temperature by the printer and extruded out from the extruder nozzle onto a platform
along the calculated path. After the printed layer binds to the layer beneath it, the
plastic cools down and hardens. Once a layer is finished, either the platform is lowered
or the extruder is raised to proceed print on the next layer.

Figure 2.1 Fused Deposition Modelling

(Sidambe, 2014)

FDM utilises multiple extruders for printing different colours of materials

simultaneously. Furthermore, it also has good geometric accuracy and compact
machine structure (Negi, Dhiman and Kumar Sharma, 2014). However, FDM has its
limitations on the resolution of the printed products (Jose, 2014). The methods used
by FDM can often cause ribbing around the printed products. FDM also required
supporting frames to be printed under overhanging structures. Without a supporting
frames, the 3D printed product will deformed due to the lack of existence of printing
 9

platform. In short, FDM has good accuracy, compact machine structure, required
supporting frames for overhanging structures and limited printing resolution.

Similar to FDM, SLA is another techniques of AM. SLA creates 3D models in

a layer by layer manner using a method by which light causes the chains of molecules
to link and formed polymers, known as photopolymerization. A general idea of SLA
can be seen in Figure 2.2. SLA can produced high part building accuracy and smooth
surface finish (Negi, Dhiman and Kumar Sharma, 2014). Although SLA can be used
to create virtually synthetic design, the photopolymers resins which is used as a
printing material is often expensive (Ngo, 2015). Apart from that, the post-processing
time is usually longer than the common AM techniques for SLA (Negi, Dhiman and
Kumar Sharma, 2014).

Figure 2.2 Stereolithography

(Kerns J.,2015)

Lastly, SLS utilises the AM technology by using a laser to selectively scan and
sinter thin layer of powder particles. To summarize the working principle of SLS, the
powder in a container is swept upon the construction stage by a recoater. Then, a laser
selectively scans through the thin layer of powder, sintering the powder particles
together. The build platform is then lowered by one layer depth and a new coat of
powder is applied by a recoater as shown in Figure 2.3. The advantages of SLA
includes the capability to use wide variation of thermoplastics, no necessities for
support structure and it is easy for post-processing (Negi, Dhiman and Kumar Sharma,
 10

2014). This allows intricate and complicated geometries to be constructed easily.

However, similar to SLA, the cost of a machine is pretty steep.

Figure 2.3 Selective Laser Sintering

(Kerns J., 2015)

2.3 Working Principle of 3D Printer

Stepper Control System for 3D Printer

The main control system that required close consideration is the motor selected for the
axes and extruder. There are essential in ensuring accuracy. The most frequently used
system in 3D printer world is the simple stepper control where the system is an open
loop unit driving the stepper motor. Figure 2.4 shows a clearer picture on the operation
of simple stepper control (Reprap.org, 2017).
 11

Figure 2.4 Simple Stepper Control

(Source: Reprap.org, 2012)

Another type of stepper motor which is known as ‘hybrid’ stepper control is

less commonly used in 3D printing. This ‘hybrid’ stepper control operate with a similar
function as compare to the simple stepper control but with an additional sensor which
constantly provides information about the effective movement. The ‘hybrid’ stepper
control can be understood much further by referring to Figure 2.5.

Figure 2.5 ‘Hybrid’ Stepper Control

(Source: Reprap.org, 2012)

Stepper motors are used to drive the dynamic motion of the machine. In many
automation problems and machine control, there could be two or more axes of motion
that must be coordinated (Automation.com, n.d.). The terms “multi-axis
synchronisation” refers to the techniques used to achieve control of motion and the
motion requires for coordination (Kim et al., 1996). When there are two or more axes
 12

of motion are executed in a single operation, the machine is commissioning multi-axis

motion. The axes may be working individually or moving together.

Multi-axis synchronisation is necessary whenever the axes are required to

move together. The relationship between their respective motions can be important.
The most familiar example of the multi-axis synchronisation application is the X-Y
Plotter. The motion at the X and Y direction may move individually from each other
but their motion must be coordinated. Figure 2.6 shows the problems encountered to a
45 degree straight line if the X axis starts and ends its motion later than the Y axis. The
synchronisation based on position and velocity relationship between the axes are
important for proper operation of the machine (Automation.com, n.d.).

Figure 2.6 Difference between Multi-axis Synchronisation and Non-Synchronisation

Motion
(Source: Automation.com, n.d.)

G-code Interpreter

3D printing is performed via a combination set of skills in mechanical, electronics and

programming. To command a stepper motor we need a way to easily turn our human
desires into machine instruction into stepper motor steps (Dan, 2013). In effect we
need our robot brain to be interpreter. For the 3D printer, it uses a machine instruction
known as G-code to allow the machine to understand and perform the command
operation. G-code is one of the many interpreters that has been used for human-
machine communication (Shin, Suh and Stroud, 2007). It consists of an uppercase
letter which is the action command followed by a number which is the value used for
either action command or position declaration (Shin, Suh and Stroud, 2007).
 13

Each line of G-code tells the machine to execute one discrete action, including
position, rotation and velocity (Rapid S., 2016). Shapes are formed by stringing
together point-by-point sets of instructions (Shin, Suh and Stroud, 2007). All the
commands are usually read as a string without information understood by the machines.
Parsing and extraction of information are required in order to allow the machine to
understand the steps or procedures and the actions to be made in every step. The
interpreter should be flexible in interpreting all variety length of commands and able
to extract the relevant details.
One example of G-code that is commonly used for motion control is the G01
which is linear interpolation. G01 executes a movement following a straight line at a
set feed rate as shown in Figure 2.7. The feed rate that is programmed into the G01
command is the actual feed rate along the proposed tool path rather than the feed rate
of each axis (CNC Machining Handbook, 2010). On motion that involved two or more
axes movement, all the slides have to execute exactly the same length of time in order
to generate a single vector move. The machine controller will calculate the separate
feed rate of each axes, allowing the vector feed rate to be equal to that stated in G01
command.

Figure 2.7 Linear Interpolation

(Source: Denford G and M Programming for CNC Milling Machines, n.d.)

Circular interpolation is also one of the common G-code command that is used
for CNC control. G02 and G03 are clockwise and counter-clockwise circular
interpolation commands (CNC Machining Handbook, 2010). The letters I and J are
 14

addressed to program an arc motion. I relates to the address of X and its incremental
value and direction from the initial point of the arc on the X axis to the arc centre as
shown in Figure 2.8 (Denford G and M Programming for CNC Milling Machines,
n.d.).. J relates to the address of Y and is the incremental value and direction from the
initial point of the arc on the Y axis to the arc center (Denford G and M Programming
for CNC Milling Machines, n.d.).

Figure 2.8 Circular Interpolation

(Source: Denford G and M Programming for CNC Milling Machines, n.d.)

2.4 Temperature Sensor

Temperature sensor is mainly used in temperature control application within a system.

There are various types of temperature sensor being introduced and the selection of
type of temperature sensor also depending on the application requirements. Negative
temperature coefficient (NTC) thermistor, resistance thermometer detectors (RTD),
thermocouple and integrated silicon sensors are a few of the typical temperature
sensors that are used in circuits. Trade-offs amongst these devices include cost to
operate, stability, operating temperature range and noise immunity (Ametherm, 2017).
Stable devices will yield lesser output signal drift over time as compare to the unstable
devices which reduces the need for repeat calibrations.

Thermocouples are inexpensive, operate over a wide range, stable, rugged, and
are relatively linear over a wide range but deviate significantly at extremely cold or
 15

hot temperatures. A thermocouple adhere the Seeback effect to generate voltage that
correlates to the temperature. To improve the accuracy of a thermocouple, a controller
equipped with a Seeback coefficients and look-up table of thermoelectric voltages is
required to generate linear signal. Thermocouples also have a faster response time as
compare to NTC thermistors followed by RTDs (Brei T. M., 2013).

RTD elements have a varying resistance value depending on

temperature change. RTDs are offered in several different kinds of metals which
includes nickel, platinum, nickel-iron and copper. The platinum RTD is the most
accurate temperature sensor of all types of other sensors. RTDs have a better accuracy
and repeatability as compare to thermocouples and it is easier to be calibrated (Brei T.
M., 2013). Platinum RTD is stable, can covers a wide range of temperature,
demonstrates good noise immunity and has excellent repeatability and linearity (Heath,
2016). However, it is very costly to purchase and apply platinum RTD unless the
measurand condition is critical. More of that, RTDs required stable current for accurate
measurement of the resistance value.

Thermistors are temperature sensitive resistors which are known for a rapid
response. Resemble to RTDs, thermistors also have a varying resistance value
depending on the temperature change and require excitation. Thermistors generally
have higher resistance value as compare to RTDs. Therefore, it is operated under lower
reference currents and thus required lesser energy consumption. NTC thermistor
usually has a temperature drift of lower than 0.2 ֯C per year while thermocouple has a
lower stability which gives a 1 ֯C to 2 ֯C temperature drift per year (Ametherm, 2017).
However, thermistors do not have good linearity between temperature and its
resistance value. In result, a look-up table or equation is needed to interpret the
temperature values in relation to the output. Figure 2.9 shows a comparison graph of
resistance against temperature between various thermistors and platinum RTD.
 16

Figure 2.9 Graph of resistance against temperature for RTD and various thermistors
(Source: Texas Instruments)

Lastly, integrated silicon sensors are semiconductor temperature sensors that

measure and identify its temperature based on temperature-dependent relationship
between the collector current of a BJT and the base-emitter voltage. It is easily
integrated within semiconductor ICs therefore it is small in size. However, it has slow
respond on fast temperature changes. An overview of the comparison between
thermocouples, RTDs, NTC thermistors and integrated silicon sensor are as shown in
Table 2.1.

Table 2.1 Comparison between NTC thermistors, thermocouples and RTDs

(Heath, 2016)
Factor Thermocouples RTDs NTC Integrated
thermistors Silicon
Sensor
Temperature -270 to 1800 ֯C -250 to 900 ֯C -100 to 450 -55 to 150 ֯C
range ֯C
Sensitivity ±0.5 ֯C ±0.01 ֯C ±0.1 ֯C ±0.15 ֯C
Linearity Requires at least a Requires at Requires at At best
4th order least a 2nd least a 3rd within ±1 ֯C.
polynomial or order order
 17

equivalent lookup polynomial or polynomial No

table equivalent or linearization
lookup table equivalent required
lookup table
Excitation None required Current source Voltage Typically:
source supply
voltage
Output Type Voltage Resistance Resistance Typically:
supply
voltage
Typical Size Bead diameter = 0.25 x 0.25 in 0.1 x 0.1 in 0.88mm x
5 x wire diameter 0.88mm

2.5 Extrusion Process

It is declared that the concept of producing 3D printer plastic at home can be developed
using single screw extruder as shown in Figure 2.10 (“3D Printing for Beginners”,
2016). The working principles of a single screw extruder starts from a hopper. All
materials are fed in from the hopper into the barrel containing a screw, which is the
main part of the extruder (Wagner, Mount and Giles, 2014). On one end, the screw, or
sometimes referred to as auger is connected to an electric motor which helps to
transport the fed pellets towards the tip of the extruder or also known as the extruder
nozzles. A heater is placed as the extruder nozzles to soften and melt the material in
order to allow it to be extruded and form continuous filament strand.
 18

Figure 2.10 Cross-section of a Single Screw Extruder

(Rao & Schott, 2012)

The materials that is fed into the hopper are usually tiny solid pellets to speed
up heating and reduce friction on the screw. A progressive increased in temperature
profile with the setpoints temperature increasing continually from the hopper to the
extrusion nozzle is necessary to prevents premature melting and reduces melt plug
formation around the screw of bridging the throat in the hopper wall (Wagner, Mount
and Giles, 2014). This can avoid polymers or additives to becoming sticky and
adhering to the hopper wall.

To clearly define the temperature profile along the extruder barrel, the
temperature zone is separated into four zones; the feed zone, transition zone and
metering zone wall as shown in Figure 2.11 (Wagner, Mount and Giles, 2014). Resins
are input through the feed zone and the root diameter along this zone is constant. The
transition zone has a progressively increasing root diameter as compression is applied
(Whelan and Dunning, 1988). This zone is where the solid pellets is melted into molten
material. Finally, the metering zone has a uniform flight depth that transfers the melt
and controls the volumetric flow rate through the extruder into the die (Whelan and
Dunning, 1988).
 19

Figure 2.11 Extrusion Screw

(Whelan and Dunning, 1988)

2.6 System Controller

2.6.1 Programmable Logic Controller (PLC)

Programmable logic controller, in short, known as PLC is an industrial solid-state

computer control system that has been introduced in the late 1960s by an inventor
named Richard Morley (Mary R., 2011). Its ability to perform modular programming
allow PLC system to mix and match and monitor the types of inputs and outputs
devices and automate the process based on logical decisions. It was first designed and
developed to replace relay logic systems due to the unreliability and time delay created
by the relay system.

These controllers excluded the needs for rewiring and adding extra hardware
devices for each new configuration of logic. With that, it drastically reduced the
cabinet space that housed the logic while increasing the functionality of the controls.
PLC contained of CPU, inputs and outputs logical port as shown in Figure 2.12. The
CPU directs the PLC to perform control instructions, perform logic and arithmetic
operations, connect with other devices and execute internal diagnostics. Apart from
 20

that, CPU also performs memory routines, constantly inspecting the PLC to avoid
programming errors and to protect the memory from being damaged.

Figure 2.12 Internal Architecture of PLC

(Gonzalez, 2015)

There are four fundamental procedures in the process of all PLCs; input scan,
internal program execution, output update and internal checks as shown in Figure 2.13
(Agarwal T., 2015). Input scanning operation detects the condition of all input devices
that are linked to PLCs while the output update process energize or de-energize the
output devices based on the CPU internal response. Most PLCs provide libraries of
function blocks for complicated controls such as temperature control and motion
control. Components can simply be control by setting the basic parameters needed into
the function block and the output is linked to the devices required to take response.
Internal program execution run the program logic created by the user. Lastly, internal
checks performs housekeeping operation which helps communicate PLCs with
programming terminals and execute internal diagnostics.
 21

Figure 2.13 Internal Program Flow of PLCs

(Gonzalez, 2015)

PLCs uses five type of high level programming languages that are defined by
the international standard IEC-61131 (Gonzalez, 2015). Its solid standardization and
simple programming techniques speed up the production process of a machine maker.
Ladder logic is one of the most frequently used PLC languages where it utilises the
use of symbols and rungs for input and output logical control. Function block diagram
is another programming languages used in PLC where it describes the functions
between input and output variables. Structured text is a high-level language that
resembles modern C programming language. It uses sentenced commands to create
programs. Instruction list, on the other hand, is a low level language that contains
functions and variables defined by a simple list (Gonzalez, 2015). Sequential function
chart language is a technique of programming complex control system where it divides
large and complicated programming operations into simpler and more manageable
tasks.

2.6.2 Microcontroller

Microcontrollers are special purpose logic controllers that execute one operation
repeatedly. They are dedicated for single task execution. Similar to a PLC, they also
have CPU to execute the programs, RAM for data storage and input and output ports
that are capable for microcontrollers to process user command and perform a specific
 22

response on the output. Microcontrollers contained their programs in a flash program

memory while the variables data are stored in Data RAM. The logical processing
within a microcontrollers are performed by the ALU as shown in Figure 2.14. General
Purpose Register stored the configuration of microcontroller input and output ports.
All these units are linked together via a network bus system. From the aspects of
system architecture, unlike PLC, microcontrollers are incapable of running an
operating system and do not have the same amount of computing power or resources
as compare to PLC. Therefore, they are not an infinitely expandable input and output
logic controller.

Figure 2.14 Microcontroller Architecture

(Source: ATmega32 datasheet p. 6)

The development time taken for microcontrollers is longer than PLC due to
their usage of tedious machine language. More of that, microcontrollers do not offers
a standard user interface platform. The interfacing features might need to be
programmed manually onto an LCD or LED display.

However, microcontrollers are necessary and useful as a platform to perform

simpler computing tasks such as flipping a switch or controlling small components.
They are commonly used due to their low-powered consumption and low-memory
which make them to be low cost.
 23

2.7 Modular Programming

Structured programming, or sometimes known as modular programming, is a

subcategory of procedural programming that implements a logical structure on the
program that is being written to improve the efficiency and ease understanding and
modification (Rouse M., 2005). Several programmers can easily work on individual
programs at the same time and join programs in the end. This programming technique
helps to easily control the scoping variables and less code has to be written as
individual programs are simpler to code than combining all individual programs in a
single program. Modular programming is a type of top-down design programming
approach that breaks down program functions into modules (SearchSoftwareQuality,
n.d.)

In this approach, most of the variables are passed from one module to another
whenever the other module is called. In short, modular programming has similar
behaviour with plugin where the function are added whenever it is needed. Versioning
is considered to be one of the most popular approach to ensure those independent
functions to work together (Chapter 2: The Benefits of Modular Programming, 2007).
Basically, it means that every module will have a consistent passing variables. The
modification of each module will be done only in the process being programmed in
the module.

2.8 Human Machine Interface

Human Machine Interface, or also known as Graphical User Interface (GUI), is a

simplified use of computers by presenting relevant information in a manner that
enables rapid assimilation and manipulation (Toby, 2001). The use of graphic
constructs that mimic physical objects such as “buttons” and “switches” can speed
learning, by applying an intuitive technique to provide input to the computer. An
implementation of user interface is not always an improvement to a system. As
 24

demonstrated by some commonly used commercial programs, a poor user interface

implementation can obscure its functionality. Significant amount of learning time is
required for the program to be used efficiently if the user interface is organized in a
counter-intuitive manner or if the commonly performed operations required several
unexpected indirect steps to be performed (Toby, 2001). A good user interface does
not require user to memorise procedures required for task execution. Multiple step
operations can be simplified by executing all operations in a single step shortcuts.

In order to compile multiple steps into a single shortcuts, operations need to be

compiled as a single function via back-end programming. Modularity of components
has enormous benefits on assisting steps compilation when building interactive
applications. Functional units can be isolated to its most simplified form to ease
application designer in understanding, modifying and compiling each particular unit
(Krasner and Pope, 1988). More of that, it is demonstrated that one particular form of
modularity is the three separation of application components which are the model, the
view and the controller as shown in Figure 2.15 (Krasner and Pope, 1988). The model
represents the functional units that contained multiple steps operations while the view
represents the display of the application’s state. As for the controller, it signifies the
user communication with the model and the view.

Figure 2.15 Model-View-Controller Setting and Message Sending

(Krasner and Pope, 1988)
 25

CHAPTER 3

3 METHODOLOGY AND WORK PLAN

3.1 Introduction

Multi-material 3D printing holds great promises towards allowing the automated

construction of 3D models with complex structures, appearances and properties to
physical equivalents. It has accelerated the potential of innovation to create objects
that has been previously impossible or difficult to be fabricated. There have been
significant efforts from the industry as well as the academic community in building
multi-material fabrication platforms.

Motion control plays an important role in producing quality 3D printed

products. Accuracy of the motion control need to be calibrated to avoid producing
defected objects. Other than that, 3D printer system should be made reliable for low
maintenance cost during long run. Intelligent system is one of the example of reliable
system where it can perform self-diagnosis and self-calibration. In order to achieve
good accuracy and reliability, statistical methods are utilised for measuring the
performance of the system. More of that, proper electrical connection can also yield a
more reliable system. Suitable grounding techniques are relevant to reduce the noise
being induced in the signal circuits. Appropriate components are selected to optimise
between cost and system performance. In short, the objective for electrical wiring
planning and design is to improve system stability while considering the safety
measures.

From the aspects of software configuration, the first step for a 3D printing
process is reading and interpreting the language used for human-machine
communication. This required machine to have its knowledge to identify and
understand the command. The system should made capable in performing actions
based on the command interpreted. Further than that, simplified information and
settings should be presented and accessible by end users. This involves interfacing the
 26

system program with end users via user interface. Linkage is made for end users to
have appropriate level of control on the system actions.

3.2 Applied Theories

3.2.1 Program Flow

There are two main operations that are executed by the system during the operation;
motion control and temperature control. Temperature control input setpoint
temperature value from the HMI while performing controlling feedback operation on
the temperature at different zone. Motion control reads file from HMI to perform
interpretations and printing actions based on the file command. The general flow of
the concept for the framework will be described in Figure 3.1.

Function
Modules

Figure 3.1 General Program Flowchart

 27

As a further explanation of the flowchart, prior to the feeding of material, there

are parameters that require close consideration. These parameters may consist of the
auger or extruder feed rate, the feed rate for the material source located before the
mixer and the average total flow rate of the material pellets feed into the mixer.

3.2.2 Pre-processing Technique

Based on the literature that have been reviewed previously, some of the basics
languages are required in order to allow human to interact with a machine which
includes the usage of G-code. Moreover, machine required to be equipped with the
knowledge to understand the language ‘spoken’ by a human to them. The knowledge
is induced into the machines by equipping G-code Interpreter in the machines. The
objective for such implementation to allow the machine to extract the relevant
information out from the commands and perform operation.

The length of commands can be varied in length. For instance, a single ‘G01’
command can have all X, Y and Z position and might also only contain the X position.
Furthermore, in order to ensure robust G-code Interpreter, the position of each
information in a string of command should also be considered. One method proposed
is by first finding all the alphabets of relevant data that might exist in the string of
command. Rearranging and identify which data is before or after another.

Lastly, extract the value of the particular alphabet by taking the middle
information between the alphabet and the one after it. Each line of commands is
extracted and stored in an array of structure, where the structure is the final information
of all positions and extrusion rate. In order to ensure reliable and stable G-code
Interpreter, several samples of G-code is used to test the interpreter as shown in
Appendix A and Appendix B. An overview flowchart of the G-code Interpreter is as
shown in Figure 3.2.
 28

Figure 3.2 Program Flow of G-code Interpreter

 29

3.2.3 Process Framework

The information extracted from G-code Interpreter during the pre-processing is then
used for the main 3D printing process. This is also considered as the main framework
for the 3D printing. The framework will starts by initializing and resetting all position
value and velocity relevant for the normal function of the 3D printer.

After that, it will read the first structure of instruction from the array of G-code
information. All commands are grouped into a separate function block. G command
being extracted will go through each and every command and check for a match. The
particular function block will be run when it found a match. All function blocks are
programmed according to the modular programming approach to ease future
improvements. The G-code and M-code being included in the program are shown in
Table 3.1 and Table 3.2.

Table 3.1 G-code Description

G-code Description
G0 Rapid Coordinated Movement X Y Z E
G1 Coordinated Movement X Y Z E
G10 Retract filament according to settings of M207
G11 Retract recover filament according to settings of M208
G28 Home one or more axes
G90 Use Absolute Coordinates
G91 Use Relative Coordinates
G92 Reset Current Coordinate as 0 Position

Table 3.2 M-code Description

M-code Description
M0 Unconditional stop - Wait FOR user button press on UI
M17 Enable/Power all stepper motors
M23 Access File Information
M80 Turn on Power Supply. (Requires POWER_SUPPLY)
 30

M81 Turn off Power Supply. (Requires POWER_SUPPLY)

M82 Set E codes absolute (default)
M83 Set E codes relative while in Absolute (G90) mode
M104 Extruder Temperature input and control not set. Set extruder target temp
M106 Fan on
M107 Fan off
M110 Set Current Line Number
M112 Emergency stop
M114 Report current position
M120 Enable endstops detection
M121 Disable endstops detection
M140 Bed Temperature input and control not set. Set bed target temp
M201 Set max acceleration in units/s^2 for print moves
M202 Set max acceleration in units/s^2 for travel moves
M203 Set maximum feedrate
M205 Set advanced settings
M206 Set additional homing offset
M207 Set Retract Length
M220 Set Feedrate Percentage

Each of the code has its individual breakdown program flow. For instance, the
G-code G28 which is homing function initialize by commanding rapid motion for all
3 axes towards the direction of hardware configured home position. Each of the axis
stop when it reaches the minimum limit of the system and touches the end stop limit
switch. The stop command is completed by utilising the M112 emergency stop
command of the M Code. The absolute position is reset when all 3 axes reaches its
minimum limit. The program flow is as shown in Figure 3.3.
 31

M112

G92

Figure 3.3 G28 Program Flow

After completing the executed function block, the next structure of instruction
will be read and the loop of flow continues. All other motion correction, temperature
 32

control and emergency stop tasks are added in the loop of the framework as separate
task. Each task execution is weight by using the priority set.

Concurrently, the value such as the position of 3D printer, temperature of heat

bed and extruder, percentage of printing completion and relevant information for
displaying to user will be displayed on the HMI.

3.3 Hardware Configuration

3.3.1 Circuit Wiring

Planning and designing are the initial procedures to construct an electrical system.
Cooling fan is mounted on the control panel to assist air ventilation within the control
panel. The arrangement of the devices in the control panel is arranged based on the
heat dissipation capability of the device. The larger the heat dissipated by the device,
the nearer it should be placed in the control panel to improve ventilation on the device.

TB6600 motor drivers are selected for mixer stepper motor control due to the
limited cost available for purchasing EL7031 Beckhoff stepper motor card. This motor
driver, with its controller board mounted on a heat sink, has larger heat dissipation
capability. Therefore, it is placed beside the cooling fan as shown in Figure 3.4. Power
supplies are isolated from the controller to reduce the risk of short circuit. Power and
ground terminals are introduced to redirect and complete all connections.
 33

Signal Wire Live

24V DC Neutral
12V DC Earth
Ground

Figure 3.4 Control Panel Layout

Labelling has been tagged on each cables to ease future development. Larger
cables are used for heavy duty applications such as triggering the heating of the heat
cartridge through a SSR. Shielded wires are used as signalling wire to reduce the risk
of e.m.f disturbance. Trunking is built to ensure proper arrangement of wires in the
control panel. Capacitive and inductive coupling can happen when all wires are
arranged and direct through the trunking. However, with shielded wires, the
disturbance can be reduce and it can reduce the effect of noise.

Grounding is categorized into 3 categories which is the power earth, safety earth and
signal earth. All 24V, 12V and 5V direct current supply are grounded to the power
earth. Alternating current is grounded to safety earth. Lastly, instead of separating
logic earth and analogue earth, all signals including digital and analogue signals’ wires
are grounded to signal earth. The electrical schematic is drawn as shown in Appendix
H before connection process begin.
 34

3.3.2 Selection of Relay

There are two relays that are recommended to be applied in controlling the response
of the heat cartridge which is the SSR and EMR due to its suitability in input response.
However, SSR is selected to be used instead of EMR. This is because SSR generate
relatively smaller electrical disturbance as compare to EMR. More of that, SSR also
required lower input power for switching loads as compare to EMR.

Switching debouncing is another factor to consider when it comes to switching

devices. SSRs do not generate electric arcs or sparks and do not bounce mechanically
or electrically (Wendt, 2017). As comparing to SSR, EMR has longer switch
debouncing time and response time. However, SSR generates more heat as compare
to EMR. This issue can be solved by mounting a cooling fan in the control panel to
ventilate the heat being produced.

3.3.3 Selection of Temperature Sensor

Based on the literature reviewed, it is concluded to use thermocouples as the

temperature measuring devices for all the critical points along the extruder and heat
bed. This is mainly due to its good linearity capability within small range of
temperature and fast response time. A minor accuracy is sacrificed when
thermocouples are used but it will not affect the system as a minor tolerance on the
temperature will not affect much on the quality of the plastic materials.

Furthermore, according to the literature reviewed, thermocouples can detect

extremely high temperature which is up to 1800 ֯C. The working principle of 3D printer
is to melt materials for easy printing and solidify it after cooling. Therefore, for the
considerations of further future applications where higher melting point materials can
be used as printing materials, thermocouple is selected. Other than that, it is also easier
 35

and more compatible by pairing thermocouple with EL3314 Beckhoff Thermocouple

Card.

The 3D printer aims to print plastic materials which are usually melted below
540 ֯C and the heat bed temperature should be above room temperature to avoid
deflected printed product. Therefore, type K thermocouple is used as it has better
linearity among all the other type of thermocouple, good resistance against oxidation
below 1000 ֯C and it is the most stable among thermocouple of inexpensive material.

3.3.4 Thermocouple Cable Extension

Thermocouple extension cables is used to extend the thermocouple from the machine
to the control panel which directly linked into the EL3314 Beckhoff 4-channel
thermocouple input terminal. However, in order to standardize all cables extension
through a 72 ways socket crimp connectors, thermocouple wires are extended through
a normal crimp connectors instead of a standard thermocouple extension connectors.
Therefore, the measured value of thermocouple might experience a slight differ in
temperature from the actual due to the potential drop between different materials of
connectors and thermocouple.

Experiments are performed to determine the accuracy of the thermocouple. The

experiments will be conducted within a range of temperature and the thermocouple
measured temperature is plotted based on the temperature measured using infrared
thermometer. The behaviour and performance of the thermocouple within the range
can be determined via the graph. An offset calibration is recommended if the behaviour
of the thermocouple shows a linear error when compare with the temperature measured
by infrared thermometer. If the thermocouple shows a non-linear error behaviour,
either a system response should be equate or a lookup table is to be generated and
configure into the software for calibration purposes.
 36

3.4 Control Configuration

3.4.1 Motion and Scale Factor Configuration

The stepper motor used in all axes has a specification of 1.8 ֯ angular displacement per
pulse and it is not equipped with any encoder feedback control. It is controlled by
system framework via EL7031 Beckhoff stepper card as shown in Figure 3.5.

Motion Control Function

G28 - Homing G00 – Rapid Movement G01 – Direct Movement

M112 – Emergency Stop G92 - Reset G90 – Absolute Control

...

PLC

X Axis Y Axis Z Axis

EL7031 EL7031 EL7031

Figure 3.5 Stepper Motor Electrical Schematic

Moreover, the X, Y and Z axis stepper motor is equipped with a gear transition
and a lead screw which converts rotational motion to translational motion. The gear
ratio and the pitch-to-pitch distance of the lead screw is determined for accurate
positioning. The distance travelled per revolution of the axis motor is determined by
utilising the equation 3.1. The EL7031 Beckhoff stepper card required a software
configuration of scaling factor based on the motion transition for synchronisation
purpose with the stepper motor. Equation 3.2 is an equation provided by Beckhoff to
determine the software scaling factor required to configure for stepper motors without
 37

encoder feedback control. By combining equation 3.1 and 3.2, the total equivalent
equation for determining the scaling factor is as shown in equation 3.3.

𝑑 = 𝐺𝑟 𝑥 𝑑𝑝𝑝 (3.1)

𝑑𝑟𝑒𝑣
𝑆𝐹 =
𝑓𝑢𝑙𝑙 𝑠𝑡𝑒𝑝𝑠 𝑥 𝑚𝑖𝑐𝑟𝑜𝑠𝑡𝑒𝑝𝑠 (3.2)

𝐺𝑟 𝑥 𝑑𝑝𝑝
𝑆𝐹 =
𝑓𝑢𝑙𝑙 𝑠𝑡𝑒𝑝𝑠 𝑥 𝑚𝑖𝑐𝑟𝑜𝑠𝑡𝑒𝑝𝑠 (3.3)

The number of teeth for pinion and gear is identified to be 12 and 30

respectively while the pitch-to-pitch distance is measured to be 5mm using vernier
calliper as shown in Figure 3.6. Microsteps is fixed by Beckhoff with a value of 64
microsteps. Lastly, the stepper motor of X axis has a 1.8 ֯ step angle per pulse.
Therefore, the stepper motor required 200 pulses in order for it to rotate a complete
revolution. Utilising the information collected, the software scaling factor of X axis is
determined to be 1.5625 x 10-4 as shown below using equation 3.3. Other than that, the
scaling factor is also the maximum precision that can be achieved by the stepper
system.

TG = 30 teeth

dpp = 5mm/rev

TP = 12 teeth

Figure 3.6 Power Transmission Schematic of Axis Motion

𝐺𝑟 ∗ 𝑑𝑝𝑝
𝑆𝐹 =
𝑓𝑢𝑙𝑙 𝑠𝑡𝑒𝑝𝑠 𝑥 𝑚𝑖𝑐𝑟𝑜𝑠𝑡𝑒𝑝𝑠
 38

Tp = 12 teeth full steps = 200 steps/rev

TG = 30 teeth microsteps = 64 microsteps
dpp = 5mm/rev

𝑇𝑃
∗ 𝑑𝑝𝑝
𝑇𝐺
𝑆𝐹 =
𝑓𝑢𝑙𝑙 𝑠𝑡𝑒𝑝𝑠 𝑥 𝑚𝑖𝑐𝑟𝑜𝑠𝑡𝑒𝑝𝑠
12 𝑡𝑒𝑒𝑡ℎ
∗ 5𝑚𝑚
30 𝑡𝑒𝑒𝑡ℎ
𝑆𝐹 = 𝑠𝑡𝑒𝑝𝑠
200 𝑥 64 𝑚𝑖𝑐𝑟𝑜𝑠𝑡𝑒𝑝𝑠
𝑟𝑒𝑣

𝑆𝐹 = 1.5625 𝑥 10−4 𝑚𝑚/𝑠𝑡𝑒𝑝𝑠

The maximum angular velocity that can be achieved by the stepper motors is
determined by using the equation 3.4 according to the documentation stated in the
commissioning techniques of Beckhoff EL7031 stepper motor card. The base
frequency is configured to 8000 fullsteps/s while the motor frequency, depending on
the stepper motor used, is 200 fullsteps/rev. By using the parameters identified, the
maximum velocity is calculated as shown below.

𝑓𝑏𝑎𝑠𝑒
𝜔𝑚𝑎𝑥𝑝𝑖𝑛𝑖𝑜𝑛 =
𝑓𝑚𝑜𝑡𝑜𝑟 (3.4)

𝜔𝑚𝑎𝑥𝑝𝑖𝑛𝑖𝑜𝑛
𝑣𝑚𝑎𝑥𝑔𝑒𝑎𝑟 =
𝐺𝑟 𝑥 𝑑𝑝𝑝 (3.5)

However, the maximum configurable angular velocity calculated is the

maximum angular velocity of the stepper motor. Gear ratio is also required to be taken
into account for this situation. Therefore, the actual allowable maximum velocity is
calculated using equation 3.5 as below.
8000
200
𝑣𝑚𝑎𝑥𝑔𝑒𝑎𝑟 = 12
𝑥5
30

𝑣𝑚𝑎𝑥𝑔𝑒𝑎𝑟 = 20 𝑚𝑚/𝑠

The distance travelled per revolution for the stepper motors at feeder and mixer
are also calculated using equation 3.1. The accuracy and reliability of the stepper
 39

motors using the calculated scaling factor is determined by using mean root square
error and correlation method respectively. The accuracy can be determined from the
equation 3.4. The lower the root mean square error, the better the accuracy. As for the
reliability measurement, it is determined via correlation formula as shown in equation
3.5. Similar to correlation, the higher the correlation value, the higher the reliability of
the system.

𝑛
1
𝑅𝑀𝑆𝐸 = √ ∑(𝑦𝑖 − 𝑦̂𝑖 )2
𝑛
𝑖=1
(3.6)

𝑛 ∑𝑛𝑖=1 𝑥𝑦 − ∑𝑛𝑖=1 𝑥 ∑𝑛𝑖=1 𝑦

𝑟=
√[𝑛 ∑𝑛𝑖=1 𝑥 2 − (∑𝑛𝑖=1 𝑥)2 ][𝑛 ∑𝑛𝑖=1 𝑦 2 − (∑𝑛𝑖=1 𝑦)2 ] (3.7)

3.4.2 Thermocouple Configuration

The main materials that will be used in this project will be thermoplastics. In order for
it to be melted, fused and extruded successfully, the temperature along the extruder
should be controlled. There are total three thermocouples and two heaters along the
barrel for extrusion and one thermocouple and heater is placed at the tip of the extruder
which is the nozzle to keep the temperature in control. The temperature will be
increasing along the barrel up until the extruder nozzle. The extruder nozzle
temperature will be at or slightly above the maximum glass transition temperature of
both fused thermoplastic.

Furthermore, temperature being measured by the thermocouple will also be

experimented to ensure accurate reading. The performance of the thermocouple will
also be determined by comparing the data with the measured data using thermistor
from the existing 3D printer. The thermocouple is mounted into the heater plate of the
extruder nozzle. Accuracy and reliability is identified through the similar equation
used for motion control which is equation 3.4 and 3.5.
 40

Graph of the temperature behaviour will be plotted to determine the

relationship between the actual and measured value. Offset calibration will be
performed based on the behaviour of the plotted graph to ensure the temperature can
be measured accurately within the temperature range. The feedback control system of
the heat cartridge is controlled by thermocouples feeding data into a software PID
temperature controller function block preconfigured in the TwinCAT3 libraries.

3.5 Human Machine Interface (HMI)

The final part for the 3D printer is on the HMI. This will be a user friendly interface
that is built to ease non-technical personnel to key in relevant information for the
printer to print an object. The interface will have a direct link to the variables of the
program during the execution phase. Commands that are needed to be added into the
interface will be such as the text reading, commence printing, emergency stop and
some basic resets, homing control and temperature control. An overview of the HMI
is shown in Figure 3.7.

Figure 3.7 Overview Architecture of HMI

 41

File reading operation is interfaced with HMI to obtained direct command from
the user. It awaits for a trigger from the File Read button and input the file path from
the HMI. The operation check for file existence before commencing reading operation.
Error description will be displayed on the HMI if the file cannot be found and it will
wait for another triggering of file read operation. The program flow of the file reading
task interfacing via HMI is shown in Figure 3.8.
 42

Figure 3.8 Program Flow of File Reading Operation Interfaced with HMI

The HMI should display the actual temperature measured by the thermocouple
and the setpoint temperature configured by the user. Temperature is controlled by
background temperature controller function interfacing with HMI. The temperature
controller compare setpoint temperature obtained from HMI with the actual
 43

temperature measured by thermocouple and uses PID to control the heat cartridge
response accordingly. For instance, if setpoint temperature is higher than actual
temperature, the temperature controller will trigger the heat cartridge to heat up to the
respective temperature. A logical flow of temperature controlling via HMI is shown in
Figure 3.9.

Figure 3.9 Program Flow of Temperature Control Interfaced with HMI

 44

CHAPTER 4

4 RESULTS AND DISCUSSIONS

4.1 Introduction

The first step for a 3D printing process is receiving and interpreting the
language used for human-machine communication. This required machine to have its
knowledge to identify and understand the command. After interpreting the command,
3D printer should have its ability to perform operation automatically and pause or stop
the process when the process might harm the surrounding. The reliability of the
interpreter is determined by measuring the flexibility and repeatability of the
interpreter in reading and extracting the correct information from random orientated
G-code.

Experiments are conducted on determining the accuracy and reliability of the

motion and temperature response. The accuracy and reliability of the system is derived
by applying root mean square error and correlation formulas on the experimental
results. Graphs are plotted to determine the behaviour of the response. The
optimization of the system is achieved by using the nominal value for the best accuracy.

HMI is inspired by the conventional 3D printer display. Clean and simple

layout design is considered for good user experience. Fundamentals information
especially on the filament extruder including temperature for all heater zone and heat
bed and cooling fans are added into the HMI. Certain level of flexibility is allowed for
users to configure product for printing, temperature of the materials and calibration.

4.2 G-code Interpreter

This subsection will provide a little recap on the experiment carried out during the first
part of this project and also some of the improvements made. The early experiment
instilled thoughts and critical thinking in enhancing the interpreter framework to
 45

ensure stability and reliability. The following content will summarise the details of the
experiment, results and the improvements made to obtain a better interpreter.

G-code Interpreter commenced by reading all the G-code from a declared text
file and storing it in a buffer. The raw data from the text file is not relevant in the future
process of 3D printing. Therefore, a temporary buffer with limited size is used to read
the text file. When the buffer is filled, G-code Interpreter will parse the raw data and
stored in into lines of code by identifying the next line command being read. After that,
it will check for end of file state from the text file being read and repeat if it is not the
end of file. The code will proceed to the extraction of information from every line of
G-code for the next step.

In extraction of information, the first attempt of coding the G-code Interpreter

was to hardcode the order of all alphabetical code in the order of G, X, Y and Z from
left to right in a line of code. The value of each code is obtain by finding the value
between its code and the next alphabetical code. For instance, the value of G is
obtained by finding the value between G position and X position. However, in some
situations there are more alphabetical code such as I, J, F, M, and R. And it is often
difficult to identify which alphabetical code comes after another in a line of code.
Using the mentioned technique can cause incorrect or invalid extraction of information.

The interpreter is improvised to be fully soft-coded in order to solve the issue.

This proposed initialize by finding all location of possible alphabetical code. Using
program to interpret which alphabetical code comes after another, the value of each
code can be extracted by finding the value between the respective alphabetical code
and its next nearest alphabetical code. All the relevant information being extracted is
then stored into a structure of code that is later used for printing process. In short, this
proposed techniques read, extract and store all G-code information before
commencing the printing process. Different from 3D printing Marlin firmware, which
it performs printing and reading process concurrently. After completion, a Boolean
logic of 1 will be output from the G-code Interpreter to indicate interpretation complete.
 46

The results of the G-code Interpreter using the sample G-code shown in
Appendix A is shown in Table 4.1. More of that, the result of the testing for G-code
Interpreter on the G-code shown in Appendix B is shown in Table 4.2. All commented
lines of G-code is filtered at the first stage of G-code Interpreter which is the reading
from text file stage.

Table 4.1 “testpieces1.txt” extracted G-code at 11th & 12th command

Expression Value
GCodeData[11] X G1
Y 0
Z 0
I 0.5
J 0
E 0
F 0
Ss 0
T 0
N 0
GCodeData[12] X G1
Y 100
Z 0
I 0
J 0
E 8
F 1000
Ss 0
T 0
N 0
 47

Table 4.2 “testpieces2.txt” extracted G-code at 11th & 12th command

Array of Structure Variables in Structure Interpreted Value
Variable Name
GCodeData[11] X G1
Y 0
Z 0
I 0
J 0
E -1
F 300
Ss 0
T 0
N 0
GCodeData[12] X G0
Y -20
Z -20
I 0.5
J 0
E -1
F 9000
Ss 0
T 0
N 0

From the results of the 2nd attempted G-code Interpreter, it is shown that all the
G-code from the sampled code is extracted correctly in stored in correct location. All
extracted data of the G-code is stored within an array of structure known as the
“GCodeStructure”. The size of the array is set up to 20,000 during the testing to ensure
all lines of G-code in the sample can be stored.
 48

4.3 G-code Functions

The 3D printing operation is a customised printing operation where it contains

different mixing ratio over the time for printing. The G-code generated should also
include a parameter for configuring the mixing ratio. To perform that, the standard
CNC control available in TwinCAT3 cannot be used as it cannot process mixing ratio
parameter. Therefore, NC operation which required manual programming of G-codes
and M-codes is used.
For simplification purposes, G-code and M-code included are only the
fundamentals codes required to complete basic printing process. All codes are
programmed based on modular programming approach. The code function takes in
enable bit from the main program to trigger the code execution and sends a completion
bit back to the main program when the process is completed. The progress of the code
completion is shown in Table 4.1. The completed code functions are used for testing
the performance of motion control. Code functions that are still under progress are
related to temperature controlling. Experiments are yet to be completed for
temperature control, therefore, it is not stable for actual use.

Table 4.3 Progress of Code Completion

G0 M0 M85 M114 M206
G1 M1 M92 M115 M207
G10 M17 M104 M117 M208
G11 M18 M105 M119 M209
G28 M48 M106 M120 M218
G29 M80 M107 M121 M220
G30 M81 M109 M140 M221
G90 M82 M110 M145 M226
G91 M83 M111 M190 M540
G92 M84 M112 M205 M600

In progress
Completed
Tested
Probe Function
Report Function
 49

4.4 Hardware Configuration

The testing of the operation for motion and temperature control required
implementation on hardware structure. The connections and position of all hardware
are configured before testing is performed on the machine as shown in Figure 4.1.

Figure 4.1 Hardware Structure of 3D Printer

The mechanical end-stop switch is mounted on the end of each axis to perform
homing operation and to avoid machine from exceeding minimum or maximum
allowable travel limit for machine safety purposes. End-stop switch is mounted only
at one end of each axis for homing configuration and minimum allowable travel limit.
The maximum allowable travel limit is set via software configuration of limit switch.
An overall schematic of the end-stop is shown in Figure 4.2.

Figure 4.2 Schematic Flow of End-Stop Limit Switch

 50

The temperature control also required heating the heat cartridges and obtaining
feedback temperature value from thermocouples. Heat cartridges is triggered by SSR
and controlled by temperature control function of Beckhoff libraries using setpoint
temperature obtained from HMI and actual temperature fed from thermocouples. The
schematic flow of the temperature control is shown in Figure 4.3.

Figure 4.3 Schematic Flow of Temperature Control

4.5 Electrical Wiring

The electronic components wiring from the machine are connected to the 72 ways
socket female connector on the back of the machine accordingly. Similarly, another
set of wires are connected from the 72 ways socket male connector into the control
panel to complete the wiring connections. Cooling fans within the control panel which
is driven by AC supply is directly connected to the main AC power supply to
constantly ventilate the control panel. Testing is done and is concluded that the
electrical wiring for the device is completed.

There are total three stepper motors that are mainly driven by stepper motor
driver. And the control of stepper motor required a 5V pulse. Therefore, voltage
regulators are applied to step down digital voltage output from Beckhoff digital output
card. 5V pulse is successfully sent into the motor driver. An overview of the circuit
connection in the control panel is as shown in Figure 4.4.
 51

12V PLC Control and IO Cards

Power Stepper Motor Card

Supply

Solid State Relay 24V Power Supply

Figure 4.4 Circuit Connection of Control Panel

4.6 Human Machine Interface (HMI)

The HMI of the 3D Printer is shown in Figure 4.5. It is separated into 3 sets
which is the overall system status, control and configuration and selection box. Overall
system status is shown in the left side of the HMI. It gives an overview of temperature
in all points of the extruder and heat bed. The control and configuration box is
positioned in the middle, allowing user to have manual control and simple
configuration of the system. User can commands any of the axes to jog or perform auto
homing via user interface. Furthermore, temperature for all points in the system is also
configured via the control and configuration box. Lastly, the selection box consists of
categories of control and configuration. User can configured system temperature by
selecting the “Settings” in the selection box. Other than that, manual interrupt such as
pause and emergency stop which is used for safety and flexibility purpose can also be
controlled via selection box.
 52

Figure 4.5 Human Machine Interface with ABS Temperature Configuration

4.7 Motion Control

Experiments are conducted to identify the accuracy and reliability of the scale
factor configured and the stepper motor performance as shown in Appendix F. The
root mean square error and correlation of the translated motion is calculated using
excel sheet based on the experimental data. The root mean square and correlation is 0
and 1 respectively. There are no tolerance between the actual and programmed. By
referring to Graph 1, it is shown that the programmed travelled distance has a perfect
linear relationship with actual travelled distance. Similar position is experimented
repeatedly to ensure reliable performance. In conclude, the motion of the system is
measured to be accurate and reliable.
 53

Graph of Programmed Displacement against Actual

Displacement
Programmed Displacement (mm) 140
120
100
80
60
40
20
0
0 20 40 60 80 100 120 140
Actual Displacement (mm)

Graph 1 Graph of Programmed Displacement against Actual Displacement

Furthermore, calibration has been made and the printing volume is identified
to be 210 x 158 x 76mm. However, the printing volume is scale down to 200mm x
150mm x 76mm to avoid the hardware structure from over run that can cause damage.

4.8 Temperature Control

Temperature is directly measured using thermocouple connected into Beckhoff

EL3314 thermocouple card. The experimental data collected is as shown in Appendix
G.

It is identified from Appendix G that a tolerance of maximum ±0.3 ֯C exist

between the thermocouple measured temperature and the thermistor measured
temperature at standard room temperature which is 26.6 ֯C. This might be due to the
different material used between the connector for the extension of thermocouple or the
inaccurate temperature measured by thermistor thermometer. The root mean square
error and the correlation is calculated to be 1.2229 and 0.9874 using excel sheet.

According to the Graph 2 and the correlational value, it is shown that the
temperature measured by thermocouple shows a near to linear relationship with respect
 54

to temperature measured by thermistor. However, the accuracy of the temperature

measured is low when the temperature increases. In other words, the higher the
temperature the lower the accuracy. By referring to the graph, it can be clearly
identified that the relationship between the parameters are not perfectly directly
proportional. Therefore, a second order polynomial equation is generated via excel to
input into the system for calibration as shown in Graph 2.

Graph of Temperature of Thermocouple against

Thermistor
325
Temperature of Thermocouple ( ֯C)

275 y = 0.0004x2 + 0.6981x + 9.0679

225
175
125
75
25
25 75 125 175 225 275 325 375
Temperature of Thermistor ( ֯C)

Graph 2 Graph of Temperature of Thermocouple against Infrared

Thermometer

The percentage error for temperature at 200 ֯C with a thermocouple measured

temperature of 241.6 ֯C is shown as below.

𝑇𝑡ℎ𝑒𝑟𝑚𝑜𝑐𝑜𝑢𝑝𝑙𝑒 = 241.6 ֯C
𝑇𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑 = 200.0 ֯C

𝑇𝑡ℎ𝑒𝑟𝑚𝑜𝑐𝑜𝑢𝑝𝑙𝑒 − 𝑇𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟, 𝑒𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑥 100%
𝑇𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑
241.6 − 200
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟, 𝑒𝑎𝑐𝑡𝑢𝑎𝑙 = 𝑥 100%
241.6
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟, 𝑒𝑎𝑐𝑡𝑢𝑎𝑙 = 20.8%
 55

By using the calibrated equation generated, the percentage error using the stated
equation can be identified. The percentage error is reduced by 20.3% from the actual
thermocouple measurement. In conclusion, the accuracy can be improved by using the
polynomial equation generated. However, further calibration need to be performed to
refined the accuracy of the thermocouple system response.

𝑇𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 = 0.0004(𝑇𝑡ℎ𝑒𝑟𝑚𝑜𝑐𝑜𝑢𝑝𝑙𝑒 )2 + 0.6981(𝑇𝑡ℎ𝑒𝑟𝑚𝑜𝑐𝑜𝑢𝑝𝑙𝑒 ) + 9.0679

𝑇𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 = 0.0004(241.6)2 + 0.6981(241.6) + 9.0679
𝑇𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 = 201.0 ֯C

𝑇𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 − 𝑇𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟, 𝑒𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 = 𝑥 100%
𝑇𝑚𝑒𝑎𝑠𝑢𝑟𝑒𝑑

201.0 − 200.0
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟, 𝑒𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 = 𝑥 100%
200.0
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑒𝑟𝑟𝑜𝑟, 𝑒𝑐𝑎𝑙𝑖𝑏𝑟𝑎𝑡𝑒𝑑 = 0.5%
 56

CHAPTER 5

5 CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusions

Based on the results obtained with the assessment of the performance of the framework
and reliability of the system, the main aim of developing a PC based 3D printer is
fulfilled. The minimum objective which is to develop a framework for the 3D printing
process is accomplished through the development of G-code Interpreter techniques
which provides flexibility in reading codes with inconsistent arrangement of position
and the motion control of the printer.

The reliability and accuracy of the motion positioning system of the printer is
guaranteed via configuration of scale factor. Experiments were conducted to prove the
accuracy and reliability of the motion positioning system. The accuracy is very high
as the root mean square error calculated using the data obtained is 0. The reliability of
the system is very high as the programmed distance travelled has perfect linear
relationship with the measured distance travelled.

The behaviour of the thermocouple is experimented on a heating block and

compared with the value measured from a thermistor. The temperature measured by
thermistor is taken as actual value in this experiments. It is shown that the error of the
thermocouple is close to a linear error as the error increased as the temperature
increased. Therefore, a polynomial equation is generated to compensate and calibrate
the temperature measured by the thermocouple. The percentage error of the calibrated
value as compared to the actual temperature is low after calibration. In short, the
accuracy is enhanced after calibration. Reliability is high as it shows a correlational
value of 0.9874.

The other objectives are also initiated and in progress throughout the period of
development. Tasks are taken to paves way for future development. The practice of
printer development in different areas which includes the arrangement of wires,
 57

labelling of wires, modular programming, variables declaration, version control and

mechanical assembly techniques are standardized.

The hardware configuration of the system is completed with the end-stop

switch mounted at each axis and gear ratio is considered during gear ratio calculation.
However, further modifications are required to be done for heat bed with critical
considerations on the allowable travel space for Z axis. Bulky design of heat bed can
scale down the allowable printing volume of the machine. Mounting of fans for
feedback and cooling control of the extruder should also be reconsidered to ensure that
the heat will not be transmitted up to the stepper motor as it can easily damage the
stepper motor. Electrical wiring is completed and tested with direct AC power supply
connected the system. All wires are safely grounded and connected with minimal
exposure of conductive area.

In addition, from the aspects of programming, G-code is successfully read from

external files with the file type of txt. G-codes are interpreted and stored into the
system command correctly for printing process. There are two main categories of
processing to be focused after G-code interpretation; the motion operations of the G-
code. Motion control is programmed and completed by including all fundamentals and
relevant G and M Codes required for 3D printing process. However, temperature
control is yet to be completed as the parameters for PID temperature controlling
required to be tested and fine-tuned.

The fundamental structure of HMI is accomplished with close consideration

on user experience, ease of configuration and simple presentation. HMI is designed to
have minimal complexity by categorizing all selection and using diagrams
representation. Due to the issue in temperature control, HMI can also yet to be fully
completed as the temperature is not completely configured.
 58

5.2 Recommendations for future work

Future development can be done by fine tuning the PID temperature control function
of the system. The temperature system response is required to be configured to
optimise the temperature control system. Overshoot can be implemented to speed up
the heating process. However, the overshoot percentage should not be too high to avoid
time taken required for the temperature to reach stable condition.

More of that, more improvements can also be done on the HMI by adding more
features to the HMI. Due to time limitations and many literatures are required to
review and development work are required, HMI is only completed up to the minimal
requirements of controlling the motion. In the current state, the buttons for most of the
features are created for future progress but not all features are fully programmed and
equipped.

Finally, increasing printing volume is also another issue to be considered for

further improvements. The current design of the extruder barrel is large and bulky
limiting the motion range of the Z axis. The maximum printable height of the current
design is only limited to 150mm. By shrinking down the size of the extrusion barrel, a
larger printing limit can be achieved. However, close considerations need to be done
on the temperature control as the plastic pellets materials required gradual temperature
increase to avoid the material quality from degrading. Small extrusion barrel are not
capable to achieve a change of 80 ֯C while ensuring a gradual increase in temperature
with such a short distance.
 59

REFERENCES

SearchSoftwareQuality. (n.d.). What is structured programming (modular

programming)? - Definition from WhatIs.com. [online] Available at:
http://searchsoftwarequality.techtarget.com/definition/structured-programming-
modular-programming [Accessed 1 Apr. 2018].
Chapter 2: The Benefits of Modular Programming. (2007). Sun Microsystems, pp.1-4.

Rao, N. and Schott, N. (2012). Understanding Plastic Engineering Calculations:

Hands-on Examples and Case Studies. Cincinnati: Hanser Publishers, pp.2-4.

Dan (2016). How to build an 2-axis Arduino CNC Gcode Interpreter. [online]
Available at: https://www.marginallyclever.com/2013/08/how-to-build-an-2-axis-
arduino-cnc-gcode-interpreter/ [Accessed 1 Apr. 2018].

Reprap.org. (2017). Motor control loop - RepRapWiki. [online] Available at:

http://reprap.org/wiki/Motor_control_loop [Accessed 1 Apr. 2018].

Brei, T. (2008). RTD vs Thermocouple - What's the difference?. [online] Sure Controls.
Available at: http://www.surecontrols.com/rtd-vs-thermocouple/ [Accessed 1 Apr.
2018].

Heath, J. (2016). Temperature Sensors: thermocouple vs. RTD vs. thermistor vs.
semiconductor IC. [online] Analog IC Tips. Available at:
http://www.analogictips.com/temperature-sensors-thermocouple-vs-rtd-vs-
thermistor-vs-semiconductor-ic/ [Accessed 1 Apr. 2018].

Reprap.org. (2012). Prusa i3 - RepRapWiki. [online] Available at:

http://reprap.org/wiki/Prusa_i3 [Accessed 13 Apr. 2018].

Ametherm. (2017). Temperature Sensors. Thermistors vs Thermocouples. [online]

Available at: https://www.ametherm.com/blog/thermistors/temperature-sensors-
thermistors-vs-thermocouples [Accessed 1 Apr. 2018].

Chen, K. (2015). Choice of Wiring System & Types of Cables Used In Internal Wiring.
[online] Linkedin. Available at: https://www.linkedin.com/pulse/choice-wiring-
system-types-cables-used-internal-kevin-chen [Accessed 1 Apr. 2018].

Kain, A., Mueller, C. and Reinecke, H. (2009). High aspect ratio- and 3D- printing of
freestanding sophisticated structures. Procedia Chemistry, 1(1), pp.750-753.

Argawal, T. (2015). Different Types of Relays used in Protection System and their
Workings. [online] ElProCus - Electronic Projects for Engineering Students. Available
at: https://www.elprocus.com/different-types-of-relays-used-in-protection-system-
and-their-workings/ [Accessed 1 Apr. 2018].

Wendt, Z. (2017). Solid State vs. Electromechanical Relays. [online] Available at:
https://www.arrow.com/en/research-and-events/articles/crydom-solid-state-relays-vs-
electromechanical-relays [Accessed 1 Apr. 2018].
 60

Sidambe, A. (2014). Biocompatibility of Advanced Manufactured Titanium

Implants—A Review. Materials, 7(12), pp.8168-8188.

Jefferies, K. (2014). Info Zone. [online] Au.rs-online.com. Available at: https://au.rs-

online.com/web/generalDisplay.html?id=infozone&file=automation/good-practice-
in-extending-thermocouple-cable [Accessed 1 Apr. 2018].

Texas Instruments (2007). Removing Ground Noise in Data Transmission Systems.

SLLA268. [online] Texas Instruments, pp.1-7. Available at:
http://www.ti.com/lit/an/slla268/slla268.pdf [Accessed 1 Apr. 2018].

Gregorec, J. (2018). Preventing Electrical Shocks With Proper Grounding

Techniques | IAEI Magazine. [online] Available at:
https://iaeimagazine.org/magazine/2005/05/16/preventing-electrical-shocks-with-
proper-grounding-techniques/ [Accessed 1 Apr. 2018].

Jose, J. (2014). Design, Development and Analysis of FDM based Portable Rapid
Prototyping Machine. International Journal of Latest Trends in Engineering and
Technology (IJLTET), [online] 4(4), pp.1-5. Available at: https://www.ijltet.org/wp-
content/uploads/2014/11/1.pdf [Accessed 1 Apr. 2018].

Thiele, T. (2018). Why Is Electrical Grounding So Important?. [online] The Spruce.

Available at: https://www.thespruce.com/what-is-grounding-1152859 [Accessed 1
Apr. 2018].

Krasner G. E. and Pope S. T. (1988). A Description of the Model-View-Controller

User Interface Paradigm in the Smalltalk-80 System. Byte, The Small Systems
Journal, Special Smalltalk-80 Issue, [online] pp.2-3. Available at:
https://www.researchgate.net/profile/Stephen_Pope/publication/248825145_A_cook
book_for_using_the_model_-
_view_controller_user_interface_paradigm_in_Smalltalk_-
_80/links/5436c5f30cf2643ab9888926/A-cookbook-for-using-the-model-view-
controller-user-interface-paradigm-in-Smalltalk-80.pdf [Accessed 1 Apr. 2018].

Argawal, T. (2015). Understanding a Programmable Logic Controller (PLC).

[online] Available at: https://www.elprocus.com/understanding-a-programming-
logic-controller/ [Accessed 1 Apr. 2018].

Toby, B. (2001). EXPGUI, a graphical user interface forGSAS. Journal of Applied

Crystallography, [online] 34(2), pp.210-213. Available at:
https://ncnr.nist.gov/xtal/software/EXPGUI_reprint.pdf [Accessed 1 Apr. 2018].

Mary, R. (2011). What is PLC? - PLC (Programmable Logic Controller) Tutorial.

[online] Available at: https://www.engineersgarage.com/articles/plc-programmable-
logic-controller [Accessed 1 Apr. 2018].

Weller, C., Kleer, R. and Piller, F. (2015). Economic implications of 3D printing:

Market structure models in light of additive manufacturing revisited. International
 61

Journal of Production Economics, [online] 164, pp.43-56. Available at:

https://www.researchgate.net/profile/Frank_Piller/publication/276898572_Economic
_Implications_of_3D_Printing_Market_Structure_Models_Revisited/links/562a41f6
08aef25a243ff3f6/Economic-Implications-of-3D-Printing-Market-Structure-Models-
Revisited.pdf [Accessed 1 Apr. 2018].

Gonzalez, C. (2015). Engineering Essentials: What Is a Programmable Logic

Controller?. [online] Machine Design. Available at:
http://www.machinedesign.com/engineering-essentials/engineering-essentials-what-
programmable-logic-controller [Accessed 1 Apr. 2018].

Whelan, A. and Dunning, D. (1988). The Dynisco extrusion processors handbook.

[London]: [Dynisco].

Negi, S., Dhiman, S. and Kumar Sharma, R. (2014). Basics and applications of rapid
prototyping medical models. Rapid Prototyping Journal, [online] 20(3), pp.256-267.
Available at:
https://www.researchgate.net/profile/Sushant_Negi2/publication/262574639_Basics_
and_applications_of_rapid_prototyping_medical_models/links/568cac2408ae153299
b66f3d.pdf [Accessed 1 Apr. 2018].

Kaplan, A., & Haenlein, M. (2006). Toward a Parsimonious Definition of Traditional

and Electronic Mass Customization. Journal Of Product Innovation
Management, 23(2), 168-182. http://dx.doi.org/10.1111/j.1540-5885.2006.00190.x

Types of 3D printers or 3D printing technologies overview | 3D Printing from scratch.

(2018). 3D Printing from scratch. Retrieved 1 April 2018, from
http://3dprintingfromscratch.com/common/types-of-3d-printers-or-3d-printing-
technologies-overview

Sitthi-Amorn, P., Ramos, J., Wangy, Y., Kwan, J., Lan, J., Wang, W. and Matusik,
W. (2015). MultiFab. ACM Transactions on Graphics, 34(4), pp.129:1-129:11.

Holmström, J., Partanen, J., Tuomi, J. and Walter, M. (2010). Rapid manufacturing
in the spare parts supply chain. Journal of Manufacturing Technology Management,
21(6), pp.687-697.

Ngo, D. (2015). Formlabs Form 2 3D Printer review: An excellent 3D printer for a

hefty price. [online] CNET. Available at: https://www.cnet.com/products/formlabs-
form-2-3d-printer/review/#! [Accessed 11 Apr. 2018].

Wagner, J., Mount, E. and Giles, H. (2014). Extrusion. Oxford [u.a.]: Andrew,
Elsevier.

Kokkinis, D., Schaffner, M. and Studart, A. (2015). Multimaterial magnetically

assisted 3D printing of composite materials. Nature Communications, [online] 6(1).
Available at: https://www.nature.com/articles/ncomms9643.pdf [Accessed 1 Apr.
2018].
 62

Automation.com. (n.d.). Multi-Axis Synchronization in Motion Control. [online]

Available at: https://www.automation.com/library/articles-white-papers/motion-
control/multi-axis-synchronization [Accessed 1 Apr. 2018].

Kim, N., Ryu, M., Hoo, S., Saksena, M., Choi, C. and Shin, H. (1996). Visual
Assessment of a Real-Time System Design: A Case Study on a CNC Controller.
IEEE Real-Time Systems Symposium. [online] Available at:
https://www.researchgate.net/profile/Manas_Saksena/publication/3677999_Visual_A
ssessment_of_a_Real-
Time_System_Design_A_Case_Study_on_a_CNC_Controller/links/00b49519f97e5
0a4d7000000/Visual-Assessment-of-a-Real-Time-System-Design-A-Case-Study-on-
a-CNC-Controller.pdf [Accessed 1 Apr. 2018].

Shin, S., Suh, S. and Stroud, I. (2007). Reincarnation of G-code based part programs
into STEP-NC for turning applications. Computer-Aided Design, [online] 39(1),
pp.1-16. Available at:
http://www.alvarestech.com/temp/ana/Reincarnation%20of%20G-
code%20based%20part%20programs%20into%20STEP-NC%20for.pdf [Accessed 1
Apr. 2018].

CNC Machining Handbook. (2010). McGraw-Hill, pp.1-10.

Denford G and M Programming for CNC Milling Machines. (n.d.). West Yorkshire:
Denford Limited, pp.30-33.
 63

APPENDICES

APPENDIX A : “testpieces1.txt” G-code sample

; thinWallAllowedOverlapPercentage,30
; singleExtrusionMinLength,1
; singleExtrusionMinPrintingWidthPercentage,50
; singleExtrusionMaxPrintingWidthPercentage,200
; singleExtrusionEndpointExtension,0.2
; horizontalSizeCompensation,0 G90
M83
G28 ;z
G1 X50 Y0 Z10 F3000 ; move to wait position off
table
M106 S0 ;fan speed
M190 R60 T0;stabalize heat bed temperature
M109 R235 T0;stabalize extruder temperature
M300 S1000 P400 ; Beep
M300 S1500 P400 ; Beep
G92 E0 ;zero the extruded length again
G1 Z0.5 ; position nozzle
G1 X100 Y0 E8 F1000; slow wipe
G92 E0
;Put printing message on LCD screen
M117 Printing...
G1 Z0.270 F1800
; process Process1
; layer 1, Z = 0.270
T0
; tool H0.300 W0.528
; skirt
G1 X76.713 Y120.897 F4000
G1 X77.683 Y120.495 E0.0212 F1440
G1 X97.694 Y120.495 E0.4036
G1 X98.126 Y120.567 E0.0088
G1 X98.572 Y120.721 E0.0095
G1 X98.957 Y120.930 E0.0088
G1 X100.218 Y121.913 E0.0323
 64

APPENDIX B : “testpieces2.txt” G-code sample

G28 ; home all axes

G29
M109 S[first_layer_temperature]
G92 E0
G1 F200 E4
G92 E0
G1 X100 Y100 F-4000;and End
Gcode:
M104 S0 ;extruder heater off
M140 S0 ;heated bed heater off (if
you have it)
G91 ;relative positioning
G1 E-1 F300 ;retract the filament a
bit before lifting the nozzle, to
release some of the pressure
G0 Z+0.5 E-1 X-20 Y-20
F9000 ;move Z up a bit and retract
filament even more
G28 X0
G90 ;move X/Y to min endstops, so
the head is out of the way
G0 Y180
M84 ;steppers off
G90 ;absolute positioning
 65

APPENDIX C: Part 1 Gantt Chart

No. Project Activities W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

Research on
methods proposed
M1 by other parties in
3D Printing and
controller used.
Research on
techniques to
interpret and
M2
perform G-code
function for
Beckhoff PLC.
Assemble
mechanical
M3
structure for mixer
and extruder.
Perform wiring
connection for
stepper motor,
M4
thermocouple and
switches with
Beckhoff IO Card.
Study on the
programming
techniques of
M5 required sensors
and actuators and
Beckhoff PLC
programming.
 66

APPENDIX D : Part 2 Gantt Chart

No. Project Activities W1 W2 W3 W4 W5 W6 W7 W8 W9 W10 W11 W12 W13 W14

Fine tuning the extruder

M1 structural support and
position
Planning, designing and
M2 drawing electrical
schematic
Rewiring all circuit
M3 connections into 72 ways
socket connector
Rearranging and
labelling all electrical
M4
wiring in the control
panel and machine

Testing and fine tuning

M5
G-code Interpreter

Brainstorming 3D
M6 Printer firmware
architecture

Planning and designing

M7
User Interface

Testing all G-code and

M8
M Code functions
 67

APPENDIX E : Z Axis Spacer Design

 6 5 4 3 2 1

D D
10

C C

55
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN Vincent Hoong 06/09/17

CHK'D

APPV'D

MFG
A Q.A MATERIAL: DWG NO. A
A4
Mild Steel
Z Axis Spacer1
WEIGHT: SCALE:1:1 SHEET 1 OF 1

6 5 4 3 2 1
 69

APPENDIX F : Experimental data of the translated motion with 1.5625x10-4

scale factor

Programmed travelled Actual travelled Difference between

distance (mm) distance (mm) programmed and actual
distance (mm)
5.00 5.00 0
10.00 10.00 0
25.00 25.00 0
32.00 32.00 0
43.00 43.00 0
43.00 43.00 0
47.00 47.00 0
50.00 50.00 0
50.00 50.00 0
50.00 50.00 0
52.00 52.00 0
65.00 65.00 0
65.00 65.00 0
74.00 74.00 0
74.00 74.00 0
81.00 81.00 0
92.00 92.00 0
92.00 92.00 0
105.00 105.00 0
105.00 105.00 0
108.00 108.00 0
108.00 108.00 0
115.00 115.00 0
115.00 115.00 0
120.00 120.00 0
 70

APPENDIX G : Experimental and Actual Data of the Temperature Measured

Temperature Difference between

Temperature
measured with temperature measured by
measured with
infrared thermocouple and infrared
thermocouple ( ֯C)
thermometer ( ֯C) thermometer ( ֯C)
26.5 26.8 0.3
26.5 26.8 0.3
26.5 26.8 0.3
27.0 26.8 0.2
26.5 26.3 0.2
26.5 26.3 0.2
25.6 25.5 0.1
25.5 25.5 0.0
25.3 25.5 0.2
25.4 25.5 0.1
35.0 35.3 0.3
34.3 34.5 0.2
36.4 36.5 0.1
36.4 36.5 0.1
34.2 34.0 0.2
34.0 34.0 0.0
33.8 34.0 0.2
30.8 30.8 0
27.8 27 0.8
42.8 40 2.8
40.9 41 0.1
58.1 50 8.1
84.3 70 14.3
108.8 90 18.8
134 110 24
159.4 130 29.4
 71

183.8 150 33.8

207.6 170 37.6
231.5 190 41.5
241.6 200 41.6
252.4 210 42.4
263.5 220 43.5
273.5 230 43.5
283.4 240 43.4
293.2 250 43.2
303.6 260 43.6
313.5 270 43.5
323.5 280 43.5
327.7 285 42.7

90.6 77 13.6
89.3 75 14.3
88.1 74 14.1
86.3 73 13.3
84 73 11
82.8 72 10.8
81 71 10
80.1 69 11.1
79.9 68 11.9
77.9 67 10.9
77.1 66 11.1
75.3 65 10.3
73.3 63 10.3
70.2 62 8.2
69.8 60 9.8
65.5 57 8.5
61.9 54 7.9
54.9 48 6.9
51.6 46 5.6
 72

47.5 43 4.5
45.1 41 4.1
43 39 4
39.8 37 2.8
37.1 35 2.1
35.6 33 2.6
34.3 32 2.3
34.2 32 2.2
28.1 30 1.9
27.4 30 2.6
26.9 29 2.1
26.6 28 1.4
77.4 65 12.4
76.3 65 11.3
59.3 54 5.3
58.4 54 4.4
49.8 46 3.8
48.6 44 4.6
41.2 38 3.2
39.4 36.5 2.9
 73

APPENDIX H : Electrical Schematic Diagram

 1-PC-BASED 3D PRINTER

Drawing Function Location Revision Date Created by Description Folder designation

01 F1 L1 0 27/1/2018 Vincent COVER PAGE

02 F1 L1 0 27/1/2018 Vincent Drawing list

03 F1 L1 0 27/1/2018 Vincent COLORS OF CABLES

04 F1 L1 0 27/1/2018 Vincent CONTROL PANEL LAYOUT

05 F1 L1 0 27/1/2018 Vincent POWER SCHEMATIC CIRCUIT

06 F1 L1 0 28/1/2018 Vincent POWER SCHEMATIC CIRCUIT 2

08 F1 L1 0 27/1/2018 Vincent SOLID STATE RELAY

09 F1 L1 0 28/1/2018 Vincent STEPPER MOTOR CARD

10 F1 L1 0 28/1/2018 Vincent EL7031(X AXIS)

11 F1 L1 0 28/1/2018 Vincent EL7031(Y AXIS)

12 F1 L1 0 28/1/2018 Vincent EL7031(Z AXIS)

13 F1 L1 0 28/1/2018 Vincent EL7031(E AXIS)

14 F1 L1 0 27/1/2018 Vincent EL2008 OUTPUT (1)

15 F1 L1 0 28/1/2018 Vincent EL2008 OUTPUT (2)

16 F1 L1 0 28/1/2018 Vincent EL1889 INPUT

17 F1 L1 0 28/1/2018 Vincent 72 WAY SOCKET DETAILS

18 F1 L1 0 28/1/2018 Vincent END-STOP AND EMERGENCY SWITCH

19 F1 L1 0 28/1/2018 Vincent STEPPER MOTOR

20 F1 L1 0 28/1/2018 Vincent THERMOCOUPLE

21 F1 L1 0 28/1/2018 Vincent HEAT CATRIDGE

REVISION
PC-BASED 3D PRINTER 0
0 27/1/2018 Vincent
REV. DATE NAME CHANGES SCHEME
LOCATION: User data 1 User data 2
CONTRACT: +L1 Location 1 Vincent Hoong
02

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

ELECTRICAL UTILITIES : SINGLE PHASE AC240V 50HZ + NEUTRAL + EARTH

COLORS OF CABLES COLORS SHORT LIST

MAIN DIAGRAM SINGLE PHASE AC240V L : RED/BROWN 1) BLUE : BL
N : BLUE/BLACK 2) YELLOW : YE
PE : GREEN/YELLOW 3) RED : RD
4) BLACK : BK
5) BROWN : BN
CONTROL DIAGRAM 24VDC P24 : RED
6) WHITE : WH
G : BLACK
7) GREEN : GN
8) ORANGE : OG
12VDC P12 : RED
G : BLACK

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER COLORS OF CABLES 02 0
0 27/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
04 03
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

L.SIDE PANEL FRONT PANEL R.SIDE PANEL

-TRUNKING
MOTOR CARD (S1) MOTOR CARD (S2)

FAN MOTOR CARD (S3) MOTOR CARD (S4)

24V DC
72 WAY
POWER SUPPLY HOSE
CX5120 BECKHOFF IO CARD

RELAY (H1)
GROUND 12V 24V LIVE NEUTRAL
TERMINALTERMINALTERMINALTERMINALTERMINAL

RELAY (H2)

AIR FILTER
RELAY (H3) RELAY (H4) RELAY (H5)

BASE PANEL

12V DC POWER SUPPLY

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER CONTROL PANEL LAYOUT 03 0
0 27/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
05 04
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

24V DC P24
POWER SUPPLY G

12V DC P12
POWER SUPPLY G

LCD
DISPLAY

FAN

L N PE

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER POWER SCHEMATIC CIRCUIT 04 0
0 27/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
06 05
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

C-S1 P5-S1

GND P24
GND P5

5V

-U1
12V
C-S2 P5-S2

GND P24
GND P5

5V

-U2
12V
C-S3 P5-S3

GND P24
GND P5

5V

-U3
12V
C-S4 P5-S4

GND P24
GND P5

5V

-U4
12V
20

GND

GND P24
GND P5

5V

-U5
12V
21

GND

GND P24
GND P5

5V

-U6
12V

P24
GND
PROJECT: TITLE: PREVIOUS REVISION
PC-BASED 3D PRINTER POWER SCHEMATIC CIRCUIT 2 05 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
08 06
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

H1

H1
-H1
C49 C49

H2

H2
-H2
C50 C50

H3

H3
-H3
C51 C51

H4

H4
-H4
C52 C52

H5

H5
-H5
C53 C53

L
L

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER SOLID STATE RELAY 06 0
0 27/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
09 08
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

P12 P12

-PWR 1 -TB6600 (S1) -PWR 2 -TB6600 (S2)

GND GND

-GND 1 -GND 2

20 -DIR-1 1 20 -DIR-2 1
20 20
-DIR+1 1 -DIR+2 1

20 -PUL-1 1 20 -PUL-2 1
P5-S1 P5-S2
-PUL+1 1 -PUL+2 2

20 -ENA-1 5 20 -ENA-2 1
20 20
-ENA+1 1 -ENA+2 2

-A+1 17 -A-1 17 -B+1 1 -B-1 17 -A+2 1 -A-2 1 -B+2 2 -B-2 1

C25
C26
C27
C28
C29
C30
C31
C32

C25 C26 C27 C28 C29 C30 C31 C32

P12 P12

-PWR 3 -TB6600 (S3) -PWR 4 -TB6600 (S4)

GND GND

-GND 3 -GND 4

21 -DIR-3 1 21 -DIR-4 1
21 21
-DIR+3 3 -DIR+4 4

21 -PUL-3 1 21 -PUL-4 1
P5-S3 P5-S4
-PUL+3 3 -PUL+4 4

21 -ENA-3 1 21 -ENA-4 2
21 21
-ENA+3 3 -ENA+4 4

-A+3 2 -A-3 2 -B+3 2 -B-3 2 -A+4 1 -A-4 1 -B+4 1 -B-4 1

86
88
90
92

C33
C34
C35
C36
C33 C34 C35 C36

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER STEPPER MOTOR CARD 08 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
10 09
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL7031(X AXIS)

P24 A+ A- B+ B- G

C1
C2
C3
C4

P24
GND

24V C1 C2 C3 C4 GND

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER EL7031(X AXIS) 09 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
11 10
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL7031(Y AXIS)

P24 A+ A- B+ B- G

C5
C6
C7
C8

P24
GND

24V C5 C6 C7 C8 GND

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER EL7031(Y AXIS) 10 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
12 11
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL7031(Z AXIS)

P24 A+ A- B+ B- G

P24
C13
C14
C15
C16
GND

24V C13 C14 C15 C16 GND

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER EL7031(Z AXIS) 11 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
13 12
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL7031(E AXIS)

P24 A+ A- B+ B- G

P24
C19
C20
C21
C22
GND

24V C19 C20 C21 C22 GND

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER EL7031(E AXIS) 12 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
14 13
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL2008

P24 Q1.0 Q1.1 Q1.2 Q1.3 Q1.4 Q1.5 Q1.6 Q1.7 G

H1
H2
H3
H4
H5

P24
C47
C55
C57
GND

24V H1 H2 H3 H4 H5 FAN1 FAN2 FAN3 GND

C47 C55 C57
PROJECT: TITLE: PREVIOUS REVISION
PC-BASED 3D PRINTER EL2008 OUTPUT (1) 13 0
0 27/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
15 14
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL2008

P24 Q2.0 Q2.1 Q2.2 Q2.3 Q2.4 Q2.5 Q2.6 Q2.7 G

P24
C-S1
C-S2
C-S3
C-S4
GND

24V C-S1 C-S2 C-S3 C-S4 NIL NIL NIL NIL GND

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER EL2008 OUTPUT (2) 14 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
16 15
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-EL1889

P24 I1.0 I1.1 I1.2 I1.3 I1.4 I1.5 I1.6 I1.7 G

98
99

P24
100
101

C10
C12
C18
C24
GND

24V C10 C12 C18 C24 GND

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER EL1889 INPUT 15 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
17 16
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER 72 WAY SOCKET DETAILS 16 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
18 17
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

-E1
C23 C24
C24

EMERGENCY STOP

-ES1
C9 C10
C10

X-AXIS ENDSTOP

-ES2
C11 C12

C23
C12

Y-AXIS ENDSTOP

C9
C11
-ES3
C17 C18
C18

Z-AXIS ENDSTOP

C17
FROM 72 WAY SOCKET

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER END-STOP AND EMERGENCY SWITCH 17 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
19 18
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

C1 C5 C13 C19

-MotA1 -MotA2 -MotA3 -MotA4

C2 C6 C14 C20

C3
C4
C7
C8
C15
C16
C21
C22

-MotB1
-MotB2
-MotB3
-MotB4

C25 C29 C33

-MotA5 -MotA6 -MotA7

C26 C30 C34

C27
C28
C31
C32
C35
C36

-MotB5
-MotB6
-MotB7

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER STEPPER MOTOR 18 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
20 19
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

C37 -+ 20 C39 -+ 21
-THERMOCUP1 -THERMOCUP2

C38 -- 20 C40 -- 21

C41 -+ 22 C43 -+ 23
-THERMOCUP3 -THERMOCUP4

C42 -- 22 C44 -- 23

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER THERMOCOUPLE 19 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
21 20
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
 1 2 3 4 5 6 7 8 9 10

C49 -L 17
-HEAT CATRIDGE 1

-N 17

C50 -L 18
-HEAT CATRIDGE 2

-N 18

C51 -L 19
-HEAT CATRIDGE 3

-N 19

PROJECT: TITLE: PREVIOUS REVISION

PC-BASED 3D PRINTER HEAT CATRIDGE 20 0
0 28/1/2018 Vincent
REV. DATE NAME CHANGES NEXT SCHEME
DRAWN BY: APPROVED BY:
CONTRACT: Vincent Hoong
21
UTAR

SOLIDWORKS Electrical
Document realized with version : 2015.0.3.24
4/16/2018 Beckhoff Embedded PC series CX5000 - CX5010, CX5020 | Embedded PC series with Intel® Atom™ processor

CX5010, CX5020

Status
Ethernet and LEDs
USB connection

Battery compartment
(behind the flap)

DVI connection
Compact
Flash insert (behind
Optional interfaces the flap)
e. g. RS232, PROFIBUS,
CANopen

CX5010, CX5020 | Embedded PC series with Intel®

Atom™ processor
The CX5010 and CX5020 are Embedded PCs from the CX5000 series based on Intel® Atom™ processors and differ only by the CPU version.
The CX5010 has a 1.1 GHz Intel® Atom™ Z510 processor, while the CX5020 has a 1.6 GHz Intel® Atom™ Z530 processor. Apart from the
clock speed, the two processors also differ by the fact that the Z530 features hyperthreading technology, i.e. it has two virtual CPU cores for
more effective execution of software.

Depending on the installed TwinCAT runtime environment, the CX5010/CX5020 can be used for the implementation of PLC or PLC/Motion
Control projects (with or without visualisation).

The extended operating temperature range between -25 and +60 °C enables application in climatically demanding situations.

The order identifier of the CX5000 devices is derived as follows:

Technical data CX5010-x1xx CX5020-x1xx

Processor processor Intel® Atom™ Z510, 1.1 GHz processor Intel® Atom™ Z530, 1.6 GHz
clock frequency (TC3: 40) clock frequency (TC3: 40)
Flash memory 128 MB Compact Flash card (optionally extendable)
Internal main memory 512 MB RAM (internal, not expandable) 512 MB RAM (optionally 1 GB installed ex
factory)
Persistent memory integrated 1-second UPS (1 MB on Compact Flash card)
Interfaces 2 x RJ45, 10/100/1000 Mbit/s, DVI-D, 4 x USB 2.0, 1 x optional interface
Diagnostics LED 1 x power, 1 x TC status, 1 x flash access, 2 x bus status
Clock internal battery-backed clock for time and date (battery exchangeable)
Operating system Microsoft Windows Embedded CE 6 or Microsoft Windows Embedded Standard 2009
https://www.beckhoff.com/english.asp?embedded_pc/cx5010_cx5020.htm 1/4
4/16/2018 Beckhoff Embedded PC series CX5000 - CX5010, CX5020 | Embedded PC series with Intel® Atom™ processor

Control software TwinCAT 2 PLC runtime or TwinCAT 2 NC PTP runtime

I/O connection E-bus or K-bus, automatic recognition
Power supply 24 V DC (-15 %/+20 %)
Current supply E-bus/K-bus 2A
Max. power loss 12 W (including the system interfaces) 12.5 W (including the system interfaces)
Dimensions (W x H x D) 100 mm x 106 mm x 92 mm
Weight approx. 575 g
Operating/storage temperature -25…+60 °C/-40…+85 °C
Relative humidity 95 %, no condensation
Vibration/shock resistance conforms to EN 60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2/EN 61000-6-4
Protection class IP 20
TC3 performance class performance (40); please see here for an overview of all the TwinCAT 3 performance classes

Ordering information E- K- no Windows Windows optional TwinCAT 2 TwinCAT 2

bus bus operating Embedded Embedded TwinCAT 3 PLC NC PTP
system CE 6 Standard 2009 runtime runtime
CX5010-0100 x – x – – – – –
CX5010-0110 x – – x – x – –
CX5010-0111 x – – x – – x –
CX5010-0112 x – – x – – x x
CX5010-0120 x – – – x* x – –
CX5010-0121 x – – – x* – x –
CX5010-0122 x – – – x* – x x
CX5010-1100 – x x – – – – –
CX5010-1110 – x – x – x – –
CX5010-1111 – x – x – – x –
CX5010-1112 – x – x – – x x
CX5010-1120 – x – – x* x – –
CX5010-1121 – x – – x* – x –
CX5010-1122 – x – – x* – x x
CX5020-0100 x – x – – – – –
CX5020-0110 x – – x – x – –
CX5020-0111 x – – x – – x –
CX5020-0112 x – – x – – x x
CX5020-0120 x – – – x* x – –
CX5020-0121 x – – – x* – x –
CX5020-0122 x – – – x* – x x
CX5020-1100 – x x – – – – –
CX5020-1110 – x – x – x – –
CX5020-1111 – x – x – – x –
CX5020-1112 – x – x – – x x
CX5020-1120 – x – – x* x – –
CX5020-1121 – x – – x* – x –
CX5020-1122 – x – – x* – x x

Accessories
CX1900-0204 1 GB DDR2 RAM for CX5020,
instead of 512 MB DDR2 RAM;
pre-assembled ex factory
CX1800-0400 Windows Embedded Standard 7 E
instead of Windows Embedded
Standard 2009; requires at least 1
GB RAM and 8 GB Compact
Flash; supported devices: CX5020
CX1800-0401 Windows Embedded Standard 7 P
32 bit instead of Windows
Embedded Standard 2009; requires

https://www.beckhoff.com/english.asp?embedded_pc/cx5010_cx5020.htm 2/4
4/16/2018 Beckhoff Embedded PC series CX5000 - CX5010, CX5020 | Embedded PC series with Intel® Atom™ processor
at least 1 GB RAM and 8 GB
Compact Flash; supported devices:
CX5020
CX1900-00xx Optionally expandable memory ex
factory.
Instead of 128 MB Compact Flash
card: 1, 2, 4 and 8 GB Compact
Flash card
CX1900-00xx Aditionally expandable memory: 1,
2, 4 and 8 GB Compact Flash card
CX1900-001x Formatting a Compact Flash card
(bootable)

Optional interfaces
CX5010-N020 audio interface, 3 x 3.5 mm jack
sockets, Line In, Mic In, Line Out
or 5.1 Surround
CX5010-N030 RS232 interface, D-sub plug, 9-pin
CX5010-N031 RS485 interface, D-sub socket, 9-
pin, configuration as an end point,
without echo, termination on
CX5010-N031-0001 RS485 interface, D-sub socket, 9-
pin, configuration as an end point,
with echo, termination on
CX5010-N031-0002 RS485 interface, D-sub socket, 9-
pin, configuration as drop point,
without echo, termination off
CX5010-N031-0003 RS485 interface, D-sub socket, 9-
pin, configuration as drop point,
with echo, termination off
CX5010-N031-0004 RS422 interface, D-sub socket, 9-
pin, configuration as full duplex
end point, termination on
CX5010-B110 EtherCAT slave interface,
EtherCAT IN and OUT (2 x RJ45)
CX5010-M310 PROFIBUS master interface, D-sub
socket, 9-pin
CX5010-B310 PROFIBUS slave interface, D-sub
socket, 9-pin
CX5010-M510 CANopen master interface, D-sub
plug, 9-pin
CX5010-B510 CANopen slave interface, D-sub
plug, 9-pin
CX5010-M930 PROFINET RT, controller
interface, Ethernet (2 x RJ45)
CX5010-B930 PROFINET RT, device interface,
Ethernet (2 x RJ45 switched)
CX5010-B950 EtherNet/IP slave interface,
Ethernet (2 x RJ45 switched)
CX5020-N020 audio interface, 3 x 3.5 mm jack
sockets, Line In, Mic In, Line Out
or 5.1 Surround
CX5020-N030 RS232 interface, D-sub plug, 9-pin
CX5020-N031 RS485 interface, D-sub socket, 9-
pin, configuration as an end point,
without echo, termination on
CX5020-N031-0001 RS485 interface, D-sub socket, 9-
pin, configuration as an end point,
with echo, termination on
CX5020-N031-0002 RS485 interface, D-sub socket, 9-
pin, configuration as drop point,
without echo, termination off
CX5020-N031-0003 RS485 interface, D-sub socket, 9-
pin, configuration as drop point,
with echo, termination off
CX5020-N031-0004 RS422 interface, D-sub socket, 9-
pin, configuration as full duplex
end point, termination on
https://www.beckhoff.com/english.asp?embedded_pc/cx5010_cx5020.htm 3/4
4/16/2018 Beckhoff Embedded PC series CX5000 - CX5010, CX5020 | Embedded PC series with Intel® Atom™ processor

CX5020-B110 EtherCAT slave interface,

EtherCAT IN and OUT (2 x RJ45)
CX5020-M310 PROFIBUS master interface, D-sub
socket, 9-pin
CX5020-B310 PROFIBUS slave interface, D-sub
socket, 9-pin
CX5020-M510 CANopen master interface, D-sub
plug, 9-pin
CX5020-B510 CANopen slave interface, D-sub
plug, 9-pin
CX5020-M930 PROFINET RT, controller
interface, Ethernet (2 x RJ45)
CX5020-B930 PROFINET RT, device interface,
Ethernet (2 x RJ45 switched)
CX5020-B950 EtherNet/IP slave interface,
Ethernet (2 x RJ45 switched)

Product announcement CX50x0-B950: estimated market

release 1st quarter 2016

*CX50x0 systems with Microsoft Embedded Standard 2009 require Compact Flash with a capacity of at least 2 GB (must be ordered
separately).

https://www.beckhoff.com/english.asp?embedded_pc/cx5010_cx5020.htm 4/4
 Digital input EL1889

Signal LEDs Signal LEDs

1…8 9…16

Input 1 Input 9

Input 2 Input 10

Input 3 Input 11
Power contact
+24 V
Input 4 Input 12

Input 5 Input 13
Power contact 0 V
Input 6 Input 14

Input 7 Input 15

Input 8 Input 16

Top view Contact assembly

EL1889 | HD EtherCAT Terminal, 16-channel digital input

24 V DC, 0 V (ground) switching
The EL1889 digital input terminal acquires the binary control signals from the process level and transmits them, in an electrically isolated form, to the
higher-level automation device. The EtherCAT Terminal contains 16 channels, whose signal states are displayed by LEDs. The terminal is particularly
suitable for space-saving use in control cabinets. By using the single-conductor connection technique, a multi-channel sensor can be connected in the
smallest space with a minimum amount of wiring. The power contacts are looped through.

The EL1889 EtherCAT Terminal takes the 24 V power contact as its reference for all inputs. The conductors can be connected without tools in the case of
solid wires using a direct plug-in technique.

The HD EtherCAT Terminals (High Density) with increased packing density feature 16 connection points in the housing of a 12 mm terminal block.

Technical data EL1889

Connection technology 1-wire
Number of inputs 16
Nominal voltage 24 V DC (-15 %/+20 %)
“0“ signal voltage 18…30 V
“1“ signal voltage 0…7 V
Input current typ. 3 mA
Input filter typ. 3.0 ms
Distributed clocks –
Current consumption power typ. 35 mA
contacts
Current consumption E-bus typ. 110 mA
Electrical isolation 500 V (E-bus/field potential)
Bit width in the process image 16 inputs
Configuration no address or configuration setting
Conductor types solid wire, stranded wire and ferrule
Conductor connection solid wire conductors: direct plug-in technique; stranded wire conductors and ferrules: spring actuation by screwdriver
Rated cross-section solid wire: 0.08…1.5 mm²; stranded wire: 0.25…1.5 mm²; ferrule: 0.14…0.75 mm²
Weight approx. 55 g
Operating/storage temperature -25…+60 °C/-40…+85 °C
Relative humidity 95 %, no condensation
Vibration/shock resistance conforms to EN 60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2/EN 61000-6-4
Protect. class/installation pos. IP 20/variable (see documentation)
Approvals CE, UL, Ex

BECKHOFF New Automation Technology We reserve the right to make technical changes.
 Digital output EL2008

Signal LED1 Signal LED2

Signal LED3 Signal LED 4
Signal LED5 Signal LED6
Signal LED7 Signal LED 8

Output 1 Output 2

Output 3 Output 4
Power contact
+24 V

Output 5 Output 6
Power contact 0 V

Output 7 Output 8

Top view Contact assembly

EL2008 | 8-channel digital output terminal 24 V DC, 0.5 A

The EL2008 digital output terminal connects the binary control signals from the automation unit on to the actuators at the process level with electrical
isolation. The EtherCAT Terminal indicates its signal state via an LED.

Technical data EL2008 | ES2008

Connection technology 1-wire
Number of outputs 8
Rated load voltage 24 V DC (-15 %/+20 %)
Load type ohmic, inductive, lamp load
Distributed clocks –
Max. output current 0.5 A (short-circuit-proof) per channel
Short circuit current typ. < 2 A
Reverse voltage protection yes
Breaking energy < 150 mJ/channel
Switching times typ. TON: 60 µs, typ. TOFF: 300 µs
Current consumption E-bus typ. 110 mA
Electrical isolation 500 V (E-bus/field potential)
Current consumption power typ. 15 mA + load
contacts
Bit width in the process image 8 outputs
Configuration no address or configuration setting
Weight approx. 55 g
Operating/storage temperature -25…+60 °C/-40…+85 °C
Relative humidity 95 %, no condensation
Vibration/shock resistance conforms to EN 60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2/EN 61000-6-4
Protect. class/installation pos. IP 20/see documentation
Pluggable wiring for all ESxxxx terminals
Approvals CE, UL, Ex

BECKHOFF New Automation Technology We reserve the right to make technical changes.
 Analog input EL3054

Run LED Run LED

Error LED 1 Error LED2
Run LED Run LED
Error LED3 Error LED4

Input 1 Input 2

+24 V +24 V
Power contact
+24 V

Input 3 Input 4
Power contact 0 V

+24 V +24 V

Top view Contact assembly

EL3054 | 4-channel analog input terminal 4…20 mA,

single-ended, 12 bit
The EL3054 analog input terminal processes signals in the range between 4 and 20 mA. The current is digitised to a resolution of 12 bits and is
transmitted (electrically isolated) to the higher-level automation device. The input electronics are independent of the supply voltage of the power
contacts. In the EL3054 with four inputs, the 24 V power contact is connected to the terminal in order to enable connection of 2-wire sensors without
external supply. The power contacts are connected through. The signal state of the EtherCAT Terminal is indicated by light emitting diodes. The error
LEDs indicate an overload condition and a broken wire.

Technical data EL3054 | ES3054

Number of inputs 4 (single-ended)
Technology single-ended
Signal current 4…20 mA
Distributed clocks –
Internal resistance 85 Ω typ.
Input filter limit frequency 1 kHz
Dielectric strength max. 30 V
Conversion time 0.625 ms default setting, configurable
Resolution 12 bit (16 bit presentation, incl. sign)
Measuring error < ±0.3 % (relative to full scale value)
Electrical isolation 500 V (E-bus/signal voltage)
Current consumption power –
contacts
Current consumption E-bus typ. 130 mA
Bit width in the process image inputs: 16 byte
Configuration no address or configuration setting required
Special features standard and compact process image, activatable FIR/IIR filters, limit value monitoring
Weight approx. 60 g
Operating/storage temperature -25…+60 °C/-40…+85 °C
Relative humidity 95 %, no condensation
Vibration/shock resistance conforms to EN 60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2/EN 61000-6-4
Protect. class/installation pos. IP 20/variable
Pluggable wiring for all ESxxxx terminals
Approvals CE, UL, Ex

BECKHOFF New Automation Technology We reserve the right to make technical changes.
 Analog input EL3314

Run LED 1 Error LED 1

Run LED 2 Error LED2 Observe for earthed
Run LED 3 Error LED 3 thermocoupler:
Run LED 4 Error LED 4 differential inputs
max. ± 2 V to ground

+TC1 -TC1

+TC2 -TC2
Power contact
+24 V

+TC3 -TC3
Power contact 0 V

+TC4 -TC4

Top view Contact assembly

EL3314 | 4-channel thermocouple input terminal with

open-circuit recognition
The EL3314 analog input terminal allows four thermocouples to be connected directly. The EtherCAT Terminal circuit can operate thermocouple sensors
using the 2-wire technique. A microprocessor handles linearisation across the whole temperature range, which is freely selectable. The error LEDs
indicate a broken wire. Compensation for the cold junction is made through an internal temperature measurement at the terminal. The EL3314 can also
be used for mV measurement.

Technical data EL3314

Number of inputs 4
Power supply via the E-bus
Thermocouple sensor types types K, J, L, E, T, N, U, B, R, S, C (default setting type K), mV measurement
Distributed clocks –
Input filter limit frequency typ. 1 kHz; dependent on sensor length, conversion time, sensor type
Connection method 2-wire
Wiring fail indication yes
Conversion time approx. 2.5 s up to 20 ms, depending on configuration and filter setting, default: approx. 250 ms
Temperature range in the range defined in each case for the sensor (default setting: type K; -200…+1370 °C); voltage measurement: ±30
mV…±75 mV
Resolution 0.1 °C per digit
Measuring error < ±0.3 % (relative to full scale value)
Electrical isolation 500 V (E-bus/signal voltage)
Current consumption power –
contacts
Current consumption E-bus typ. 200 mA
Bit width in the process image 4 x 32 bit TC input, 4 x 16 bit TC output
Configuration no address setting, configuration via the controller
Special features open-circuit recognition
Weight approx. 60 g
Operating/storage temperature -25…+60 °C/-40…+85 °C
Relative humidity 95 %, no condensation
Vibration/shock resistance conforms to EN 60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2/EN 61000-6-4
Protect. class/installation pos. IP 20/variable
Approvals CE, UL, Ex

Related products
EL3314-0010 4-channel thermocouple input terminal, high-precision, with open-circuit recognition
EL3314-0020 4-channel thermocouple input terminal, high-precision, with open-circuit recognition, with calibration certificate
EL3314-0090 4-channel thermocouple input, 16 bit, TwinSAFE SC

BECKHOFF New Automation Technology We reserve the right to make technical changes.
 Motion EL7031

Run LED Power LED

Turn CW LED Turn CCW LED
Enable LED Warning
Error A LED Error B LED

A1 A2

B1 B2
Power contact
+24 V

Power contact 0 V

E1 E2

Top view Contact assembly

EL7031 | Stepper motor terminal 24 V DC, 1.5 A

The EL7031 EtherCAT Terminal is intended for the direct connection of different small Stepper Motors. The slimline PWM output stages for two motor
coils are located in the EtherCAT Terminal together with two inputs for limit switches. The EL7031 can be adjusted to the motor and the application by
changing just a few parameters. 64-fold micro-stepping ensures particularly quiet and precise motor operation.

Technical data EL7031 | ES7031

Technology direct motor connection
Number of outputs 1 stepper motor, 2 phases
Number of inputs 2
Number of channels 1 stepper motor, 2 digital inputs
Load type uni- or bipolar stepper motors
Nominal voltage 24 V DC (-15 %/+20 %)
Power supply 24 V DC via the power contacts, via the E-bus
Max. output current 1.5 A (overload- and short-circuit-proof)
Max. step frequency 1000, 2000, 4000 or 8000 full steps/s (configurable)
Step pattern 64-fold micro stepping
Current controller frequency approx. 25 kHz
Diagnostics LED error phase A and B, loss of step/stagnation, power, enable
Resolution approx. 5000 positions in typ. applications (per revolution)
Electrical isolation 500 V (E-bus/signal voltage)
Current consumption power typ. 30 mA + motor current
contacts
Current consumption E-bus typ. 120 mA
Distributed clocks yes
Control resolution approx. 5000 positions in typ. applications (per revolution)
Special features travel distance control
Weight approx. 50 g
Operating/storage temperature 0…+55 °C/-25…+85 °C
Relative humidity 95 %, no condensation
Vibration/shock resistance conforms to EN 60068-2-6/EN 60068-2-27
EMC immunity/emission conforms to EN 61000-6-2/EN 61000-6-4
Protect. class/installation pos. IP 20/see documentation
Pluggable wiring for all ESxxxx terminals
Approvals CE, UL

Accessories
EL9576 brake chopper terminal, 72 V, 155 µF
AS20xx | AS10xx Product overview stepper motors
Leitungen und Getriebe Prefabricated connecting cables in IP 20 and IP 67 protection for AS10xx stepper motors

BECKHOFF New Automation Technology We reserve the right to make technical changes.
 Related products
EL7037 stepper motor EtherCAT Terminal, IMAX = 1.5 A, 24 V, IP 20, vector control
EL7041 stepper motor EtherCAT Terminal, IMAX = 5 A, 50 V, IP 20
EL7047 stepper motor EtherCAT Terminal, IMAX = 5 A, 50 V, IP 20, vector control
EP7041-0002 stepper motor EtherCAT Box (industrial housing), IMAX = 5 A, 50 V, IP 67
KL2531 stepper motor Bus Terminal, IMAX = 1.5 A, 24 V, IP 20
KL2541 stepper motor Bus Terminal, IMAX = 5 A, 50 V, IP 20

BECKHOFF New Automation Technology We reserve the right to make technical changes.