View source for RPI Step Motor controller - Viktor Mihalovic

== Project Overview: ==
The primary goal of the RPI Step Motor Controller project is to automate the process of controlling the height of the Oree R-t model laser arm for laser marking in production. This automation involves automatically scanning a product's serial number, retrieving information from a database, and adjusting the height of the laser arm accordingly. This project was focused on part to manage height of laser arm

== Hardware Setup: ==
* Raspberry Pi Model 4 4GB
* Oree R-t model laser
* Step Motor: 57CM22X
* Microstep Drive: DM542
* Controller with display: MC-24MR-4MT-500-FX-A
* Bottom and top sensors: TL-Q5MC1-Z


== Raspberry Pi Contact Board: ==
To interface the Raspberry Pi with the Microstep Drive DM542 and incorporate buttons and LEDs for control and feedback, a custom contact board was created. The contact board consists of the following components:

* Transistors
* Resistors
* Buttons
* LEDs
* Wires


This contact board facilitates the control and monitoring of the stepper motor and provides visual feedback through LEDs. It is responsible for translating signals between the Raspberry Pi GPIO pins and the connected components, enabling seamless integration into the overall system. Chalange was to change input signals to 3.3V and output signals to 5V. For this purpose I need to use transistors and other components.


[[File:Viktor_mihalovic_contact_board.jfif|900px]]

== Software Setup: ==
Programming Language: Python
Libraries/Frameworks: RPi.GPIO, time

== Testing and Validation: ==

Extensive testing was conducted to ensure the accuracy and reliability of the height adjustment process. Commands were implemented to adjust the height for different locations, and the system demonstrated precise control, achieving adjustments accurate to within a tenth of a millimeter.

== Code Explanation: ==

<syntaxhighlight lang=python>
import RPi.GPIO as GPIO #Import necessary libraries
import time
GPIO.setmode(GPIO.BCM) #Set GPIO mode
class Arm:
    def __init__(self):
        # Initialize GPIO pins and variables
        self.settings()
        self.sensor_down = False
        self.sensor_up = False
        self.buttonUp = False
        self.buttonDown = False
        self.actHeight = -1
        self.check_read_sensors()
        self.numberOfSteps = 0
    
    # Function to initialize GPIO settings
    def settings(self):
        # Define GPIO pins for motor control, sensors, and buttons
        self.motor_direction_pin = 27
        self.motor_step_pin = 22
        self.sensor_down_pin = 23
        self.buttonUpPin = 25
        self.buttonDownPin = 6
        self.sensor_up_pin = 24
        self.delay = 0.000003  # Adjust this delay for motor speed
        self.pulses_per_rev = 5000   # Set pulses per revolution
        # Setup GPIO pins
        GPIO.setup(self.motor_direction_pin, GPIO.OUT)
        GPIO.setup(self.motor_step_pin, GPIO.OUT)
        GPIO.setup(self.sensor_down_pin, GPIO.IN, pull_up_down=GPIO.PUD_DOWN)
        GPIO.setup(self.sensor_up_pin, GPIO.IN, pull_up_down=GPIO.PUD_DOWN)
        GPIO.setup(self.buttonUpPin, GPIO.IN, pull_up_down=GPIO.PUD_UP)
        GPIO.setup(self.buttonDownPin, GPIO.IN, pull_up_down=GPIO.PUD_UP)

    # Function to perform a single step
    def step_once(self):
        self.numberOfSteps += 1
        GPIO.output(self.motor_step_pin, True)
        time.sleep(self.delay)
        GPIO.output(self.motor_step_pin, False)
        time.sleep(self.delay)
    
    # Function to step the motor forward
    def step_forward(self):
        GPIO.output(self.motor_direction_pin, True)
        self.step_once()
        self.actHeight += 0.0008
        
    # Function to step the motor in reverse
    def step_reverse(self):
        GPIO.output(self.motor_direction_pin, False)
        self.step_once()
        self.actHeight -= 0.0008

    # Function to stop the motor
    def stopMotor(self):
        GPIO.output(self.motor_step_pin, False)
        
    # Function to read sensor states
    def check_read_sensors(self):
        self.sensor_down = not GPIO.input(self.sensor_down_pin)
        self.sensor_up = not GPIO.input(self.sensor_up_pin)
        self.buttonUp = not GPIO.input(self.buttonUpPin)
        self.buttonDown = not GPIO.input(self.buttonDownPin)

    # Main function to start height adjustment
    def start(self):
        while True:
            self.check_read_sensors()
            if self.sensor_down and self.buttonDown:
                self.stopMotor()
                print('Hit bottom')
                continue
            if self.sensor_up and self.buttonUp:
                self.stopMotor()
                print('Hit top')
                continue
            if self.buttonUp and self.buttonDown:
                self.stopMotor()
                print('Both Sensors')
                break
            if self.buttonUp:
                self.step_forward()
                print('Forward')
                continue
            if self.buttonDown:
                self.step_reverse()
                print('Backward')
                continue
            self.stopMotor()
        GPIO.cleanup()

    # Function to find the bottom position
    def findBottom(self):
        while not self.sensor_down:
            self.check_read_sensors()
            self.step_reverse()
        self.actHeight = 143
        self.numberOfSteps = 0
    
    # Function to move to a specified height
    def goto(self, height):
        self.check_read_sensors()
        if self.actHeight <= height:
            while round(self.actHeight,2) != round(height,2) and not self.sensor_up:
                self.step_forward()
                self.check_read_sensors()
        else:
            while round(self.actHeight,2) != round(height,2) and not self.sensor_down:
                self.step_reverse()  
                self.check_read_sensors()

#Main function
if __name__ == "__main__":
    print("Program has started")
    a = Arm()
    a.findBottom()
    print('I am at 0 cm')
    time.sleep(4)
    print('Going up to 480 mm')
    a.goto(480)
    print('I am at 480 mm')
    time.sleep(4)
    print('Going up to 200 mm')
    a.goto(200)
    print('I am at 200 mm')
    time.sleep(4)
    print('Going up to 0 mm')
    a.goto(0)
    print('Stopped at 143 mm due to height limit')
    GPIO.cleanup()
</syntaxhighlight>

== Video: ==

<youtube>1esaYziMh98</youtube>

== Conclusion: ==

The RPI Step Motor Controller project successfully achieves the goal of automating the process of controlling the height of the Oree R-t model laser arm. With further improvements and enhancements, it can effectively contribute to the automation of the laser marking process in production.

== Sources: ==

* [https://kitaez-cnc.com/f/dm542.pdf DM542]
* [https://forums.raspberrypi.com/  Raspberry forums]
* [https://www.oreelaser.com/product/Desk-Table-Fiber-Laser-Marking-Machine-R-T-47.html Oree laser machine]
* [https://www.youtube.com/watch?v=RJ1fmAvi-Vw Step motor rotation speed]

__notoc__