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LumenPnP Control Box

Introduction

The purpose of these work instructions is to cover the assembly process for the LumenPnP's Control Box. This assembly is used by the LumenPnP to contain its microcontroller and pneumatics system.

Prepare control-box

  • Remove support material from the 3D printed control-box alt text alt text

  • Glue 2x M5-hex-nut into the control-box

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Prepare pneumatics

Right-side pneumatic system

  • Perform the following steps:
    • Connect vacuum-pump to solenoid-valve with a 70mm piece of 6x4-soft-pvc-tubing-blue
    • Connect solenoid-valve to reduction-tee-4-6-4 with a 60mm piece of 6x4-soft-pvc-tubing-blue
    • Adhere a Right Valve label to the end of the solenoid-valve wire

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Left-side pneumatic system

  • Perform the following steps:
    • Connect vacuum-pump to solenoid-valve with a 70mm piece of 6x4-soft-pvc-tubing-red
    • Connect solenoid-valve to reduction-tee-4-6-4 with a 60mm piece of r6x4-soft-pvc-tubing-red
    • Adhere a Left Valve label to the end of the solenoid-valve wire

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Install pneumatics systems into control-box

Install left-side pneumatic system

  • Suspend the vacuum-pump in the control-box with 2x rubber-band, matching the arrangement shown below alt text
  • Click the solenoid-valve into the mounting receptacle as shown below alt text
  • Slide the reduction-tee-4-6-4 into the mounting bracket found next to vacuum line inlet alt text alt text

Install right-side pneumatic system

Repeat the above process to install the right-side pneumatic system

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Bolt 2x reduction-tee-4-6-4 to control-box

  • Use 2x m3x30-socket-head and 2x m3-hex-nut to attach 2x reduction-tee-4-6-4 to control-box alt text alt text alt text

Perform cable management

  • Tuck the Left Valve and Right Valve cables into to the cable management feature on the back wall of control-box

    • Route the Left Valve wire underneath the tubing

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  • Tuck the Left Pump and Right Pump cables into the back corner of the control-box

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Connect vacuum lines to motherboard-rev05

  • Prepare a 145mm piece of pu-tube-4x2.5-blue
  • Prepare a 165mm piece of pu-tube-4x2.5-red

  • Gather 1pcs motherboard-rev05 from inventory

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  • Connect the tubes

    • Connect pu-tube-4x2.5-blue to the vacuum sensor labled Right Vac
    • Connect pu-tube-4x2.5-red to the vacuum sensor labeled Left Vac

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  • When completed the assembly should resemble the image shown below:

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Screw motherboard-rev05 into control-box

  • Place motherboard-rev05 into control-box while sliding the USB and barrel jack ports into the cutouts on the left side of the print alt text alt text

  • Install motherboard-rev05 into control-box with 4x m3x12-button-head-self-tapping-screw

    • Set the torque driver to ~1.5 to avoid stripping a screw hole alt text alt text alt text

Connect a vacuum line to each reduction-tee-4-6-4

  • Route the vacuum lines underneath the back right motherboard standoff before plugging each tube into its respective reduction-tee-4-6-4 alt text alt text

Perform cable management

  • Connect the Left Pump, Right Pump, Left Valve, and Right Valve cables into the corresponding ports on motherboard-rev05 alt text
  • Run the cables back along the pathway between the two rows of connectors
  • Add a zip-tie around all four cables to keep them well managed alt text

You may now proceed to Gundam Testing!

Gundam Testing

  • Install control-box-asm into Gundam alt text alt text
  • Remove control-box-lid and set it aside alt text
  • Connect the vacuum tubes, being sure to match the colors up correctly alt text alt text
  • Begin to connect the Gundam jig's cables into motherboard-rev05 alt text alt text alt text
  • Proceed to connect USB-B cable to the motherboard.
  • Hold the BOOT button on the motherboard, and plug in the 24v DC barrel jack while holding it. After two seconds, you can stop pressing BOOT.
  • In a new terminal window, type flashmarlin to install the firmware onto the motherboard.
  • Once complete, press the RESET button on the motherboard.
  • Open the Gundam test software.

  • If it's not already open, in a new terminal window, just type gundam.

  • Select the “REV05-Mobo.json” test from the dropdown menu, then hit “Run Test”.

  • Perform each of the tests in Gundam, and follow the prompts.

  • If some of the tests fail, continue through the rest of the test until every test has been run.

  • The last test is assigning the control box a serial number. Only perform this test if all others have passed. We only want to assign a serial number to a working control box.

  • This text just prompts you for a serial number. Grab a new serial number sticker from the sheet and a new 4"x6" label from the pile, ensuring the serial numbers match, and input the serial number into the prompt for the test.

  • Unplug the USB and Power cables from the control box.

  • Unplug all of the cables and pneumatics from the control box.

  • Put the serial number sticker in the recess in the back of the control box

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  • Fit a lid on the control box, and make sure the 4"x6" label is sandwiched between the box and the lid.

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  • Check that both buttons click well.

The control box has passed Gundam QC testing!