By
Richard Christophorus Keriahan 11501029
BACHELOR’S DEGREE in
MECHANICAL ENGINEERING-MECHATRONICS CONCENTRATION FACULTY OF ENGINEERING AND INFORMATION TECHNOOGY
SWISS GERMAN UNIVERSITY The Prominence Tower
Jalan Jalur Sutera Barat No. 15, Alam Sutera Tangerang, Banten 15143 - Indonesia
July 2019
Revision after thesis defense on 12th of July 2019
contains no material previously published or written by another person, nor material which to a substantial extent has been accepted for the award of any other degree or diploma at any educational institution, except where due acknowledgement is made in the thesis.
Richard Christophorus Keriahan
__________________________________________
Student Date
Approved by:
Dr. Rusman Rusyadi, B.Sc., M. Sc.
_____________________________________________
Thesis Advisor
Date
Benny Widjaja, M.T.
_____________________________________________
Thesis Co-Advisor Date
Dr. Maulahikmah, S.Kom., M. Sc.
_____________________________________________
Dean Date
ABSTRACT
DEVELOPMENT OF LASER CUTTING AND ENGRAVING CNC MACHINE USING LINUXCNC
By
Richard Christophorus Keriahan Dr. Rusman Rusyadi, B.Sc., M. Sc.
Benny Widjaja, M.T.
SWISS GERMAN UNIVERSITY
The purpose of this research is to make a mini laser cutting and engraving machine. The system in this research will be controlled by LinuxCNC through parallel port. The variance of distance due to the Z-axis is expected to make this machine to have the ability of laser cut instead of only engraving. A custom kinematic code for CoreXY kinematics is also needed in order to make the machine work. Modification in the HAL file also needs to be made to be able to output the laser beam.
Keywords: LinuxCNC, CoreXY, Laser cut, Laser engraving
© Copyright 2019
By Richard Christophorus Keriahan All rights reserved
DEDICATION
I dedicate this work for God, my family and friends who never failed to believe in me and the sake of the future of my country, Indonesia.
ACKNOWLEDGEMENTS
First and foremost, I want to express my gratitude to Jesus Christ, my Lord and Savior, as He never fails to give me His blessings and guidance in each and every day. Secondly, I want to thank my family especially to my father who always advise and calm me down each time I feel tired, and to my mom who always listen to all of my thoughts. Thirdly, I want to thank every single one of my lecturers who have guided me so far until this point, especially to Mr. Rusman Rusyadi for the endless weekly meetings and updates and Mr.
Benny Widjaja for patiently coping up with all of my questions.
Last but not least, I want to thank all of my friends who believe in me:
− Was Corn Now Tamales: Thank you for all of the craziness since the 1st semester.
I believe that every single one of us has our own story which will end in happiness.
− Alexander Agung, Davin Edison, Fransiska: You guys play a big role in my university life, especially for all the laughter, the food recommendations and mental support. Thank you.
−
− Brewok Study Club: I thank each one of you for all of the mental support and amazing experience in this so called “study group”. Especially Geraldus Aldo for always helping me in most of my critical times, Kelvin Galiny for endlessly giving me mental support and Mikael Kevin (Mikat) for all of our dark jokes and support since our 1st semester.
− Mas Freddy and Ko Kris: Thank you for all the ideas, inspirations and support since the beginning of my thesis work until the day of my thesis defense.
− Leonard Chandra & Yosua Adit: Thank you for introducing me to “Tahu Petis” and other foods at “Tenda Biru”.
− Jason Pratama, Ignatius Deo, Dinar Sukanto and other fellow “Anak WS”.
− To all of my friends who have given me ride to campus and going back to my dorm during my university life.
To all of the people out there whose name I could not mention one by one, I thank you.
TABLE OF CONTENTS
STATEMENT BY THE AUTHOR ... 2
ABSTRACT ... 3
DEDICATION ... 5
ACKNOWLEDGEMENTS ... 6
CHAPTER 1 - INTRODUCTION ... 14
1.1. Background ... 14
1.2. Thesis Objectives ... 15
1.3. Thesis Problem ... 15
1.4. Thesis Scope ... 16
1.5. Thesis Limitation ... 16
1.6. Significance of Study ... 16
1.7. Research Question ... 16
1.8. Hypothesis ... 17
1.9 Thesis Organization ... 18
CHAPTER 2 – LITERARTURE REVIEW ... 19
2.1. CNC Machine ... 19
2.1.1. Machines that are retrofitted: ... 19
2.1.2. Machine that are custom-built for CNC Operation: ... 20
2.2. Laser Cutting and Engraving ... 21
2.2.1. The Machine ... 21
2.2.2. Difference Between Laser Cutting and Engraving ... 23
2.2.3. Different Kinds of Laser ... 23
2.3. CNC Machine Software ... 24
2.3.1. CAD Software ... 24
2.3.2. CAM Software ... 25
2.4.1. How G-code works ... 29
2.4.2. Other NC codes... 30
2.5. I/O Device ... 32
2.5.1. Breakout Board ... 32
2.5.2. Raspberry Pi ... 33
2.5.3. Mesa 7I54 Board ... 33
2.5.4. D-subminiature ... 34
2.6. Linux and Real-Time System ... 35
2.6.1. Linux on real-time system ... 35
2.6.2. Types of Linux-based RTOS ... 36
2.6.3. Task Scheduling... 38
CHAPTER 3 – RESEARCH METHODS ... 40
3.1. Introduction ... 40
3.2. System Design ... 40
3.3. Mechanical Design ... 44
3.3.1. The Assembly Structure Design ... 44
3.3.2. CoreXY Motion Kinematics ... 44
3.3.3. Force for Static Torque Calculation in CoreXY System ... 47
3.3.4. Force for Dynamic Torque Calculations in CoreXY system ... 52
3.3.5. Torque Calculation Compared With 3-Axis Cartesian System ... 55
3.4. Software Design ... 57
3.4.1. Starting the LinuxCNC ... 58
3.4.2. Modified Kinematics Code ... 63
3.4.3. Modified HAL Code for Laser Output ... 64
3.5. Electrical Schematic ... 67
CHAPTER 4 – RESULTS AND DISCUSSIONS ... 71
4.1. Component Testing ... 79
4.1.1. Movement along X Axis ... 79
4.1.2. Movement along Y Axis ... 80
4.1.3. Movement along Z Axis ... 80
4.2. Integrated System Testing ... 82
4.2.1. Diagonal Line Engraving Test ... 82
4.2.2. Shape Cutting Test for Wood ... 92
4.2.3. Shape Cutting Test for Acrylic ... 94
4.3. Latency Analysis ... 98
4.4. Products from laser engrave and laser cut ... 101
CHAPTER 5 – CONCLUSIONS AND RECCOMENDATIONS ... 102
5.1. Conclusions ... 102
5.2. Recommendations ... 104
GLOSSARY ... 105
APPENDIX ... 106
REFERENCES ... 115
CURRICULUM VITAE ... 116
