Building a DIY SMT Pick&Place Machine with OpenPnP and Smoothieboard (NXP LPC1769)

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This article is about a project I have started back in January 2018. As for many of my projects, it took longer than anticipated.But now it is working, and the result is looking very good: a DIY automated pick and place machine to place parts on circuit boards. In the age of cheap PCBs, that machine closes the gap for small series of boards which have to be populated in a time consuming way otherwise.

OpenPnP Pick&Place Machine

OpenPnP Pick&Place Machine

Outline

This DIY machine can populate circuit boards with SMD/SMT parts. If you are wondering, what this is: it is about putting Surface Mounted Devices (SMD) on a Printed Circuit Board (PCB). I gave a talk at the Embedded Computing Conference 2018 on this subject (ECC18 Styger – PickAndPlace mit OpenPnP).

The following videos give an overview about the current state of that machine:

The motivation of building such a machine is that at the university we are populating boards by hand:

Solder gets placed on the boards (stencils are rarely used):

Applying solder

Applying solder

Solderpaste on PCB

Solder paste on PCB

Then parts get placed on the boards

manual placing

manual placing

We do have as well vision support for the manual placing:

manual placing with vision

manual placing with vision

Resistors placed on PCB

Resistors placed on PCB

And finally they run through a reflow oven:

Reflow Oven

Reflow Oven

That’s all working fine. The problem is that this all takes a lot of time. Doing it for one board is one thing, but doing it for 10-50 boards takes too much time. Clearly, for mor than 50 or 100 boards, outsourcing is the logical choice. But for a few boards as we usually have to do, outsourcing is not the best option as it is expensive and takes a lot of time too.

What I wanted is a machine to automate the manual placing of components. Such a machine is called a ‘Pick and Place’ machine: it picks parts and places them on a PCB.

DIY Pick & Place Maschine: OpenPnP

When searching for such Pick&Place machines, I stumbled over the OpenPnP project at http://openpnp.org/: A open source community and project which builds such machines. So I thought: why not building one myself too? And here we go :-).

OpenPnP offers a framework to run such a machine. They have guides and tutorials how to build such a machine. And it is up to you how you build it and what features get added. I did not want to build the fastest or the cheapest machine: my goal was to keep the hardware costs below $1000, and that the machine is able to place parts down to the 0402 size.

SMD Sizes

SMD Sizes

All the software and BOM are available on GitHub (see links section at the end of this article).

The machine uses 24V stepper motors for X, Y and Z axis. Two smaller stepper motors on the head (C1, C2) can be rotated. Attached to the head is a down-looking camera.

Integrated in the work area are nozzle changers, a bottom camera and different feeders.

Under the base plate all the other electronics (solenoid, pump, USB Hub, feeder and controller board with LCD and power supply.

CAD (KiCAD, Altium, Eagle) data is loaded on a host PC running OpenPnP.

System Overview

System Overview

Below are pictures of the machine under construction with some details. I hope this gives you ideas and an inspiration to build your own machine.

Microcontroller

The heart of the machine is the NXP LPC1769 on the Smoothieboard:

NXP LPC1769

NXP LPC1769

It is responsible for all the sensors and drives all the motors. The picture below shows first tests with a stepper motor:

first stepper

first stepper

Frame

The frame is constructed with 20×20 and 20×40 standard aluminum extrusion profiles:

Aluminium

Aluminium

The profiles allow an easy construction of the frame.

Aluminium Frame Construction

Aluminium Frame Construction

2040 Profiles

2040 Profiles

Rails

The linear rails arrived very well oiled and in good shape.

Linear Rails arrived

Linear Rails arrived

The rails get attached to the top of the frame:

Rail mounted on frame

Rail mounted on frame

It has been an iterative process, and many parts first have been built with a laser cutter and plywood. Below is a picture of an early version:

Rail with end bracket

Rail with end bracket

Vacuum Pump

Actuators in the system are 24V. Below is the diaphragm vacuum pump used for the nozzles:

24V Vacuum Pump

24V Vacuum Pump

Terminals of the pump:

Vacuum Pump Connectors

Vacuum Pump Connectors

The pump together with the two high-speed solenoid on a base plate. To reduce noise, the pump has been placed into a box standing on anti-vibration feet:

Pump with Enclsosure

Pump with enclosure

Pump Top View

Pump Top View

Below a first test with three stepper motors:

Bench

Bench

Power Supply

For the 24V 13.4A Power supply I added an on-off switch with integrated fuse holder:

Power Supply with On-Off Switch

Power Supply with On-Off Switch

Flyback Diodes

As flyback diodes for the pump and solenoids I used the Vishay BYV27-200-TAP:

Protection Diodes

Protection Diodes

Vacuum Valves

I’m using the STNC TM-06 high frequency valve (24VDC) with 1/8″ pipe connectors:

STNC TM-06 Valve

STNC TM-06 Valve

Below how they are connected to the board with the flyback diodes mounted to the connectors:

Protection Diodes for Soleoinide

Protection Diodes for Solenoids

For example the M813 G-Gode turns it ON (2-1 connected), and M812 turns it OFF (2-3 connected). The image below shows the air flow:

STNC Directions

STNC Directions

That means the vacuum pump will be on connection 1 and the nozzle on connection 2, with connection 3 used to release the vacuum.

End Stops

The total of 6 end stops are optical ones:

End Stops

End Stops

The first (not ideal) way to mount the end stops:

First way for endstops

First way for endstops

Second version of end stop mounting with 3D printed holder:

3D Printed End Stop Holder

3D Printed End Stop Holder

3D Printed End Stop Holder back side

3D Printed End Stop Holder back side

Mounted End Stop

Mounted End Stop

3D Printed End Stop Parts

3D Printed End Stop Parts

3D printing end stop blades:

3D Printing End stop Blades

3D Printing End stop Blades

Mounted end stopper blade:

Mounted End Stopper Blade

Mounted End Stopper Blade

In a next step lowered the end stop position:

Lowered End Stop Position

Lowered End Stop Position

Belt and Endstop

Belt and Endstop

Pick and Place Head

Very first version of the head:

First Pick Head

First Pick Head

Holder for the pick stepper motor:

Holder for the Pick Stepper Motor

Holder for the Pick Stepper Motor

Rails for the pick head steppers:

Pick Head Raiis

Pick Head Rails

Frame with first pick head:

Frame with first pick head

Frame with first pick head

Pick head with end stops:

Pick Head with End Stops

Pick Head with End Stops

Because the X axis was not rigid enough, 3D printed brackets were added:

3D Printed Bracket

3D Printed Bracket

X-Y-Rail

Mounting Bracket for X-Y Rail

Mounting Bracket for X-Y Rail

T-Nuts on X-Y Rail:

T-Nuts on X-Y Rail

T-Nuts on X-Y Rail

Y Steppers

Two stepper motors wired together are driving the Y axis. It works, but I would not recommend that approach: better use a single motor with an extended shaft and coupling.

Wiring of Y motors

Wiring of Y motors

Y Stepper Wiring

Y Stepper Wiring

Laser cutting the motor and pulley brackets:

Laser Cutting Motor Backets

Laser Cutting Motor Brackets

Of course it was an iterative process, and many design ideas did not end up in the final machine. The good thing with plywood is that it is cheap and is easy to construct with it.

Pile of plywood

Pile of plywood

Second Pick Head Design

The second version of the pick head was more compact and easier to attach to the linear rail.

Assembling the Pick Head

Assembling the Pick Head

Below the head attached to the X axis:

2nd Pick Head

2nd Pick Head

Pick Head 2nd Version

Pick Head 2nd Version

Below an early version of the head with no cable chains attached:

Head without cable chains

Head without cable chains

I used 3D printed parts to attach the heads with the Z axis belt:

Z-Axis Belt with 3D printed parts

Z-Axis Belt with 3D printed parts

The belt is attached to the linear rails using a press-fit connection, and the connector acts as an end stop the same time:

Press-Fit Belt Holder

Press-Fit Belt Holder

Here with the rails, belt and endstop mounted:

Head Rails and Endstops mounted

Head Rails and Endstops mounted

Here the head with the pick heads:

Pick Heads

Pick Heads

Downlooking Camera

Below an early design of the downlooking camera integrated into the bottom of the head:

First version of downlooking camera

First version of downlooking camera

First down camera and light tests:

First Camera Tests

First Camera Tests

First Camara and LED ring holder:

First Camera Holder

First Camera Holder

Head with Camera Holder

Head with Camera Holder

A plexiglass with a sheet of whiter paper acts as diffuser:

LED Ring diffuser

LED Ring diffuser

Pick heads with downlooking camera:

Pick Heads with downlooking camera

Pick Heads with downlooking camera

Mounted head with first cable chains:

PnP Machine

PnP Machine

Metal Pick Head

The next iteration oft the pick&place had is a version built with aluminium profiles. The first step was to use aluminium profiles for the head mounts:

Alu Head mounts

Aluminium Head mounts

Alu Motor Mounts

Aluminium Motor Mounts

Then the head backplane has been built with aluminium profiles:

Alu Profile Pick Head

Aluminium Profile Pick Head

That way the head was more sturdy than the one made of plywood.

Alu Profile Head

Aluminium Profile Head

Below with the hollow shaft stepper motors mounted, plus a cable chain for the end stops, LED ring and camera USB cable on the left:

Aluminium Profile Pick and Place Head

Aluminium Profile Pick and Place Head

Machine with Metal Head

Machine with Metal Head

Nozzle Holder

Nozzle Holder, magnet holds the nozzle:

Nozzle in Holder

Nozzle in Holder

Nozzle and Nozzle Holder

Nozzle and Nozzle Holder

Improved nozzle holder with 1.5 mm space between the plates and acrylic on the top:

Nozzle Holder with Acrylic

Nozzle Holder with Acrylic

Nozzle Holders mounted on base plate

Nozzle Holders mounted on base plate

NozzleHolderLabel

NozzleHolderLabel

Different Nozzles

Different Nozzles

Cut Tape Holder

See  3D Printed SMT Cut Tape Holder for more details.

SMD Strip Holder

SMD Strip Holder

Cover

Cover

Tape Holder with Magnets

Tape Holder with Magnets

Tape Holder 3D Model

Tape Holder 3D Model

SMD Tape Holder

SMD Tape Holder

Feeder

The automatic feeder is designed by Simon Huber. The goal was to create a feeder for SMD parts on rolls.

SMD Resistors

SMD Resistors

The feeder uses 3D printed parts:

3D Printed Feeder

3D Printed Feeder

Feeder with SMT Tape

Feeder with SMT Tape

Each feeder uses a NXP K20DX128 (ARM Cortex-M4) as the controller:

AutoFeeder

AutoFeeder

One DC motor moves the tape and one DC motor peels the cover:

Feeders removing cover

Feeders removing cover

A tinyK20 (NXP K22FN512, ARM Cortex-M4) receives M-Codes from OpenPnP and passes them to all feeders:

tinyK22

tinyK22

The feeders are in a daisy chain, and the machine has space for up to 16 feeders.

Nozzles

The first nozzle stepper motors did not work well. The M5 screw did not match the stepper motor hollow shaft. The designed adapter had too much wobble and was not usable.

First Pick Head with Nozzle Adapter

First Pick Head with Nozzle Adapter

So I had to put aside the nice and small hollow shaft stepper motors. I ordered new (bigger) ones so I can easier attach the nozzle changes and a vacuum tube connector on the back. The new motors had on both sides an M5 screw so I can attach rotation tube adapters and attach easily the nozzle adapter.

New Nozzle Stepper Motors

New Nozzle Stepper Motors

Because the motors were bigger, I had to create new motor holders:

New Nozzle Motor on the head

New Nozzle Motor on the head

Pick Heads

Pick Heads

Cable Chains

The first cable chains were too small to hold all the tubing and cables, so a new one has been installed.Below the machine with the first (too tiny) cable chains:

PnP Machine with small cable chains

PnP Machine with small cable chains

Small cable chain attached to the head:

Small cable chain attached to the headSmall cable chain attached to the head

Small cable chain attached to the head

Machine with small cable chains

Machine with small cable chains

Machine with second version of head

Machine with second version of head

New cable chains arrived:

New Cable Chain arrived

New Cable Chain arrived

That larger (40×15 mm) was able to keep all the cables and tubing.

Bigger Chain holds it all

Bigger Chain holds it all

Below with the new chain attached to the head:

Head with new cable chain

Head with new cable chain

Cable Chain

Cable Chain

Side View with Cable Chain

Side View with Cable Chain

Base Plate

Machine with new base plate

Machine with new base plate

The bottom plate with cutouts for the feeders and the bottom camera:

Base Plate ready for paint

Base Plate ready for paint

It gets painted with three layers of magnetic paint:

Magnetic Paint

Magnetic Paint

Painted Base Plate with Magnetic Paint

Painted Base Plate with Magnetic Paint

Bottom Camera

Laser Cutting the Enclosure for the Bottom Camera

Laser Cutting the Enclosure for the Bottom Camera

Assembling the bottom camera enclosure:

Assembling bottom camera case

Assembling bottom camera enclosure

Assembled bottom camera case:

Bottom Camera Enclosure

Bottom Camera Enclosure

Testing the camera:

Testing the Bottom Camera

Testing the Bottom Camera

Up camera mounted into base plate:

Uplooking Camera in Base Plate

Uplooking Camera (Bottom Vision) in Base Plate

Bottom Vision

With the bottom camera, OpenPnP can move a part over the camera to correct angle and position with the vision system:

Bottom Vision Capture

Bottom Vision Capture

It uses a vision pipeline, below with a blur filter applied:

Bottom Vision Gaussian Blur

Bottom Vision Gaussian Blur

Masking:

Bottom Vision Circle Mask

Bottom Vision Circle Mask

getting the part outline:

Bottom Vision Threshold

Bottom Vision Threshold

Getting the contours:

Bottom Vision Draw Contours

Bottom Vision Draw Contours

Detecting part position and angle:

Bottom Vision Rotation Rectangle

Bottom Vision Rotation Rectangle

OpenPnP includes a loose part feeder: parts can be put into a bin and the vision system can identify it:

LoosePartsFeeder 1

LoosePartsFeeder 1

LoosePartsFeeder 2

LoosePartsFeeder 2

LoosePartsFeeder 3

LoosePartsFeeder 3

LoosePartsFeeder 4

LoosePartsFeeder 4

PCB Holder

As the top camera has rather small focus area, I need to keep the feeder pick (see “3D Printed SMT Cut Tape Holder“) height and the PCB surface on the same height. For this I have created 3D printed magnetic PCB board holders.

3D Printed PCB Holders Red PCB

3D Printed PCB Holder with Red PCB

3D Printed PCB Holder

3D Printed PCB Holder

Graphic LCD

Similar as for my laser cutter (see “Upgrading a Laser Cutter with Cohesion3D Mini and LCD“) I added a graphics LCD to the board.

Machine with LCD Display

Machine with LCD Display

http://smoothieware.org/rrdglcdadapter describes the settings and installation of a graphics LCD on the Smoothieboard.

I decided to order an adapter board from 3DWare:

GLCD Adapter Board Top Side

GLCD Adapter Board Top Side

Below the bottom side of the board:

GLCD Adapter Board Bottom Side

GLCD Adapter Board Bottom Side

Below how the adapter board is installed on the board:

Location of GLCD Adapter on Smoothie

Location of GLCD Adapter on Smoothie

Below the display attached to the board and working :-):

Smoothie with GLCD

Smoothie with GLCD

Below the (still messy) electronic parts on a base plate:

Electronics

Electronics

Added to the display is an emergency stop button. Below the connection to the controller board:

Emergency Stop Connection

Emergency Stop Connection

LCD with Emergency Stop

LCD with Emergency Stop

OpenPnP Software

The OpenPnP software runs on the host PC.

OpenPnP Software

OpenPnP Software

The host PC does all the image processing and sends commands to the machine.

Running an OpenPnP Job

Running an OpenPnP Job

Drop Box

For bad parts or to drop parts, OpenPnP can use a dedicated ‘drop area’. for this I created a custom (laser cut) drop box: It uses 3mm red acrylic on the top:

PnP Drop Container

PnP Drop Container

4mm plywood on the bottom with magnets so it sticks to the machine surface:

PnP Drop Container with magnets

PnP Drop Container with magnets

Plexiglas Brackets

The motor and belt brackets originally were cut out of plywood: here I replaced the 4mm plywood with 5 mm laser-cut plexiglas ones which looks nicer :-):

Plexiglass PnP Bracket

Plexiglass PnP Bracket

X Axis with Plexiglas motor bracket

X Axis with Plexiglas/PMMA motor bracket

The machine mounted on a 16mm plywood base plate:

Mounted on BasePlate

Mounted on BasePlate

Summary

It has been a fun project, and the machine works well, but still needs some tuning. I plan to add a solder paste dispenser: that way, if no stencil is available, the machine can add the solder paste to the pads on the board. Another thing is to use pressure sensors to monitor the vacuum for each nozzle. And for the motor auto-feeder I would like to update the design. So there is always something to improve. Currently the machine can place around 500-600 parts per hour down to 0402 size. With this and little setup, we can run small board series successfully.

PS: a big “thank you!” to the OpenPnP community: without all their work and contributions, such a project would not have been possible.

Happy Picking 🙂

Links

196 thoughts on “Building a DIY SMT Pick&Place Machine with OpenPnP and Smoothieboard (NXP LPC1769)”

  3. Hi Erich. This is such an interesting project. I’m always amazed as to how well you document every process from the beginning. Congratulations!

    Like

    Reply ↓

    • Thank you! In retrospect I should have taken more pictures or even document it better. I hope the files on the GitHub site gets everyone a good start who wants to build such a machine too.

      Like

      Reply ↓

  4. Hi Eric,

    I own a commercial PnP machine and your setup makes me want to sell it and build one like you have 🙂

    It’s very impressive indeed.

    Like

    Reply ↓

  5. Hello,

    Thank you for sharing all project. It’s awesome. I followed on twitter.

    I see that it is possible to use from 0201, this is ok for me.

    But is it possible to use MAP-BGA169?

    Kinetis K26 K27 K28

    + one BGA Inspection Tool, as ERSA or BGA-100.

    Best regards

    Liked by 1 person

    Reply ↓

  6. Pingback: A Pick-And-Place That Is A Work Of Art | Hackaday

  9. Hello,

    You can update the next in the hardware doc?
    https://github.com/ErichStyger/McuOpenPnP_Machine/blob/master/Hardware/McuOpenPnP%20Bill%20of%20Material.xlsx

    Line 31 – 2040 Cross support 42.5cm –> https://www.aliexpress.com/item/CNC-3D-Printer-Parts-European-Standard-Anodized-V-Slot-Linear-Rail-Aluminum-Profile-Extrusion-2040-for/32813313600.html

    I do not see any of 42.5cm

    Line 32 – 2020 Ground Plate Mount 38 cm –> https://www.aliexpress.com/item/HOT-Sale-CNC-3D-Printer-Parts-European-Standard-Anodized-V-Slot-Linear-Rail-Aluminum-Profile-Extrusion/32816279219.html

    I do not understand what this is, the url is a rail but there are no measures of 38cm.

    Line 28 – USB Cameras –> Which is the size of the focus?
    3.6mm
    6mm
    8mm
    12mm
    16mm
    2.8-12mm(manual)
    2.1mm
    No Lens

    Thanks and regards

    Like

    Reply ↓

  10. Hello,

    I have bought all the pieces, they are on the way.

    I am doing the pieces with a drill and a jigsaw and with wood and aluminum. I do not have a 3D printer or CNC.

    Can you share a image of the new pick head made in aluminium?

    Also how you placed the endstop and the top camera.

    Regards

    Like

    Reply ↓

  13. Hello,

    When I insert a nozzle with my hand, I have to do a lot of pressure. Did you eliminate any of the rubber grommets? because in the video it seems to come and go more easily.

    Like

    Reply ↓

  15. Hello,

    What configuration did you use for the DIP switch of the DM542?

    And how did you connect the motors, in series or in parallel?

    I connected the dm542 to the smoothieboard like this:
    PUL- DIR- ENA- to GND
    ENA+ to EN5
    DIR+ to DIR5
    PUL+ to ST5

    Best regards

    Like

    Reply ↓

  18. Works Erich. Works!!!!! XD

    I’m having a problem with serial communication in linux, but I managed to connect once to 115200 /dev/ttyACM1 and I could operate the vacuum pump, the lights, the selenoids and move the Z and the X. I could not prove the Y because I closed the application and then I could not connect anymore.

    I do not know yet what can be if on the side of linux or on the side of the smoothieboard.

    I also made a prototype for the dispenser, it is functional and simple, I would like to try it when I clarify with this.

    Best regards

    Like

    Reply ↓

  19. Can you share your DM542 configuration?

    I have changed from common anode to common cathode but not works to me.

    I have changed it back to common anode. I read that 3V3 is not enough.

    I have +5V connect to PUL+ DIR+ ENA+

    EN5 –>> ENA-
    DIR5 –>> DIR-
    ST5 –>> PUL-

    Nema 17 Motors:

    Phase A
    Red A+ –>> A+
    Gray A- –>> A-

    Phase B
    Yello B+ –>> B+
    Green B- –>> B-

    Like

    Reply ↓

      • I guess the error it’s in the smoothieboard config file

        # Using Y (beta) with external stepper driver in open drain mode (‘o’ added to the pin, see http://smoothieware.org/general-appendixes)
        # NOTE: using external stepper motor driver!
        beta_step_pin 2.1o # Pin for beta stepper step signal
        beta_dir_pin 0.11o # Pin for beta stepper direction, add ‘!’ to reverse direction
        beta_en_pin 0.10o! # Pin for beta enable
        beta_current 2.0 # Y stepper motor current
        beta_max_rate 5000.0 # Maxmimum rate in mm/min

        I’m using M5 (or epsilon) and that port (2.1) it’s of M2, I think.

        M5 it’s used by extruder:

        ## Extruder module configuration
        # See http://smoothieware.org/extruder
        extruder.hotend.enable true # Whether to activate the extruder module at all. All configuration is ignored if false
        extruder.hotend.steps_per_mm 18 # Steps per mm for extruder stepper ==> 1mm == 1 degree: (200*32)/360==> 17.7777
        extruder.hotend.default_feed_rate 600 # Default rate ( mm/minute ) for moves where only the extruder moves
        extruder.hotend.acceleration 500 # Acceleration for the stepper motor mm/sec²
        extruder.hotend.max_speed 100 # Maximum speed in mm/s

        extruder.hotend.step_pin 2.3 # Pin for extruder step signal
        extruder.hotend.dir_pin 0.22! # Pin for extruder dir signal ( add ‘!’ to reverse direction )
        extruder.hotend.en_pin 0.21 # Pin for extruder enable signal

        # Extruder offset
        #extruder.hotend.x_offset 0 # X offset from origin in mm
        #extruder.hotend.y_offset 0 # Y offset from origin in mm
        #extruder.hotend.z_offset 0 # Z offset from origin in mm

        # Firmware retract settings when using G10/G11, these are the defaults if not defined, must be defined for each extruder if not using the defaults
        #extruder.hotend.retract_length 3 # Retract length in mm
        #extruder.hotend.retract_feedrate 45 # Retract feedrate in mm/sec
        #extruder.hotend.retract_recover_length 0 # Additional length for recover
        #extruder.hotend.retract_recover_feedrate 8 # Recover feedrate in mm/sec (should be less than retract feedrate)
        #extruder.hotend.retract_zlift_length 0 # Z-lift on retract in mm, 0 disables
        #extruder.hotend.retract_zlift_feedrate 6000 # Z-lift feedrate in mm/min (Note mm/min NOT mm/sec)

        delta_current 0.7 # First extruder stepper motor current

        # Second extruder module configuration
        extruder.hotend2.enable true # Whether to activate the extruder module at all. All configuration is ignored if false
        extruder.hotend2.steps_per_mm 18 # Steps per mm for extruder stepper
        extruder.hotend2.default_feed_rate 600 # Default rate ( mm/minute ) for moves where only the extruder moves
        extruder.hotend2.acceleration 500 # Acceleration for the stepper motor, as of 0.6, arbitrary ratio
        extruder.hotend2.max_speed 100 # mm/s

        extruder.hotend2.step_pin 2.8 # Pin for extruder step signal
        extruder.hotend2.dir_pin 2.13! # Pin for extruder dir signal ( add ‘!’ to reverse direction )
        extruder.hotend2.en_pin 4.29 # Pin for extruder enable signal

        extruder.hotend2.x_offset 0 # x offset from origin in mm
        extruder.hotend2.y_offset 0.0 # y offset from origin in mm
        extruder.hotend2.z_offset 0 # z offset from origin in mm

        epsilon_current 0.7 # Second extruder stepper motor current

        2.8, 2.13 and 4.29 they are the ones that I need to use, I think.

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        Reply ↓

        • Ok, sorry, I’m rolling it.

          I have to change the wires, not the ports, extruder is C1 and C2 (M4 and M5)

          I have to connect the DM542 to M2, I think that’s the error, I’ll try.

          Liked by 1 person

        • Now if the motors move, but it does not move well on the beta axis. As if they were uncoordinated, it throws more than one side of the other.

          Like

  22. Hi Erich,
    I am making progress on my PnP machine. https://youtu.be/U4nb6RTz-xY
    There is one design feature of yours I am stealing 🙂 It is the base and magnetic mounting system. Are the 3d files for your various magnetic holders available? How well are they working for you with the magnetic paint?
    Another question I have is why dump the laser cut head components and move to aluminum? You never mentioned exactly why that was.

    My machine is similar to a MyData Machine, X is on a fixed gantry, and Y moves an entire tray with boards and fixed strip feeders attached. My X and Y are linear motor slides, they will accelerate at 5G and run 3000mm/s.
    You used wood with magnetic paint for your base. Mine, Ideally it will be light and rigid.
    I’m thinking a sheet of magnetic stainless steel, with ribs and features on the bottom to add rigidity.

    I notice you have a photo of a solder paste stencil with your magnetic holders on it. Is that made from magnetic stainless? A stencil alone would probably be to floppy for me, but maybe sandwiched to some other flat rigid and light material will work for me.

    Like

    Reply ↓

    • Hi Brynn,
      your machine looks really great! Yes, the 3D files are available on https://github.com/ErichStyger/McuOpenPnP_Machine/tree/master/3D.
      They work well with the magnetic paint (You have to paint it in multiple layers (4-5)), and because the surface is rather rough and sensitive to moisture because of the iron parts, I added another normal color layer on the top.
      The plywood head was cheap and easy to build, but not as rigid as it should be. Plus there was the concern that water/moisture in the air could affect precision.
      A sheet of stainless steel is something others use too: but that would have been expensive for me, it was not really available and I did not had the tools to cut it in shape with the holes for the cameras/etc. So wood was much easier for me. The solder stencil is magnetic (I think, but I don’t have one with me to test right now).

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      Reply ↓

      • Hi Erich,
        the McuOpenPnP_Machine/3D/PCBHolder.stl that I see looks like the long strip feeder with cover. I was looking for the pieces you have that are holding the PCB edges up. I’m probably going to have to redesign them anyway, because I want more height – My Z travel currently will be 75mm max. that gives me room
        do 18mm parts on top and bottom of the board, and held on the nozzle.

        Z=0 max height above board
        Z=18 bottom of tallest part I hope to handle when picked
        Z=19 1mm extra clearance
        Z=37 top of board – also top of fixed magnetic strip feeders and tray feeders
        Z=39 bottom of board (rounded off)
        Z=57 magnetic tray
        Z=70 allowance for tray and stiffener thickness
        Z=72 position of top of components in autofeeders

        I think that will give me enough room to work with. (I’m just thinking out loud…)

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  23. hi Erich,
    I have a couple commercial solder stencils in aluminium frames. I checked with a magnet, and they are apparently non-magnetic stainless steel. though the frames are sturdy, I think with some ribs and a sheet of magnetic steel they could by my Y tray.
    Are you using you pnp a lot?
    Brynn

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  27. I have done similar projects with laser machines
    and from my experience nema17 are prone to loose steps at higher speeds & accelerations
    also gt2 6mm at high accelerations will have backlash & oscillation (is there room for 15-20mm gt2 ?)
    There is a dc brushed servo open source project for small dc servos (tarocco)
    and another for brushless dc servos (odrive).
    Without too much cost increase you can replace steppers with dc servos.

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    • Yes, loosing steps can be an issue. But I have not experienced this as I did not want a fast machine: I wanted an accurate machine. And driving the NEMA17 with the correct and enough current did not loose me any steps.
      Of course if I would build a machine with my own controller, I would go for DC motors with encoders. But because I built the machine around the Smoothieboard, I was going to use stepper motors.
      Other machine designs are using stepper motors in combination with encoders to make sure they do not loose steps, but these machine are running at higher speed than the one I have built.
      Servo motors usually are not able to generate enough torque imho. Again, it depends on what controller you are going to use.

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    • I did not count them, as I had them available in different length and sizes. I belive most had 15 mm length. But I’m away from the machine right now, so I cannot tell for sure.

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  29. For example odrive take step dir as input & quadrature incremental encoders
    also in ebay you can find bldc nema17(+encoder) so you can replace steppers
    without any change to controller.
    Controller will output step-dir odrive will get it as input to drive bldc.
    odrive will handle the servo loop not controller.
    If i order 50/50/50 15mm/20mm/25mm M3/M5 hex screws will be ok ?

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  30. I have 2x850mm & 2x550mm mgn12 linear rails
    So i have the option to use the long rails (850mm) on x or y axis
    y uses 2 rails and x 1 rail.
    On which axis to use the long rails ane why?

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    • A bigger size is not *really* needed. I mean: 500×500 is fine. A bigger size will give you more space for feeders and parts. The disadvantages of a bigger is size are that you need more space for the machine, and if you are using longer belts, the backslash compensation will be bigger (potenitally less accurate, so you need to compensate more. The mass of the moving parts might be bigger too (depending on which axis you make longer). I think 500×500 is somewhat of a sweet spot: not too big, not too small, packages <=500mm costs less to be shipped, rails are cheaper. It is all about compromises.

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  33. There is room for small improvements
    look these videos
    https://www.youtube.com/watch?v=6agTZWNQBGc (you can not use gear but timing belt in the opposite direction something like servobelt https://www.youtube.com/watch?v=OdJoVh6DRPA )

    https://www.youtube.com/watch?v=bFcTj3hsVrI (simple feeders in both sides left & right with 2 actuators that bring next part close to machine )

    odrive dc brushless servos for exceptional speeds ( https://www.youtube.com/watch?v=FUh36RUHzdU )

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  34. For reducing cost have you tried V-slot aluminum profiles with wheels for V-slot ?
    Have this system enough stability like mgn12 linear rails?
    Plus is reduced cost / more simple / less weight/inertia
    Minus is less stability-accuracy

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    • No, I have not used V-Slots. But I saw that others have built machines based on V-Slots, so it is definitely possible. I was aiming at the linear rails because expecting higher accuracy. I did not consider higher mass as a problem, as I was not aiming at speed but more at accuracy.

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  35. Hi, I have seen the slides of a presentation you had and noticed that you are aware of the “lite place”. While I love to build thing, one must acknoledge that life time is limited. So I wonder what the key advantages of this solution over the lite placer are? Is your machine faster, more precise or is the main benefit the price.
    I absolutely like this project and I want to congratulate you to a job well done. With all the public documentation you clearly gone above and beyond.

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    • Thank you for your kind words. I have not used the LitePlacer, so I cannot really comment on speed or accuracy.
      If you are looking for a mostly complete kit, the LitePlacer is definitely the way to go.
      I would say that both machines have similar capabilities, but the LitePlacer has only one nozzle. To me a dual head has advantages with more speed.
      But if your main concern is about limited time, then I recommend you buy a commercial machine instead?

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  37. Hi Erich Styger. I am very impressed with your skill. Having reviewed your article, I decided to make such a machine for myself. I wanted to ask you if the vector files for cutting plywood are relevant? I plan to make all of the plywood as you and looking at the files, I noticed that in some details there are uneven contours. Namely in the OpenPnP_Head file. Maybe if you have the latest drawings, please send me. Thanks! Good luck to you in such projects.

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  40. Cool project and perfectly implemented 🙂
    You write you wanted to stay <$1000. What would you estimate you've spend?

    Michael

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  41. Hey Erich!

    Thanks a ton for this, its the only comprehensively documented build of an openpnp i could find.

    Your belted head assembly is different to the ones most people use with cam and springs, i like this one alot better tho.

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  42. Thanks for the update. I will definetly follow and more likety try to follow your instructions to build a machine from scratch for myself.

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  43. At Fox.Build, a makerspace near Chicago, we are trying to reproduce your work and add some details describing our attempt at building it. We also hope to have a full 3D model for people to reference on Onshape. Please see our blog on hackaday and please confirm we have been sufficiently transparent in linking back to your work. We would welcome you as a project member if you are so inclined. https://hackaday.io/project/165743-foxbuild-pnp

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  44. Erik, do you have any updates for instructions or BOM with the pasta dispenser addition. I have ordered now most of the parts based on the BOM file on foxbuild-pnp but some of the instructions you have given there are visible only for the team members.

    There were some issues in bom list I tried to ask on public chat there but have not yet received any answer.

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  45. In cases where I order the PCB’s from factory I can also get the stencil easily. But in cases I do the PCB’s myself to get things done withing same day (PCB milling or laser etching), I would then need some way to do the Stencil somehow.

    Therefore the idea from the combination of paste dispenser and PNC machine sounds interesting. Now that you have some experience from new machine, would you recommend building a separate pasta dispenser machine and separate PNP machine instead of trying to combining them together?

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    • I would build a machine for solder paste dispensing only and not extend the PnP machine.
      This would cost more, but will allow to apply paste while the second machine is placing the parts.

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  46. Thanks. I think I will then follow your suggestion and plan for the separate paste dispenser machine. Once I receive all parts I have ordered so far, I will concentrate first for replicating the PNP machine based on your documentation in this page and the ones in the foxbuild of hackaday.io.

    I assume that the dispenser machine could use pretty much same frame size, construction, stepper motors and drivers than the pnp machine?

    Do you know are the all your suggestion for modifications in their group already included to public design files in foxbuild site?

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  47. Pingback: OpenPnP Solder Dispenser Sneak Preview | MCU on Eclipse

  48. Hello!
    U did a lot of work.
    Recently I made the same machine, but I have problem.
    My machine use two nozzles, and when i start a job – only one is working. What I need to do for getting second nozzle working? What the config?

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  49. Thanks for the replies. Excuse me, I’ve read this manual many times but still haven’t figured out where to enter it ?: G0 {BacklashOffsetX: X% .4f} {BacklashOffsetY: Y% .4f} {Z: Z% .4f} {Rotation: A% .4f} F {FeedRate:%. 0f}
    G1 {X: X% .4f} {Y: Y% .4f} {Z: Z% .4f} {Rotation: A% .4f} F {BacklashFeedRate:%. 0f}

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    • Go to Machine Setup > Driver > GcodeDriver > General Settings tab and add the Backlash X and Y offsets.
      Then go to Machine Setup > Driver > GcodeDriver > Gcode tag, select ‘Default’ as Head Mountable and ‘MOVE_TO_COMMAND’ for the Setting. This configures the command to be exectuted for a move command. By default you should see something like this:

      G0 {X:X%.4f} {Y:Y%.4f} {Z:Z%.4f} {Rotation:E%.4f} F{FeedRate:%.0f} ; Send standard Gcode move (MOVE_TO_COMMAND)

      I have changed it to:

      ; Default MOVE_TO_COMMAND
      ; G0 {X:X%.4f} {Y:Y%.4f} {Z:Z%.4f} {Rotation:E%.4f} F{FeedRate:%.0f} ; Send standard Gcode move (MOVE_TO_COMMAND)
      G0 {BacklashOffsetX:X%.4f} {BacklashOffsetY:Y%.4f} {Z:Z%.4f} {Rotation:E%.4f} F{FeedRate:%.0f} ; Send standard Gcode move (MOVE_TO_COMMAND) with Backlash compensation
      G0 {X:X%.4f} {Y:Y%.4f} {Z:Z%.4f} {Rotation:E%.4f} F{BacklashFeedRate:%.0f}
      M400 ; Wait for moves to complete before returning

      I hope this helps?

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  50. This is seriously cool! Thank you for taking the time and effort to put this up here. Would you be able to share your Smoothie configuration for this project? I am building a similar machine except I’m using the Re-Arm for RAMPS instead of the Smoothieboard.

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  51. Hello.
    Thanks for the help, your tips have been very helpful.
    Now almost everything works, but there is another problem.
    I can’t customize Bottom Vision Pipeline,
    details aligns but does not center.
    How to be, help.

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  53. Thank you Erich for your help and advice. Everything worked for me. Very good project, I am satisfied with my work. Thank you again. I add a video. youtu.be/BgPN-ml3-0g

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  55. Pingback: OpenPnP Solder Paste Dispensing Video | MCU on Eclipse

  56. Pingback: Erich Styger Upgrades his OpenPnP Pick-and-Place Machine to Dispense Solder Paste - PC Solution

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  59. Long time ago now that this machine was built, but I’ve seen your videos and read through this buildlog a couple of times, I’m starting to feel that.. I need a machine like this! 🙂 Really love your documentation here!

    Anyhow I’m a little bit puzzled on the size of the machine. Of course, bigger is better as you can fit more feeders and features. But as I have “limited” space, I’m not going to interior decorate a whole room with the PnP machine. I’m trying to figure out a good size and thought that maybe I could ask what size you went for with this machine?

    I’ve decided to go with same style of aluminium rails and those hiwin kind of linear guide rails. As far as I can tell the linear guide rails are as long as your aluminium rails, correct?

    Hope to hear from you soon.

    Thanks for sharing your build and experience Erich!

    Best regards from Sweden
    Christopher Fredriksson

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  60. Pingback: Retrofitting a Charmhigh CHM-T36VA Machine with OpenPnP | MCU on Eclipse

  61. Hi, Are you using 4mm ID tubes for the vacuum pump? Do you have an image of how the pump is connected to the tubes? I have the same pump and it seems the inlet connector is about 6.4mm in diameter.

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  62. Erich, I just wanted to take a minute to thank you for this excellent log of your project. I’m considering something similar, and your excellent documentation is a real help. Thank you so much for taking the time to put it all together and to answer so many questions!

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      • Thanks for your reply Erich! I was an exchange student in Switzerland when I was in college! I still maintain good relations with my host family there though I haven’t been back in about 8 years.

        I guess I do have a couple of questions for you.

        What is your computer hardware running OpenPNP? There seems to be no consensus… I understand that separate USB hosts is a necessity for the cameras…

        Why did you choose the Samsung nozzles over the more common Jukis?

        My machine will have dual Y motors like yours. On my CNC I just ganged the two motors to the same driver. Is there as reason you used a separate driver for the Y motors? Just for more power?

        Thank you for your time! -Malcolm

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        • Hi Malcolm,
          You definitely should come back for a re-visit then (after all that COVID-19).
          I’m using a 5 year old DELL Laptop (quad core, 1.8 MHz) to run OpenPnP. The thing with the USB host is about the cameras and probabaly because of Windows (did not try on Linux): you will need two USB camera connections: and having them combined in a hub seems to create too much traffic and that won’t work. Usually notebooks have two or more USB units and then it works. Probably if you would use a USB3 active hub with a USB3 notebook that would help too.
          The other hint I have (although not required) is to use different camera models: having the exact same camera for top and bottom makes it kind of try-and-error in the camera selection if the USB cable is moved to a differnt port.
          I have chosen Samsung simply because it was easier for me to get an adapter for it to the motors.
          I used separate drivers for the Y motors because of the needed power, you have that correctly found out. But I do *not* recommend (as noted in the article) to use such a combined-motor-thing: while this ‘works’ it requires more calibration and setup whenever the machine gets powered up, and mechanically it makes things much more complex: I highly recommend a single motor solution!
          ~Erich

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        • Hey Erich!

          I’m almost finished with my mechanical build and am currently fighting my way through the confusion of how to set up OpenPNP with a Smoothie board. It seems there are many different firmware/configuration file combinations out there! I’ve looked through your github and I didn’t see mention of which firmware and config file you’ve used in your Smoothie. Is this something you’d share? My machine is similar enough to yours that it would give me a place to start. Your build has been an excellent resource. Thank you! -Malcolm

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  63. I find it a very interesting project that I intend to build shortly. I have two questions about the automatic feeders that you have developed and it is the following:
    What is the maximum number of feeders that can be put in series connected to a master?
    And.
    Can you put more than one master in openpnp ?. How would it be configured?
    Thank you

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    • The number of possible feeders is only limited by available space. Realistically it is in the range of around 30.
      And you can have any numbers of masters in OpenPnP: simply add a new subdriver for it.

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  64. Hi Erich, thanks for the write up of your PNP project. Very interesting.
    I am in the middle of my PNP build and mine has a lot of similarities – Smoothieboard, OpenPNP, dual head and even the same Vac pump 😀. I have used a single Y motor.
    I am trying to work out how to home the Z axes. I note you home Z to Min and use – 15 as the Min value. Where is your Z limit switch? Top, bottom or middle?
    I am trying to home to the top (using hall effect sensor) but I haven’t worked out how to get it to move back to the Middle.
    Did you ever add the paste dispenser? I was disappointed to learn that OpenPNP has dropped support for paste dispensers. 😢

    Regards DG

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    • Hi David,
      thank you! Good that you have a single Y motor (this really was not that intelligent choice on my side. My Z limit switch is on the top, you can see the sensors on https://mcuoneclipse.files.wordpress.com/2018/03/pick-head-with-end-stops.png.
      To go back to the middle you have to check the head Z transform function: I had to tweak it too and to do some trial and error.
      Paste dispenser: yes, we did it, see https://mcuoneclipse.com/2019/08/15/openpnp-solder-dispenser-sneak-preview/ and https://mcuoneclipse.com/2019/11/26/openpnp-solder-paste-dispensing-video/.
      It worked well (not excellent I have to say, the problem is with the temperature of the paste). We used an auger pump which is excellent, but still it is open loop. We wanted to add some close loop with vision, but then OpenPnP dropped the support. And my time is limited, otherwise I would have moved that one forward. So for the moment the past dispensing is on hold.

      BR
      Erich

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      • Ah yes, I missed noting the limit switches on Z. Why two?
        I got something working before I saw your reply. I told Smoothie that the Max value after home is 20 (Gamma_max 20) then I added to the OpenPNP Head Home GCode:
        G28 Z ; Home just Z axis
        G0 Z 0 ;Move Z back to mid position
        G28 XY; Home X & Y axes

        It seems to be doing what I want – after an exhaustive series of 6 tests 🙂
        I saw an interesting paste dispenser kit from Mexico that could form the basis for my dispenser:
        https://www.tindie.com/products/danm/dm-solder-paste-and-adhesive-dispenser/
        a bit of a waste though as I don’t really need the controller.
        Cheers,
        DG

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        • Yes, it would be possible to have just one limit switch, assuming the motor direction is known. If the motor moves, one goes up and the other goes down. With two limit switches I can catch any case.
          I looked at such solder paste dispenser: the problem is that the do not use an auger pump, and without it the amount of solder always is different. Without closed loop control this makes things worse.
          With an auger pump the amount of fluid at least is much more controlled.

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        • Fair enough. Yet another thing that needs to be tried! I like your magnetic paint BTW – must try that.
          I hadn’t thought about the need for a camera on the paste. Is it necessary or just nice to watch?

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        • It is nice to watch. The idea was to have a ‘manual mode’ too: the machine moves to the pad, then the user can manually control the amount of solder paste dispensed.

          Like

    • Hi MikeZ,
      I’m using the Ultimaker 2 for years and I’m very happy with it. But there are certainly other good printers out there: beside Ultimaker I would recommend to have a look at the Prusa ones too.
      Good luck!

      Like

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