ENHANCING AND ENRICHING AN EXISTING 3-AXIS CNC MACHINE FOR TEACHING AND LEARNING: A CASE STUDY AT IIUM

Abstract

CNC machines are widely used in manufacturing, but their controllers are vulnerable to damage, which can render the entire machine inoperable. Repairing or replacing a damaged controller can be expensive and time-consuming, leading to significant downtime and lost productivity. This project aims to address these issues by developing a replacement controller for stepper motor-based CNC machines. The objective is to create a controller that can be easily installed and used to quickly restore machine operation in the event of controller damage, minimizing waste and lost productivity. The project utilizes a systematic approach, incorporating various key elements. An Arduino-based GRBL controller, known for its open-source firmware, is chosen for seamless integration with the CNC machine's stepper motor drivers, enabling precise control over axis movement. To provide users with a user-friendly interface for machine control, g-code file loading, and status monitoring, a graphical user interface (GUI) is developed using C# Windows Forms. A Raspberry Pi serves as the machine's computer due to its affordability and powerful capabilities. Running the GUI and necessary software, the Raspberry Pi enhances user interaction through a connected touch screen. Additionally, a protective case is constructed to house all components, ensuring their safety and facilitating device transportation and setup. To enable remote monitoring and receive alerts, the device incorporates IoT monitoring using AWS. This feature adds convenience and functionality for users. Rigorous testing is conducted to ensure the replacement controller performs reliably as expected. The developed replacement controller achieves a high level of precision for most CNC machines, with repeatability within +/- 0.01 mm for the X and Y axes and +/- 0.02 mm for the Z axis.