A gestalt framework for virtual machine control of automated tools

Thesis: S.M., Massachusetts Institute of Technology, Department of Mechanical Engineering, 2013.Cataloged from PDF version of thesis.Includes bibliographical references (pages 139-141).Computer aided design has become affordable and ubiquitous, in part as a result of the development of open source design software and web-based 3D modeling tools. Consequently, a broad spectrum of individuals are expressing demand for access to digital fabrication tools that are capable of automatically rendering their computer-based designs into physical objects. In response, manufacturers have begun to produce low-cost versions of a limited set of automated, personal-use fabrication tools, including 3D printers and desktop milling machines. Simultaneously, groups of individuals and organizations are establishing community workshops where resources can be pooled to acquire industrial-grade machinery. Both of these approaches have been successful at increasing the penetration of digital fabrication capabilities into the general population. However, there are many industrial tools which currently have no consumer-centric equivalent, and for which demand is insufficient to warrant acquisition by a community workshop. Additionally, as digital design continues to find new applications among a larger and more diverse audience, new needs will likely arise for yet non-existent automated fabrication tools. Gestalt is an accessible and flexible control framework which aims to augment the ability of individuals to create new automated tools, and to thus self-extend their abilities to create objects which would be too tedious or impossible to create by hand. This work will enable individuals to rapidly construct controllers and rich user interfaces for automated personal fabrication tools. The approach taken is that of a software-based virtual machine controlling a physical machine. This allows for increased modularity in controller implementation, and tighter integration of the tool with user applications than is possible with traditional controller architectures. The foundation of the proposed system provides a means for building APIs to communicate with modular hardware components, and a method of combining the functionality of these components at the virtual machine level (rather than in hardware) to yield higher-level functionality. The Python library developed in this work enables the rapid construction of cross-platform virtual machines that are capable of representing and controlling a wide variety of tools over commonly available interfaces such as USB. Additionally, a matching C library assists in developing microcontroller firmware for building custom modular hardware elements that can communicate with the virtual machine. A spectrum of unique fabrication tools controlled using the Gestalt framework are presented as case studies which elucidate both the successes and limitations of our approach.by Ilan Ellison Moyer.S.M

Angewandte Metrologie für additive Herstellungsverfahren

The fabrication of products by additively building them layer by layer promises exciting possibilities, including realisation of Industry 4.0, sustainability, local manufacturing and a measurement dataset which describes every voxel of the produced part. Measurement methodologies, which can measure such a dataset and interpret the result, are therefore needed. A cost-effective additive manufacturing technique, which can help with the worldwide plastic pollution problem, is Fused Filament Fabrication. This is an open source concept and ideal for adoption by developing economies. Measurement approaches are needed, though, to develop this technology beyond a rapid prototyping and modelling tool, to a functional production solution. This thesis develops cost effective, accessible solutions to improve the material feed mechanism, which is one of the most critical process components. A detailed review of the process steps is given first, which also contributes to this still rapidly developing field. This review includes the motion tool chain, from the stepper motor actuation to the firmware implementation to realise motor control. The feedstock materials and the liquefier design are also presented. Five methods for optimisation of the process are developed and experimentally tested. This includes the optical monitoring of the feed mechanism, which can measure the volumetric flow rate, a method to measure the exit flow rate, a pressure sensor to measure the liquefier state, single print optimisation with design of experiments and a link between the in-process and post process measured data. This is taken further by presenting the Vapour Deposition Fabrication concept, which is like the Dynamic Stencil Lithography process, but realised with a configuration based on the Fused Filament Fabrication electronics and firmware. The design and construction of the first Vapour Deposition Fabrication micro-printer are presented. This thesis finds that rate material addition in additive manufacturing is an important process variable, which needs to be monitored with indirect methods. Furthermore, standardisation is important for additive manufacturing, and this includes how G-codes are interpreted by the printer firmware. Finally, many process parameters must be optimised, and the single print optimisation method shown here is an example method, which can form part of a complete printer development, qualification and conformance solution.Die Fertigung von Produkten durch additives schichtweises Aufbauen verspricht spannende Möglichkeiten, darunter die Umsetzung von Industrie 4.0, Nachhaltigkeit, lokale Fertigung und einen Messdatensatz, der jeden Gitterpunkt des produzierten Teils beschreibt. Es werden daher Messmethoden benötigt, die einen solchen Datensatz messen und das Ergebnis interpretieren können. Eine kostengünstige additive Fertigungstechnik, die bei dem weltweiten Problem der Kunststoffverschmutzung helfen kann, ist Fused Filament Fabrication. Dies ist ein Open-Source-Konzept und ideal für die Verwendung in sich entwickelnden Volkswirtschaften. Um diese Technologie über ein Rapid-Prototyping-Tool hinaus zu einer funktionalen Produktionslösung zu entwickeln, sind jedoch neue Messansätze erforderlich. In dieser Arbeit werden kostengünstige und leicht zugängliche Lösungen zur Verbesserung des Materialzufuhrmechanismus entwickelt. Zunächst wird ein detaillierter Überblick über die Prozessschritte gegeben, was auch zu diesem sich schnell entwickelnden Bereich beiträgt. Diese Übersicht umfasst die Bewegungswerkzeuge vom Schrittmotor-Antrieb bis zur Firmware-Implementierung, um die Motorsteuerung zu realisieren. Fünf Methoden zur Optimierung des Prozesses werden entwickelt und experimentell getestet. Dazu gehören die optische Überwachung des Fördermechanismus, die den Volumenstrom messen kann, eine Methode zur Messung der Austrittsströmungsrate, ein Drucksensor zur Messung des Verflüssigerzustands, eine Druckoptimierung mittles statistische Versuchsplanung sowie eine Verknüpfung zwischen der Messdatenverarbeitung und Auswertung. Dies wird durch die Vorstellung des Konzeptes der physikalischen Gasphasenabscheidung weitergeführt, das dem dynamischen Schablonenlithographieprozess ähnlich ist, jedoch mit einer Konfiguration realisiert wird, die auf der Fused Filament Fabrication-Elektronik basiert. Das Design und die Konstruktion des ersten Vapor Deposition Fabrication-Mikrodruckers werden vorgestellt.Diese Arbeit schlussfolgert, dass der Materialdurchsatz in der additiven Fertigung eine wichtige Prozessvariable ist. Darüber hinaus ist eine Standardisierung wichtig für die additive Fertigung. Dies beinhaltet, wie G-Codes von der Drucker-Firmware interpretiert werden. Schließlich müssen viele Prozessparameter optimiert werden und die hier gezeigte Druckoptimierungsmethode ist ein Beispiel, das Teil einer vollständigen Druckerentwicklungs-, Qualifizierungs- und Konformitätslösung sein kann

New techniques for imaging photon-counting and particle detectors

Since the advent of space-based astronomy in the early 1960's, there has been a need for space-qualified detectors with sufficient sensitivity and resolution to detect and image single photons, ions or electrons. This thesis describes a research programme to develop detectors that fulfil these requirements. I begin by describing the role of detectors in space astronomy and follow with a review of detector technologies, with particular emphasis on imaging techniques. Conductive charge division image readouts offer high performance, simplicity, and flexibility and their potential is investigated in both theory and practice. I introduce the basic design concept and discuss the fundamental factors limiting performance in relation to physical design and to underlying physical processes. Readout manufacturing techniques are reviewed and a novel method presented. I describe specific space and ground-based readout applications which proved valuable in teaching lessons and raising questions. These questions initiated an experimental programme, whose goals were to understand limiting physical processes and find techniques to overcome them. Results are presented, and the innovation of the progressive geometry readout technique, which this programme also spawned, is described. Progressive geometry readout devices, such as the Vernier anode, offer dramatically improved performance and have been successfully flight-proven. I describe the development of a Vernier readout for the J-PEX sounding rocket experiment, and discuss the instrument calibration and the flight programme. First investigations into a next generation of charge division readout design are presented. These devices will use charge comparison instead of amplitude measurement to further enhance resolution and count rate capability. In conclusion, I summarize the advances made during the course of this research, and discuss ongoing technological developments and further work which will enable MCP detectors to continue to excel where characteristics such as true photon-counting ability, high spatial resolution, format flexibility, and high temporal resolution are required

Designing a New Tactile Display Technology and its Disability Interactions

People with visual impairments have a strong desire for a refreshable tactile interface that can provide immediate access to full page of Braille and tactile graphics. Regrettably, existing devices come at a considerable expense and remain out of reach for many. The exorbitant costs associated with current tactile displays stem from their intricate design and the multitude of components needed for their construction. This underscores the pressing need for technological innovation that can enhance tactile displays, making them more accessible and available to individuals with visual impairments. This research thesis delves into the development of a novel tactile display technology known as Tacilia. This technology's necessity and prerequisites are informed by in-depth qualitative engagements with students who have visual impairments, alongside a systematic analysis of the prevailing architectures underpinning existing tactile display technologies. The evolution of Tacilia unfolds through iterative processes encompassing conceptualisation, prototyping, and evaluation. With Tacilia, three distinct products and interactive experiences are explored, empowering individuals to manually draw tactile graphics, generate digitally designed media through printing, and display these creations on a dynamic pin array display. This innovation underscores Tacilia's capability to streamline the creation of refreshable tactile displays, rendering them more fitting, usable, and economically viable for people with visual impairments

Design and implementation of a standalone CNC controller

This bachelor thesis has been developed by Daan Ver Eecke and Elias Verstappe. We are two students at the ‘Hogeschool Vives’ in Bruges (Belgium) and both participate in the Erasmus program. The thesis has been worked out at the University of Valladolid in Spain. The general purpose of a bachelor’s thesis is to solve a specific problem (in our case with regard to the field of study electronics). This thesis describes how we control an old machine with the help of modern electronics. In a world where technological development is happening faster than ever, it is important that the possibility remains to control old devices. Due to the enormous growth, older machines are no longer supported by new operating systems. Two lecturers from the University of Valladolid, Dr. Jesús M. Hernández Mangas and Dr. Jesús Arias Álvarez, have confronted us with the following challenge: an old CNC machine is currently controlled with the help of an old computer. The program that controls the machine runs on the MS-DOS operating system. Our assignment is to design a custom controller that takes over the task of the old computer. An additional requirement is to also be able to control the (CNC) machine via a website. A fully custom printed circuit board is designed to solve this problem. The firmware that is responsible for all control is also developed by us. Briefly summarized, the requirements are the following: With the help of an SD card, a certain PCB design can be read in the machine. The machine can be controlled in two ways: on the one hand everything can be operated using the touchscreen, and on the other hand the machine must be able to be fully controlled via a website. Now that the project is finished, we can conclude that thanks to the enormous development of technology in recent years, nowadays you can easily and cheaply design a control unit for old devices. We can simulate the operation of a computer that is 25 years old with a small and simple printed circuit board that costs 45 euros (development costs not included). This result shows that you could create a ‘man in the middle’ with new hardware for many old machines. This way of working can certainly be applied to other machines. You could even apply this way of working for development of new machines. We were instructed to control a machine with a certain interface. In principle you can compare it with the development of a controller for a machine. In that case, it does not really matter what or how old the machine is.Grado en Ingeniería de Tecnologías Específicas de Telecomunicació