Ibra College of Technology , 26-28 November. 2029,Ibra Editors: Ramesh Vellaichamy Arduino 3D wire bending machine Fakher Rashid Al-rashdi , Faisal said al-musallami , Nawaf juma salim al-sharji , Tariq hamed al-hashmi ,mohammed ali al-hajri ,and Mr Ramesh vellaichamy Started project at 30 Apr /2019 finished project at 13 Dec /2020 Ministry of manpower (Mechanical Engineering, ICT, Ibra, Oman) Abstract Arduino Wire Bending machine is process which is most commonly used in processing and manufacturing at different industrial. This manufacturing is usually used to deform or bend wire metals. The development and optimization of auto wire bending machine of these processes are useful for many industrial , also according to the research of wire bending machines has archived many goals for organization and factory based on the material selections, productions cost, productivity and control of quality . In addition of that a lot of factories need to reduce their cost in manufacturing of goods with high quality and less time. The condition in engineering, wire bending machine means bending of a metal parts, by apply some amount of force pressure, into a curved shape or angular shape, or the stretching or flanging of it along a curved path. Bending of wire metal for a required shape by pressure .based on the material properties. Bender primary aims are to provide accuracy, repeatability, and interchange ability in the manufacturing of products. This metal bender shows the reduction in electrical power, machining time, manufacturing cost etc. The gear is a tooth element these teeth are mounted on a wheel which rotates and transmit motion. An electric DC motors are known as an electrical elements which converted an electrical energy into mechanical energy also Stepper motors have different sizes and capacity or power and styles and electrical characteristics which has same function of DC motor. This 3D wire bending machine is controlled by an Adriano Nano, which controls one DC motor and three servo motors for wire manipulation via DRV8825 driver boards. A servo motor is also implemented in order to push a piece of copper tubing into place to physically bend the wire. AL-Rashdi,AL-Musallami,AL-Hashmi,AL-Sarji,AL-Hhajri,vellaichamy Keywords 3D wire bending machine, wire bending mechanism, self-operation or bending, controlled by Arduino, Arduino programming Introduction There are a lot of machines manufactured for bending the wires, my project is to be design Adriano 3D wire bending machine, this machine used to bend wires into curvature shape. It works with electricity it has gears that make linear, vertically, semi rotary and rotary movement to bend the wires. The 3D wire bending machine is powered by an Adriano Nano, which controls one DC motor and three stepper motors for wire manipulation via DRV8825 driver boards. A servo motor is also implemented in order to push a piece of copper tubing into place to physically bend the wire Here’s the main function of this 3D wire bending machine. So first, the wire goes through a series roller, or straighteners. Using a stepper motor the wire is precisely fed to the wire bending mechanism which also uses a stepper motor as well as a small servo for the bending process… 2. Working principle of 3D wire bending machine. First of all the wire will be inserted in square (box number 1) then will pass between the four grooves bearings as shown in number in the picture (2) ,the use of these grooves are to keep flow of wire straight . Step (3) then will passing between anther box, bearing and pipe which rotated by DC motor all these components will make the wire flow at exact center of shaft and with no curves then will pass inside the shaft until the end of shaft which has a nozzle also the nozzle will control the flow of wire .(4) the servo motor will connected with super gear which drive the other super gear which mounted on the shaft .(5) the two blocks will support the stand of rack and pinion gears and servo motor. Stepper motor with its gear (A) which drives the super gear (B). super gear (B) is responsible for the angle of bends which is 170 degrees .(6) pinion gear will be mounted on the servo motor which rotates the pinion to drive the rack gear ,The end of rack gear has a small pipe which push the wire up to have some degree . All these working principle of motors (DC, stepper and servo) will be controlled by Arduion, as the codes for Arduino program is bit longer, it's not explained …. AL-Rashdi,AL-Musallami,AL-Hashmi,AL-Sarji,AL-Hhajri,vellaichamy B A Figure 2.1 Figure 2.2 3. Arduino Uno: The three stepper motors are using the three DRV8825 stepper drivers. For power the steppers and the full project we will use 12 V power supply with leastways 3A of current ratio. For power the servo, we use the 5V coming from the Arduino, but the MG996R servo can be powerless and the 5V voltage governor of the Arduino might not be qualified to handle it. We decided to use a separate 5V voltage governor, the LM7805, which is good enough to power the servo for this project. There is also a limit switch for the bender which to pull up resistor it is joint to a digital pin of the Arduino boards. Figure -3.1: Arduino Uno https://images.app.goo.gl/9TqtGCzy6aqM5QJM7 3 .Features of the Adriano UNO AL-Rashdi,AL-Musallami,AL-Hashmi,AL-Sarji,AL-Hhajri,vellaichamy Table 3. 1: Features of the Adriano Features Value Microcontroller ATmega328 Operating Voltage 5V Input Voltage 7-12V (recommended) Input Voltage (limits) 6-20V Digital I/O Pins 14 (of which 6 provide PWM output) Analog Input Pins 6 DC Current per I/O Pin 40 mA DC Current for 3.3V Pin 50 mA Flash Memory 32 KB of which 0.5 KB used by boot loader SRAM 2 KB (ATmega328) EEPROM 1 KB (ATmega328) Clock Speed 16 MHz Table3. 2: Pin Description Pin Category Pin Name Details Vin: Input voltage to Arduino when using an external power source. Power Vin, 3.3V, 5V, GND 5V: Regulated power supply used to power microcontroller and other components on the board. 3.3V: 3.3V supply generated by on-board voltage regulator. Maximum current draw is 50mA. GND: ground pins. Reset Reset Resets the microcontroller. Analog Pins A0 – A5 Used to provide analog input in the range of 0-5V AL-Rashdi,AL-Musallami,AL-Hashmi,AL-Sarji,AL-Hhajri,vellaichamy Input/output Digital Pins 0 – Pins 13 Serial 0(RX), 1(TX) Used to receive and transmit TTL serial data. 2, 3 To trigger an interrupt. 3, 5, 6, 9, 11 Provides 8-bit PWM output. External Interrupts PWM Can be used as input or output pins. 10 (SS), 11 (MOSI), SPI 12 (MISO) and 13 Used for SPI communication. (SCK) Inbuilt LED 13 To turn on the inbuilt LED. A4 (SDA), A5 TWI (SCA) AREF AREF Used for TWI communication. To provide reference voltage for input voltage. Table-3: (The Greek alphabet) Letter name Uppercase Number of teeth Diametral pitch Outside diameter Pitch diameter Equations Using this equations to find specification of super gears Eq.1,2 AL-Rashdi,AL-Musallami,AL-Hashmi,AL-Sarji,AL-Hhajri,vellaichamy 4. Conclusion The main advantage 3D wire bending machine which controlled by Arduino with program that it is very easy to operate. It helps to bend wire automatically . before people who bend the wires are facing problem of getting the exact angles and different shapes also it was difficult to bend more than 10 wires in the same time because of weight of the material and its need more effort and time, so that’s why we design and manufacture this mechanism or machine to reduce the risk of worker in work place. It is easy to control the parts by setting Arduino program. In future they should develop 3D wire bending machine with different movement in directions that it overcomes the limitations of this bender by controlling the machine parts by GSM network. References [1} Manufacturing Processes Reference Guide, Industrial Press Inc., 1994 [3] Khurmi, R. S., & Gupta, J. K. (1976). Theory of Machines (14th ed.). New Delhi, India: S. Chand Publishing [4]https://www.google.com/search?q=Standard+bends&authuser=1&source=lnms&tbm=isch&sa=X &ved=0ahUKEwi04rWwvonjAhVEDuwKHTUNAjcQ_AUIECgB&biw=1366&bih=657#imgrc=Sr1oOMs1 NmDe0M: [5]https://www.google.com/search?hl=ar&authuser=1&biw=1366&bih=657&tbm=isch&sa=1&ei=Ea EUXe76E-iBigP29GGGA&q=%09Edgewise+bending&oq=%09Edgewise+bending&gs_l=img.3...0.0..173...0.0..0.0.0. ......0......gws-wiz-img.tR_cfG6bD9Q#imgrc=wf-Q-Ae2L7h4CM: [6] ] https://www.enhancedradio.com/products/arduino-uno-r3-with-atmega328p