Sweep 3D Scanner V0.96 Assembly Instructions

Table of Contents
Introduction ................................................... 2
Tools Required (not Included) ....................... 2
Assembly Instructions
3D Printing the Enclosure Parts ..................... 2
3D Scanner Kit Contents ................................ 2
Test Fit All Parts ............................................. 3
Step 1. Install Bearings in Cover .................... 4
Step 2. Assemble Limit Switch ....................... 5
Step 3. Install Stepper Motor ........................ 6
Step 4. Assemble Motor HAT......................... 7
Step 5. Assemble Female Micro USB Cable ... 8
Step 6. Install Bubble Spirit Level .................. 9
Step 7. Install Raspberry Pi Assembly .......... 11
Step 8. Install 90 Degree Scanner Bracket ... 12
Step 9. Assemble Battery Holder ................. 17
Step 10. Install 9 Axis IMU ........................... 20
sweep DIY 3D Scanner Kit
A Note About Our Target Audience:
Step 11. Install Battery onto the Scanner .... 22
Troubleshooting Guide ................................ 24
This kit is for those that enjoy DIY projects. It
will require a good bit of tinkering to get the
results you want. If you have questions, which
you likely will, make it an opportunity to
become a member of our forum
(http://community.scanse.io/c/3d-scanner). We
hope you have fun building it and learning how
3D scanners work.
Software for This Project Can Be Found At:
https://github.com/scanse/sweep-3d-scanner
3D Models for This Project Can Be Found At:
https://www.hackster.io/scanse/sweep-3dscanner-035a5f
Documentation Revision Information
Rev
0.93
0.94
0.95
Date
5/16/2017
5/24/2017
6/19/2017
0.96
8/28/2017
Changes
Initial Release
Updated Sweep Install Photo
Updated Sweep Scanner Bracket &
Scanner Cover design
Added troubleshooting guide
3D Scanner Exploded View
1
Introduction
These assembly instructions will cover the mechanical assembly, programming and basic use of the
Sweep 3D scanner add-on.
Tools Required (not Included)
-
Soldering Iron and Solder
Wire Stripper
Small Philips Head Screw Driver
2.5mm Hex Key with Ball End
3D Printing the Enclosure Parts
The three main enclosure parts and the cable clip are intended to be printable using a consumer
desktop FDM (fused deposition modeling) style printer. You should get functional results when printing
using a 0.2mm layer height. We have oriented the available STL files in the direction we have found they
print best with the least amount of support material. We found that 20-30% infill works well. Our test
parts were made using standard ABS filament, but PLA or other materials can work too (with PLA you
need to worry about the parts melting in a hot car). You can also have these parts printed by a service
like Sculpteo or Shapeways, but it will cost much more.
Difficult to make parts: The last 3D printed part – the custom Light Pipe, is intended to be printed using
a clear resin with an SLA style printer. We realize this may not be as commonly accessible to most
people, which is why we are offering a kit of parts for sale that includes all the 3D printed parts.
3D Scanner Kit Contents
We have assembled all the parts you need to make this project in one convenient kit. It includes about
60 parts, including the five necessary 3D printed parts. The 3D printed parts are made of black ABS, and
are printed at 0.2mm layer heights. The one clear component is printed using SLA technology. The only
thing not included in the kit is a Sweep sensor.
The kit is available for purchase on our website: http://scanse.io/3d-scanning-kit/
2
Our 3D scanner kit includes everything you need to build this 3D scanner, except for tools listed above
Test Fit All Parts
When working with 3D prints, it is common for slight inaccuracies to be present. Use a small tool such as
a screw driver to remove all support material and small defects.
3
Step 1. Install Bearings in Cover
Parts Needed:
-
(3) 8MM OD, 3MM ID, 3MM Wide Bearings
(3) M3 X 8MM Socket Head Cap Screws
P0087 – Spherical Scanner Cover, Square 3D printed part
Make sure screw holes are clear of support material. Push bearings into the slots as shown and install
the screws one at a time using the 2.5mm Hex Key as shown.
4
Step 2. Assemble Limit Switch
Parts Needed:
-
OdiySurveil (TM) Simulated Roller Lever SPDT AC Miniature Micro Switch
Female to female jumper wire cable
10K inline resistor
Heat shrink tubing or electrical tape
Phillips Drive, #2-28 Thread Size, 3/8" Length
P0087 – Spherical Scanner Cover, Square 3D printed part.
(2) Phillips Drive, #2-28 Thread Size, 3/8" Length
Solder one end of the 10K resistor onto the common pin of micro switch. Cut the jumper wire in half, so
that each piece is approximately 100 mm (4 in) long. Strip the ends and solder one piece to the free end
of the resistor. Solder the other piece to the NC (normally closed) tab of the micro switch. Cover the
resistor with heat shrink tubing or electrical tape.
Install the micro switch into Spherical Scanner Cover in the orientation shown using the two screws.
Make sure the switch operation is not hindered by 3D printed plastic.
5
Step 3. Install Stepper Motor
Parts Needed:
- 0.9deg Round Nema 14 Stepper Motor
- (2) M3x5mm Phillips Flat Countersunk Head Machine Screws
- P0087 – Spherical Scanner Cover, Square 3D printed part.
Cut motor wires to approximately 100mm (4 inches). Strip approximately 6mm (1/4 inch) off the ends.
Screw motor into Scanner Cover in the orientation shown.
6
Step 4. Assemble Motor HAT
Parts Needed:
-
Raspberry Pi 3 Model B
Adafruit DC & Stepper Motor HAT for Raspberry Pi - Mini Kit
2.54mm Pitch Single Row Male 90 Degree Right Angle Pin Header
Female to female jumper wire
Insert the motor screw terminals into motor HAT in the direction shown, then solder in place.
Next solder the large pin receptacle into the intended location.
Next, to maintain the correct spacing, slide the Female Jumper Wires onto the Pin Headers as shown,
before soldering the headers in place. Once the headers are soldered in place, remove the jumper wire.
Finally, install the motor HAT onto the Raspberry Pi 3 Model B
7
Step 5. Assemble Female Micro USB Cable
Parts Needed:
-
-
StarTech.com 0.5m 20" Micro USB Male to Micro USB Female Cable (USBUBEXT50CM)
Double sided tape (included on cable)
P0090 – Spherical Scanner Cable Clip (3D printed part)
3.5mm (1/8 inch) Heat shrink tubing
Motor HAT/Raspberry Pi Assembly
Cut the cable about 100mm (4 inch) from the female end. Strip off the outer rubber shield of the cable
using a wire stripper blade. Separate the red (power) and black (ground) wires from the rest, and cut the
other color wires back around 20mm (3/4 inch). Strip approximately 6mm (1/4 inch) of shielding off the
ends of the black and red wires.
Remove the backing on the exposed side of the double-sided tape attached to the connector and slide
the clip and cable into the Raspberry pi. Stick the connector to the top of the Ethernet port as shown.
Slide a 25mm (1inch) piece of 3.5mm (1/8 inch) diameter heat shrink tubing over the end of the cut
wire, leaving the red and black wires poking out. Shrink in place, so that the exposed cable shielding is
covered.
8
Insert the cable’s red lead into the motor HAT screw terminal which read’s “+ power”, and the cable’s
black lead into the motor HAT screw terminal which reads “– power”. Tighten the screw terminals as
shown.
Step 6. Install Bubble Spirit Level
Parts Needed:
-
14mm Circular Bubble Spirit Level
P0087 – Spherical Scanner Cover, Square 3D printed part.
Super Glue
9
Start by finding a flat level surface (you can use the spirit level to check for this). Insert the spirit level
into the scanner cover as shown. Then put the scanner cover on the flat level surface. Next use your
fingers or a small tool like a screw driver to adjust the position of the spirit level in the hole until the
bubble sits in the center when the scanner cover is sitting flat on the level table.
Put a few beads of glue around the spirit level and let it dry in a level position.
10
Step 7. Install Raspberry Pi Assembly
Parts Needed:
-
(4) Steel Thread Rolling Screw for Plastic, Zinc Plated, Pan Head, Phillips Drive, #2-28 Thread
Size, 3/4" Length
(2) Nylon Unthreaded Spacers 3/16" OD, 7/16" Length, for Number 2 Screw Size
P0087 – Spherical Scanner Cover, Square 3D printed part.
Insert the Nylon spacers between Raspberry Pi and Motor Hat mounting holes on the side next to the
screw terminals, while inserting the screws through them as shown.
IMPORTANT: WHEN INSTALLING THE RASPBERRY PI ASSEMBLY INTO THE COVER, YOU NEED TO
REMOVE THE SD CARD. YOU CAN THEN SLIDE THE SD CARD BACK INTO THE PI FROM THE OUTSIDE.
11
Step 8. Install 90 Degree Scanner Bracket
Parts Needed:
-
Sweep Sensor
Sweep Cable
Sweep USB to Serial Adapter
Sweep USB cable
(4) M2.5x4mm 316 Stainless Steel Flat Head Phillips Machine Screws
(1) Steel Thread Rolling Screw for Plastic, Zinc Plated, Pan Head, Phillips Drive, #2-28 Thread
Size, 3/8" Length
Small zip tie
P0092 - 90 DEGREE CYLINDRICAL SCANNER BRACKET, TALL
Install the larger screw (which acts as a set screw) into the shaft hole as shown and thread part way in.
12
Assemble the Sweep Cable, Sweep USB to Serial Adapter and Sweep USB cable. Insert the cable through
the scanner bracket and insert the cable into the sideways facing connector in the Sweep sensor.
Insert the Sweep sensor into the bracket as shown. Line up the holes with the sweep connector facing
downward and the sweep led facing upward, and install the 4 small screws.
13
Mark a line with a pencil on the micro USB cable 3.25 inches (82.5mm) from the end of the micro USB
connector. Feed the micro USB cable connector through the Scanner Cover hole shown, then connect
the USB to Serial Adapter board.
Loop the serial cable inside the Scanner Bracket and then slide the USB to Serial Adapter board into the
little clip inside the Scanner Bracket in the orientation shown. Make sure the serial cable is not touching
the rotating head of the Sweep Scanner.
14
Pull the micro USB cable into the scanner cover, then slide it into the provided pinch slot where you the
made the pencil mark earlier. Put as little twist in the cable as possible as shown.
Make sure the flat on the stepper motor shaft is facing the set screw direction and push the 90-degree
bracket onto the motor. Make sure it can freely rotate around 180 degrees, and correctly engages the
limit switch. If you feel binding, gently pull the scanner bracket off the motor and remove any
obstructions.
Run the Sweep USB cable out through the small slot on the side of the scanner cover and into the USB
port on the Raspberry Pi.
Connect the limit switch wires to the Raspberry Pie. One lead should go to pin 17 on the motor HAT
header, while the other lead should go to one of the 3V pins on motor HAT power rail.
15
Next connect the four stepper motors in the color sequence shown. Use a small screw driver to tighten
the screw terminal. Do a light pull test with your fingers to make sure the wires are being held in place
snugly.
The assembly should look like this:
16
Step 9. Assemble Battery Holder
Parts Needed:
-
SINOELE Ultra Slim Universal 10000mAh Power Bank for iOS and Android Smartphones – Black
¼-20 Nut
P0091 - Spherical Scanner Light Pipe
P0088 - Spherical Scanner Battery Holder, Square
Place the nut on the top of the hexagon hole, then put the tip of your soldering iron through the nut and
turn it on (if you can control the temperature – set it to around 720F (382C)). Slowly guide the nut into
the hole as the plastic melts around it.
17
Once the nut cools, insert the battery into the holder as shown with the power light facing upward. We
have found that pushing the battery into the holder while keeping it parallel with the holder bottom
works best.
You should be able to easily activate the battery’s power button using the built in button on the 3D
print.
18
Peel away the double sided tape backing and insert the light pipe into the slot in the battery holder as
shown.
When you active the battery’s power button, you should see light exit the light pipe toward the outside
of the device.
19
Step 10. Install 9 Axis IMU
Parts Needed:
-
Adafruit 9-DOF Absolute Orientation IMU Fusion Breakout - BNO055
Female to female jumper wire Dupont cable (1) Blue, (1) Yellow, (1) Green, (1)Black, (2) Red
(4) Steel Thread Rolling Screw for Plastic, Zinc Plated, Pan Head, Phillips Drive, #2-28 Thread
Size, 3/8" Length
Solder pin strips into IMU circuit board with pins projecting out of the side with all the components on it.
Use the four screws to mount the IMU in the scanner cover, making sure to orient it with the 4 pins
closer to the Raspberry Pi.
Follow this wire connection guide to connect the IMU to the Raspberry PI:
IMU->Wire Color->Motor HAT Connections
VIN ->Red Wire->+3V Rail
GND->Black Wire->GND Rail
SDA->Blue Wire->RX0
SCL->Yellow Wire->TX0
RST->Green Wire->#4
PS1->Red Wire->+3V Rail
20
Fold the wires into cover so they do not interfere with it attaching this assembly to the battery holder.
21
Step 11. Install Battery onto the Scanner
Parts Needed:
-
(4) Steel Thread Rolling Screw for Plastic, Zinc Plated, Pan Head, Phillips Drive, #2-28 Thread
Size, 3/8" Length
(2) Micro USB Short Cable
Use the four thread forming screws to mount the battery holder onto the scanner cover. Be careful not
to over-torque the screws, as they can strip out easily.
22
If you haven’t done so already, install the SD card with the 3D scanner control software image loaded.
For more information on installing the control software on the SD card, see the instructions included
in our GitHub repository. Connect the Battery to Raspberry Pi and motor control power ports using the
short micro USB cables. The Raspberry Pi may turn on immediately. If not, press the power button on
the battery.
This completes the mechanical assembly of you Sweep 3D scanner!
To learn more about the software, please see our 3D Scanner Getting Started Guide in our GitHub
repository: https://github.com/scanse/sweep-3d-scanner
23
Troubleshooting Guide
This troubleshooting guide is oriented toward mechanical issues. To find more information on software
issues, please consult our software wiki here: https://github.com/scanse/sweep-3d-scanner/wiki.
Symptom
Possible Causes
Possible Solutions
No base movement
Motor HAT is not plugged
into a power source.
Be sure the Motor HAT is plugged into the battery and that
the battery is adequately charged.
Erratic base movement
Stepper motor wires are
inserted in an incorrect
order.
Double check the motor wiring in Step 8.
One or more wires are
disconnected from the
motor controller.
Friction when rotating
the scanner bracket
Inaccuracies in the 3D
print, or leftover support
material are causing
contact where there
should be none.
Remove the scanner bracket and look for inaccuracies in
the 3D prints. Carefully remove them with a small blade.
Friction or noise when
the Sweep sensor spins
inside the scanner
bracket
The sweep sensor could
be rubbing against the
plastic of the scanner
bracket.
Check for contact. If necessary, remove the Sweep sensor
to check for interfering material and use a blade to remove
the material.
Scanner does not make The scanner bracket is
a full 180 degree rotation slipping on the stepper
when a full scan is
motor shaft.
initiated
Tighten the set screw in the scanner bracket. If it is stripped
out, use glue to hold the set screw in place.
Sweep sensor stutters or The USB cable connecting Make sure the USB cable is coiled in the scanner bracket
freezes during part of
the Sweep sensor to the
as shown in Step 8 of these assembly instructions. Make
the scan
base may be coiled
sure to pull any excess service loop into the scanner base.
incorrectly and rubbing
against the Sweep
scanner head.
Scans are coming out
The scanner bracket may
with a “corkscrew” skew not be mounted perfectly
to them
co-axially relative to the
stepper motor shaft.
Make sure the scanner bracket is pushed down as far as it
will go onto the motor shaft, such that is rests on the three
bearings mounted in the scanner cover during the entire
180-degree scanner rotation range.
Cannot see the Pi3-AP
WiFi access point in
available networks
The Raspberry Pi is not
powered on or is still
booting up. Image was not
flashed correctly. SD card
is corrupted.
Plug the Raspberry Pi into an adequate power source. Give
the Pi time to boot up. Refresh list of visible networks.
Make sure the SD card was flashed using a decompressed
(unzipped) image file, and not the compressed .zip file.
Plug the Pi into a power source. If that fails, double check
the functionality of the Pi and SD card by flashing the latest
Raspbian release direct from the RaspberryPi Foundation.
Cannot SSH into the
Raspberry Pi
The host computer is not
connected to the Pi3-AP
WiFi access point. The
credentials are incorrect.
Connect to the Pi3AP WiFi access point using password
"raspberry". SSH into the Pi using the IP address
"172.24.1.1" (or the hostname "sweep-3d-scanner") and
password "raspberry".
24
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