This repository contains the documentation and resources for the EDM Test Rig, a test stand developed for advancing Electrical Discharge Machining (EDM) technology. The rig is designed to facilitate the development and testing of EDM components and systems.
Subassemblies of EDM Test Rig
| Subassembly | Description |
|---|---|
| Frame | Physical 4040 extrusion frame |
| DIN Rail Box | Mounts PSUs and control systems on DIN rails |
| Kinematics | Provides movement of EDM test items |
Specifications of EDM Test rig.
| Specification | Description |
|---|---|
| Approximate Cost | 2,000 USD |
| Size | 1.4 m x 0.58 m x 1.4 m |
| Construction | 40x40, 20x20 Extruded Aluminum |
| Kinematics | C7-Class Ballscrews + NEMA23 Stepper Motors |
| Linear Resolution | +- 30 Microns Maximum |
| 3D Printer | FDM, Bambu Labs X1C |
| Power | 120 VAC, 60 Hz |
| Firmware | DangerKlipper |
| Operating System | Linux |
| DIN Rail Space | 40", 35 mm wide, 7.5 mm tall |
| On-Board Power | 48 VDC, 24 VDC, 12 VDC, 5 VDC |
The frame provides a rigid, industrial grade, structure for conducting testing.
Hardware for frame. NOTE: 4040 Extrusions must be cut to length
| Item | Description | Quantity | Link |
|---|---|---|---|
| 4040 Extrusions, Length 500 mm | 4040 Aluminum T-Slot Extrusion | 4 | Amazon |
| 4040 Extrusions, Length 500 mm, Countersunks | Extrusion w/ M5 Countersinks | 2 | Amazon |
| 4040 Extrusions, Length 1000 mm | 4040 Aluminum T-Slot Extrusion | 6 | Amazon |
| 4040 Extrusions, Length 1220 mm | 4040 Aluminum T-Slot Extrusion | 4 | Amazon |
| 4040 L Plate Bracket | M8x16 Brackets for 4040 Exturions | 1 Pack of 8 | Amazon |
| 4040 L Bracket | Corner Bracket for 4040 Extruions | 1 Pack of 12 | Amazon |
| 4040 Adjustable Feet | Adjustable feed for 4040 Extruions | 1 Pack of 4 | Amazon |
The DIN rail box provides 40 inches of 35 mm x 7.5 mm DIN rail space for mounting power supply units (PSUs), control systems, and other equipment. This setup ensures organized and efficient management of components within the EDM Test Rig.
Note: The CAD models for the 2020 aluminum extrusions do not use T-slot nuts, but M4 taps. However, T-slot nuts are recommended.
Required FDM 3D prints for DIN rail box. This project requires several kilograms of filament. Print components with a brim to prevent warping. Enable ironing of top surfaces for base plates for a better surface quality.
| 3D Prints | Description | Quantity | Material |
|---|---|---|---|
| Base Plate | Connects DIN rails to extrusions | 5 | PLA or ASA |
| Top Spacer | Connects adjacent extrusions | 2 | PLA or ASA |
| End Brace | Braces adjacent extrusions | 4 | PLA or ASA |
| PEM Cover | Mounts PEM module to side | 1 | PLA or ASA |
| Side Cover | Enclosure, with knockouts for wiring | 9 | PLA or ASA |
| End Cover | Enclosure, magnetically retained | 2 | PLA or ASA |
Hardware for DIN rail box: DIN rails, 2020 Aluminum extrusions, & Fasteners.
| Item | Description | Quantity | Link |
|---|---|---|---|
| DIN Rails | 35 mm x 7.5 mm, 8" long | 5 | Amazon |
| 2020 Aluminum Extrusion | 1 Meter Length, M6 end taps | 4 | Amazon |
| Ruthex M5x9.5 mm Heat Set Insert | Heat set insert for DIN Rails | 15 | Amazon |
| T-Nuts for 2020 Extrusions | For mounting to 2020 extrusions | 46 | Amazon |
| Neodymium Magnets, 6 mm OD x 2 mm | For magnetic end covers, super glued | 32 | Amazon |
| M6x1 mm, 16 mm Long, DIN 7991 | For 2020 Extrusions & End Spacers | 4 | McMaster-Carr |
| M5x0.5 mm, 10 mm Long, ISO 7380-1 | For DIN rails and Base Plates | 15 | McMaster-Carr |
| M4x0.7 mm, 12 mm Long, DIN 7991 | For End Braces | 16 | McMaster-Carr |
| M4x0.7 mm, 16 mm Long, ISO 7380 | For mounting base plates to extrusions | 30 | McMaster-Carr |
| M3x0.5 mm. 30 mm Long, DIN 7991 | For PEM module | 2 | McMaster-Carr |
| M3x0.5 mm Nut, DIN 934 | For PEM module | 2 | McMaster-Carr |
Electronics components for DIN rail box. Includes the control board and computer for running Klipper/DangerKlipper + Linux.
| Electronics Components | Description | Quantity | Link |
|---|---|---|---|
| PEM Module | 15A 250V, with Rocker Switch | 1 | Amazon |
| Meanwell LRS-350-48 | SMPS, 48 VDC | 1 | Amazon |
| Meanwell LRS-350-24 | SMPS, 24 VDC | 1 | Amazon |
| Meanwell LRS-350-12 | SMPS, 12 VDC | 1 | Amazon |
| Meanwell LRS-100-5 | SMPS. 5 VDC | 1 | Amazon |
| SSR (optional) | 3-32 VDC, 24-480 VAC SSR | 1 | Amazon |
| NEMA 5-15R Module (optional) | Breakout module for AC interconnects | 1 | Amazon |
| M4 Ring terminal | 16-22 AWG Crimp, M4 (LRS PSU Terminal) | 100 | Digikey |
| 16 AWG Wire, Stranded, Black | For AC & DC interconnects | 25' | Digikey |
| 16 AWG Wire, Stranded, White | For AC interconnects | 25' | Digikey |
| 16 AWG Wire, Stranded, Green | For AC interconnects | 25' | Digikey |
| 16 AWG Wire, Stranded, Red | For DC interconnects | 25' | Digikey |
| Manta M5P + CB1 V2.2 Klipper Board | For Klipper/DangerKlipper firmware + Linux | 1 | Amazon |
Accessories for mounting hardware to 35 mm x 7.5 mm DIN rails.
| 3D Prints | Description | Material |
|---|---|---|
| LRS-xxx-48_24_12 | For mounting Meanwell LRS PSUs | PLA or ASA |
| LRS-100-5 | For mounting Meanwell LRS-100-5 PSU | PLA or ASA |
| Wago 221-415 | For mounting 3x 221-415 Wagos | PLA or ASA |
| Manta M5P | For mounting BTT Manta M5P | PLA or ASA |
| Breadboard 53x165 mm | For mounting medium breadboard | PLA or ASA |
| Omcron SSR | For mounting solid-state relay | PLA or ASA |
- 3D print all required prints out of PLA or ASA
- Tap ends of 2020 aluminum extrusions with 6x1 mm tap to a depth of at least 8 mm
- Base plates require the insertion of M5x9.5 mm Ruthex inserts using a heat press
- Fasten base plates to 2020 aluminum extrusion using M4 t-slot nuts & M4x0.7 mm 16 mm Long bolts
- Fasten DIN rails to base plate 3D prints using M5x0.7 mm 10 mm long bolts
- Fasten 2020 extrusions together with end brace 3D prints & M6x1 mm 16 mm long bolts
- Space extrusions using space 3D prints and M4x0.7 mm 12 mm long bolts with T-slot nuts
- Fasten PEM module to PEM panel 3D print using M3x0.5 mm 30 mm long bolts and M3x0.5 mm nuts
- Snap on side panel cover 3D prints onto 2020 aluminum extrusions
- Super glue 6 mm OD x 2 mm magnets into end covers and end brace 3D prints. Use soft-blow hammer to assist
- Wire PEM module AC interconnects to Wago 221-415s on Wago DIN rail 3D print
- Use M4 ring terminals and 16 AWG wire to connect PSUs to AC power
- Connect Manta M5P high-voltage input to LST-350-48 PSU
- Connect Manta DC-in to LRS-350-24 PSU
Notes:
- Use 16 AWG green wire for AC/EGND interconnects
- Use 16 AWG white wire for AC/Neutral interconnects
- Use 16 AWG black wire for AC/Live & DC/GND nterconnects
- Use 16 AWG red wire for DC/48V, DC/24V, DC/12V, & DC/5V interconnects
This section details the ballscrew-driven kinematics for the EDM test rig, which ensures precise and controlled movement of test objects.
Hardware for kinematics of EDM test rig: Ballscrew actuators.
| Item | Description | Quantity | Link |
|---|---|---|---|
| FUYU FSL40 Ballscrew Module, 500mm Stroke | C7 Class ballscrew, 30 micron resolution | 2 | Amazon |
| FUYU FSL40 Ballscrew Module, 1000 mm Stroke | C7 Class ballscrew, 30 micron resolution | 1 | Amazon |
| LBE-04NU2 PNP NC Endstop | 10 mm x 6 mm, NPN, NC | 2 | Aliexpress |
| M5x0.8 mm, 35 mm Long, DIN 912 | For fastening Y-axis ballscrews to 4040 | 8 | McMaster-Carr |
| M5x0.8 mm, 16 mm Long, DIN 7991 | For fastening endstop module | 4 | Mcmaster-Carr |
| M3x0.5 mm. 25 mm Long, DIN 7991 | For fastening X-axis brackets | 8 | Mcmaster-Carr |
| M3x0.5 mm. 16 mm Long, ISO 7380 | For fastening Y-axis to brackets | 8 | McMaster-Carr |
| M3x0.5 mm, 12 mm Long, DIN 7991 | For fastening endstops to endstop print | 2 | McMaster-Carr |
| M3x0.5 mm Nut, DIN 934 | For fastening endstops to endstop print | 2 | McMaster-Carr |
| 3D Prints | Description | Material |
|---|---|---|
| Left X-Axis Bracket | Connects X-axis to Y-axis | PLA or ASA |
| Right X-Axis Bracket | Connects X-axis to Y-axis | PLA or ASA |
| 4040 Endstop Module | Retains magnetic endstop | PLA or ASA |
Instructions for assembling the kinematic components, including images, will be provided in this section.