Arduino.txt

/*
 * DIWire Bender
 * 3D Wire Bender by Pensa - www.PensaNYC.com
 * Written by Marco Perry. Call (718) 855 - 5354 for questions or support.
 * Drives on 3 Stepper Motors to bender wire in 3D space
 *
 */

/*This program is to be uploaded onto the DIWire  arduino. 
 Bend angles and feed lengths are imported from processing running on a computer plugged into the arduino. 
 This program takes these lengths and angles and moves the motors and solenoid accordingly.
 */

/*
* Feed Motor 1 - drives wire
 * z Bend Motor - performs 3D bends by rotating entire assembly
 * bend Motor - performs 2D bends by bending wire over
 * benderPin - solenoid
 */

// pin assignments
// Motor pulse and solenoid pins
const int bendMotorPls = 9;
const int zMotorPls = 10;
const int feedMotorPls = 11;
const int benderPin = 12;

// AWO pins to allow motor shaft to free spin
const int bendMotorAWO = 3;
const int zMotorAWO = 4;
const int feedMotorAWO = 5;

// Direction pins to select drive direction
const int bendMotorDir = 6;
const int zMotorDir = 7;
const int feedMotorDir = 8;

//misc program constants
const int pulseWidth = 20;
const int pulseDelay = 700;

// Drive directions in english
boolean ccw = true; // counter-clockwise drive direction
boolean cw = false; // clockwise drive direction
boolean curDir = cw; // resets direction before next angle command 

int lastbend = 0;
int fieldindex=0;
int values[300]; //creates array

void setup() {
  Serial.begin (9600); //com port communication
  pinMode (bendMotorPls, OUTPUT); //Declaring motor pins as out
  pinMode (zMotorPls, OUTPUT); 
  pinMode (feedMotorPls, OUTPUT); 
  pinMode (bendMotorAWO, OUTPUT); 
  pinMode (zMotorAWO, OUTPUT); 
  pinMode (feedMotorAWO, OUTPUT); 
  pinMode (bendMotorDir, OUTPUT);
  pinMode (zMotorDir, OUTPUT); 
  pinMode (feedMotorDir, OUTPUT); 
  pinMode (benderPin, OUTPUT); 
  digitalWrite (bendMotorPls, LOW); //starts with everything off
  digitalWrite (zMotorPls, LOW); 
  digitalWrite (feedMotorPls, LOW); 
  digitalWrite (benderPin, LOW);
  digitalWrite (zMotorAWO, HIGH);
  digitalWrite (feedMotorAWO, HIGH);
  digitalWrite (bendMotorAWO, HIGH);
}

void bend (float angle) {     //bender pin movement
  if (angle!=0){              //sets direction of bend based on + or - angle
    Serial.println("bending");
    Serial.println(angle);
    boolean dir=cw;
    boolean back=ccw;
    if (angle<0){
      dir = ccw;
      back = cw;
    }
    float rotations = 0;
    angle = abs(angle);
    if (angle <= 90){
      angle = -.0012*angle*angle+.5959*angle+.2452; //converts angle into calibrated motor steps 
      angle = 6000 * (angle/360)+220;
    }
    else if (91 <= angle <= 120){
      angle = .0044*angle*angle-.5481*angle+57.981; //converts angle into calibrated motor steps 
      angle = 5960 * (angle/360)+220;
    }
    else if (121<=angle<=180){
      angle = angle-63.26;  //converts angle into calibrated motor steps 
      angle = 5960 * (angle/360)+220;
    }   //calibration will differ depending on set up 
    rotations = angle;
    // Serial.println (angle);
    digitalWrite (bendMotorDir, dir);  
    for (int i=0; i <=rotations  ; i++){ //moves bender bin the desired angle
      digitalWrite(bendMotorPls, HIGH);
      delayMicroseconds (pulseWidth);
      digitalWrite(bendMotorPls, LOW);
      delayMicroseconds (pulseDelay);
    }
    delay (100);
    digitalWrite (bendMotorDir, back);   //moves bender pin back to home position ready for next feed
    for (int i=0; i <=rotations  ; i++){
      digitalWrite(bendMotorPls, HIGH);
      delayMicroseconds (pulseWidth);
      digitalWrite(bendMotorPls, LOW);
      delayMicroseconds (pulseDelay);
    }
  }
}

void rotatePin (boolean dir, float angle) { //moves bender pin during duck. direction specified from duck subroutine
  float rotations = 0;
  angle = 6000 * (angle/360); //converts angle to steps
  rotations = angle;
  Serial.println (dir);
  digitalWrite (bendMotorDir, dir);  
  for (int i=0; i <=rotations  ; i++){ //rotates bender motor appropriate number of steps
    digitalWrite(bendMotorPls, HIGH);
    delayMicroseconds (pulseWidth);
    digitalWrite(bendMotorPls, LOW);
    delayMicroseconds (pulseDelay);
  }
}

void zbend (float angle) { //rotates z motor
  if (angle!=0){
    Serial.println("Z bending");
    Serial.println(angle);
    boolean dir=cw;
    if (angle<0){ //+ angle is clockwise - angle is counter clockwise
      dir = ccw;
    }
    float rotations = 0;
    angle = abs(angle);
    angle = (2000 * angle)/360; //converts angle to motor steps
    rotations = angle;
    digitalWrite (zMotorDir, dir);  //sets motor direction
    for (int i=0; i <=rotations  ; i++){ //rotates z motor appropriate number of steps
      digitalWrite(zMotorPls, HIGH);
      delayMicroseconds (pulseWidth);
      digitalWrite(zMotorPls, LOW);
      delayMicroseconds (2000);
    }
  }
}

void feed (float dist) { //feeds wire
  if (dist != 0){
    Serial.println("feeding");
    Serial.println(dist);
    float rotations = 0;
    float feedCalib = 25.4*PI; //feed mm per revolution of motor
    dist = 2000 * dist/feedCalib;  //dist converted from mm to steps
    rotations = dist;
    digitalWrite (feedMotorDir, 1);  //feed motor only moves forward
    for (int i=0; i <=rotations  ; i++){ //rotate feed motor appropriate number of steps 
      digitalWrite(feedMotorPls, HIGH);
      delayMicroseconds (pulseWidth);
      digitalWrite(feedMotorPls, LOW);
      delayMicroseconds (pulseDelay);
    }
  }
}

void duck (){  //ducks bender pin under wire
  digitalWrite (benderPin, HIGH); 
  delay (100);
  rotatePin (curDir, 45);
  digitalWrite (benderPin, LOW);  //pin down move under wire
  curDir = !curDir;    //direction reversed for next duck
}

void loop() {
  int copies = 0;
  while (Serial.available ()){ //starts once serial entry made
    digitalWrite (bendMotorAWO, LOW);
    digitalWrite (zMotorAWO, LOW);
    digitalWrite (feedMotorAWO, LOW);

    int in = Serial.read();
    byte incoming = in+128; //converts bytes from processing
    if (incoming != 255){   //255 signifies end of incoming array
      Serial.println (Serial.read());
      values[fieldindex] = values[fieldindex]*10+incoming; //fills array fieldindex from incoming processing
      fieldindex++;
    }
    else{
      Serial.println("END");     //if array end marker inputs from processing end
      for (int i=0; i<=fieldindex;i++){
        Serial.println(values[i]-128);
      }
      copies=copies+1;
    }
  }
  if (copies==1){ //once bend is complete eject shape
    delay (1000);
    motorrun();
    feed(50); //eject 
    copies=copies+1;
  }
}

void motorrun(){
  int lastbend=0;
  for (int i=0; i<= fieldindex;i++){
    delay (100);
    if ((values[i]-128)==126){ //convert bytes from processing and look for feed motor marker
      feed (values[i+1]-128);  //if feed motor marker detected next value in array is a feed length
    }
    else if ((values[i]-128)==125){ //convert bytes from processing and look for bend motor marker
      int bendAng = (values[i+1]-128);  //if bend motor marker detected next value in array is a bend angle
      if ((bendAng<0&&curDir==cw) || (bendAng>0 && curDir ==ccw)){ //if incoming bend angle is opposite direction from previous angle duck pin
        duck ();
        delay (100);
      }
      bend (bendAng);
      lastbend = bendAng;
    }
    else if ((values[i]-128)==124){ //convert bytes from processing and look for z motor marker
      zbend (values[i+1]-128);  //if z motor marker detected next value in array is z bend angle
    }
  }
}