DIY computer Controlled Graphical waterfall

Hi my Friends,
World is full of genius persons and i amazed to see how computer made life easier and how the ideas evolves and takes it shapes in real world...Long story short, sometime ago i saw a graphical fountain on You-tube:
http://www.youtube.com/watch?v=tnPnwET4x9k
Watching this video amazed me and convinced me to make a cheap but high quality version of the same... Looking at the fountain, it seems that water droplets are controlled through 100's of solenoid valves and each of the solenoid valve is controlled through computer in a complex manner and a complex programming...
So to make a computer controlled graphical fountain, we require:

1- A complex software that generate images into binary data and send to micro-controller.
2- Electronic hardware that plays as a bridge between Computer and Solenoid valves.
3- Mechanical structure that hold overhead reservoir with solenoid valves and a drain.

All above tasks are doable..... So i started making program and electronics hardware at the same time... when i tired from electronics i started programming... so eventually both the software and hardware completed at the same time..
The following picture of software shows how a number of solenoid valves can be operated in a manner to make beautiful stunning water effects....The Software is user freindly and designed to operate in following steps:
1- You have to select an image 'WMF' black and white

2- Select the number of solenoid valves you have installed on the fountain. The greater the number of valves the greater the resolution and beauty of fountain.

3-Convert this image into '1' and '0' i.e. binary data... If you check the 'Add each design to one file' checkbox..you will have different designs in a single file

4-Open the computer USB port at which the micro-controller is installed.

5-Press 'SEND' button and see the stunning effects..

 More explained:
1- The software convert the photograph in binary data. The Black color is '1' and the white color is '0'.
2- Considering 16 solenoid valves, will give you 16 values of '1' and '0'. these 16 values has to be considered as two bytes data.
3- my software then convert each row into hexadecimal to shorten the data.
4- this data is sent through USB serial port to the micro-controller.
5- Their is small adjustable delay between the two rows of data. this delay separate the drops of rows.
By electronic Hardware i mean the "Simulator", that consist of Microcontroller and LED's.. currently installed 16 LED's to mimic the Solenoid valves..
Here is the short video of working simulator:
http://www.youtube.com/watch?v=bGZjb0nHGJQ
I also purchased 16 solenoid valves too to start making the structure of the fountain.... I am here posting pictures of my software and its working...

Fish Platter

A long time ago i cut the Fish bowl i am sharing here
For 12mm deep Pocket operation I used 1" Barley Twist Tool, for Profile cut i used 6.5mm endmill and V-carving was done by 12.5mm 90 degree V-bit...

The Platter Length is 610mm and width 250mm and the thickness 16mm.... TOTAL TIME 45Minutes with toolchange...

A Souvenir From ROME

The description of above scan can be seen by just clicking the Topic Link.

Laser Scanning of hand carved wooden Corbel

The description of above scan can be seen by just clicking the Topic Link.

The internal of the Laser Scanner control Box

This time i am showing you the inside of the laser scanner control box... The heart of the controller unit is Arduino which is programmable microcontroller... Programming of this controller is a fun project and learn a lot...

The wiring as you see in the picture was done with great care and now i have some electronics knowledge that is used to complete this project... This hardware was completely done by me along with the microcontroller programming...

I have many options available in the hardware... The controller box is supplied with Laptop power supply , Arduino controll the Laser, stepper motor and texture light.. I also added some buttons to reverse and forward the stepper motors.. A plug is provided for installation of limit switch...

In future i will add some more functionality in this setup as i have lot of place to add some more buttons, however the wiring will be really very tricky then....

Spray Bottle Scan with Improved Hardware

Attached you can see the scan of spray bottle  .. Total 9 scans , each scan cycle took 2minutes.. Approximate height of the spray bottle is 250mm and 80mm in diameter...

The alignment and stitching was a difficult part due to symmetry in the model.. However, i learn a lot in stitching the scans... The results are attached...

Improved Laser Scanner Setup

It took a lot of time and patience to make the hardware of my laser scanner setup in such a way that:

1- It can easily perform the scanning without calibration panel.
2- It can be easily disassembled and assembled in new location.
3-Compact in size for transportation
4- Aesthetically look beautiful
5- Electronics have all the control features
6- The complete setup is light weight.
7- Accurate and reliable 

After, considering all above and lot more i was able to DIY the hardware and made the first test scan.. Attached are the pictures of my improved Hardware..

Embroidery Gcode Generator V2.4.4

Recently, I have made drastic changes in embroidery software... These changes were necessary to make optimum Gcode for embroidery work...

Previously, I have made the Gcode that took 30minutes, now the same Gcode is effiecient and takes 16minutes on the embroidery machine... I have added functionalities to move both hoop as well as Needle when the the needle is above the cloth..this saves 40% of embroidery time... I have also added 'Machine Setting' dialogue for the users that will help them for setting Z-axis (sewing Wheel) values in Mach3 software..

You can see the attached figures by clicking on them..

First Embroidery Test

Hi all,I want to share the picture of embroidery artwork RENE has done on his ordinary sewing machine using my Embroidery Gcode Generator Software... He did a great job on it and as i am busy in my Fertilizer Plant Turnaround and doing some hectic work of maintenance, these results literally freshen my mind...

I suggested Rene to do following improvements to get positive results

1- Tighten the clothe very well on the Hoop.

2- The white thread on the bobbin emerging in picture shows that Bobbin thread needs more tention...

3- He should apply some embroider paper behind the cloth..This will give drastic improvement in embroidery..
I am adding RENE work here... I hope you all will like what we can do..Further details can be seen in following thread...
http://www.cnczone.com/forums/showth...=57404&page=23

PS:Just note he is using Router and sewing machine to get this result... This is just the begining... and we have to see marvels in future.. We break into the core of high end commercial machines manufacturer... ;)

Embroidery Gcode Generator V2.4 Beta

In this Version I made following minor changes:
1- On the Top of Gcode, added Total No. of Gcode Lines
2- Made the drawing screen background Colour Black
3- On the bottom added the color information/usage in 'Same Colored Text'
4- Now You can Animate with Cross-hair showing the exact Position of stitch.
5- You can Scroll through the Gcode and Animation Cross hair will update its Position.

Attached is the Program Executable file along with some DST files.. Still need to put the Code in Menu and SaveGcode button is not functional for the time being.. I will try to make it complete and will place here...Just you can check and give me feedback for improving it.. You can unpack the zip and run the executable within the folder if it not run then The Program requires DOTNET framework or Visual Basic runtime files (Can be downloaded free from internet)

The embroidery beta release can be downloaded from following link:

http://www.cnczone.com/forums/showthread.php?t=57404&page=17

The Deer Plaque

This Deer Plaque was one of the best of my work..and it was in auction for US80$.. All the amount went into community charity... I really liked it:)

Wooden Mantle Relief

Yesterday i was looking the old work i created for one of the community event.... This piece of art took a lot of time in designing and machining... It was sold for about US14$ to a women .. She wanted it to be a Wall Keys holder..

Improvement in Embroidery Software

A couple of days ago, while testing the embroidery machine, I lost one of my controller card and this was due to small strand of wire that short-circuit the lower-side of PCB board and some FET's blown away... This was a great setback to me because i just checked the motors and want to start some embroidery work.... SAD day..:(

As my controller card is under etching, so i just started improvements in the embroidery software... I added Stitch Marks (Needle points) in the Simulation.. Added some new colours and Optimized the Gcode generation algorithm...

I hope very soon i will able to show some great embroidery work ;)...



EDIT:
Added some more functionalities like showing Colors and new MenuBar.. Now you can see the number of colors 'in-orders' and simulation of each color...

Improvement in Embroidery Software

I have blown one of my controller card of Embroidery Machine.. and it was totally my fault... This was because of my bad housekeeping Habit ;)... A strand of wire short circuit the FET's and i have lost my modular card in a second...

So again this weekend i was not able to run my machine :(... I tested the handwheel driving stepper motor but the speed the drawback is that the speed and response was not good... I have to work more on the ways to get high SPM ( Stitches Per Minutes)... Recently i worked on my embroidery software and made some enhancements... I added the needle Marks in simulation and the Gcode was optimised.. New colours added and did some blushing on the main screen...

My DIY CNC Embroidery Machine

Last year My wife stressed me to make a DIY embroidery machine with bigger Hoop and that can do all type of stitch work... .. It was a challenge to me... .. All types of stitches!!!!.. I asked her What do you mean by All type of stitches???...

She replied " I need a machine that can compete with modern industrial Machines"... Hmmm..... and the story Begins...and I left Woodwork and tried to look like a embroider..From that day and now, i have a lot of knowledge about embroidery machines and working principal...

I researched on the machines and found that The Following are the few File Formates that Embroidery machine uses..
Brother *.pes
Tajima *.dst
Viking *.hus
Melco *.exp etc

From that day, After a long long time i was able to make a software that can drive my CNC Embroidery Machine with all types of stitches that industrial machines can do. Basically, my intent was to convert low-cost manual sewing machine into embroidery machine that can compete with industrial machines. For this I have to write a software that can convert the DST file into machine readable file.. The DST file is a TAJIMA file format and it is complex binary coded...It was hard for me make a software that can read the file and simulate the design and make the Gcode..Previous experience in visual basic Programming made it possible to write a customised program...

Following is the software that i have written in Visual BAsic Language.. With my this software machine will able to do Straight stitch, Cross-stitch, Zig-zag stitch, Satin stitch, Tatami stitch,chain stitch, Motif-run stitch, triple run stitch, Contour stitch, Perpendicular coil stitch and all types of Alphabets and Pictures...

For hardware drawings are completed and 80% will be assembled within this week end. The functionality of the machine will be..

1- The Large Hoop working area ( 9" x 20")

2- For every new colour in design machine will stop with needle upward condition for colour change.

3- A bulb will lit up so that thread can be easily changed

4- Automatic thread cutting

5-If thread broke machine will stop

further functionalities can be added in future.

3 Set Table Design

Currently involve in designing of wooden table, for which i have made a 3D design...Currently i ma working on some special carved wooden legs for it...

This is another big project for my home and it is very time consuming;)... You can see my machine carved the center design in three portions and it comes out great..Currently i am facing problem with my only ball nose bit that is blunt and burning the wood..I have used it 3-years with all of my 3D projects...

I will be glad if someone contribute me few ball nose bits... You can contact me on my email address , i can send you my Posting address and specification of tool...

360 degree Plane less Scan of Deer

I am reading David's Forum from a couple of years...But a tetra-couple of months ago,I tested this great software with a Free Version...Even my crude setup gave me very good results...I continued to improve my setup day and night and getting improved results... The time has come when my scans were so good that i was in need to save those scans in High Resolution mode..In the mean time Sven and Simon put their best in David, a planless feature, communication with COM and SL functionality...

I know that David is a very low-cost solution for all of us having Home-setup and hobbiest... and I also know that the great minds their are always thinking of increasing the functionality of this software.. The VISION of David team is great....

Furthermore, I saw many helping hands in this forum like Greg, Walter, Gunter, Mattia, Ray and all of the David community...

This compelled me to buy this great software..But the revolution didn't come in one day.. I started collecting money throughout the year to improve my setup and to buy this software...

and Today was the day of extreme happiness when i recieved the USB in a very good packaging.... Now I am able to scan and save in High Resolution Mode.. Thanks Sven and Simon and all the helping hands

After Getting the david USB, I made my setup in such a way that i only need calibration once and now i can let my hardware anywhere and start scanning, no matter how bigger the object..I can scan it in patches and can merge all the scan..

Attached you can see the 360 degree scan of the Deer..

My Laser Scanner DIY Setup

From a week i am working to improve my David Laser scanner setup.. Earlier, I have a stepper motor attached to 1:60 gear box..The output was very coarse with jerks so yesterday i made MDF bearing holders and grabbed teeth Belt and Pulleys from local market..After minor modification the output from the gear box further reduced to 1:7 with timing belt..Now i can scan with very high resolution..Attached is the low resolution scan from free version of David Laser scanner..Its smoothness and interpolation kept to one..You can see how small the object with details...
The green laser pointer was gifted by my friend Richard..i made a teflon attachment with a lens to convert it into Line laser...

This improvement of setup was carried out because i want to make some ball-claw legs for the table i am machining.. The idea was to take the leg of hen and insert a marble ball into claw and scan...

Bear Jewelery Box

Sometime its good to gift something special to wife... This time i decided to make something very special to her, a Jewelery Box... What about the jewellery box in shape of a Bear?...!!!.. Yes, a lot of girls and ladies like Bears.. I don't know why?..

When i finsished this on my CNC machine and gifted to her... She was really very happy ... Now i can continue some other projects on my CNC machine ;)

My Head Post

Frankly speaking what fascinate me to make a indexer for my machine??... This story begins with the day when i joined CNCzone Forum... One of the guy their working on its 4th axis created a BEAR head on wood...He posted the picture of machined head stand aside with its computer monitor... and that was the really great work i ever seen.. i downloaded that picture and saw it many time that day...
At that time i was very new to CNC machine.. i never built my CNC machine at that time..i was just collecting the pictures, ideas and reading the posts of zone members... its a really great website for all of us with zeal of working with CNC....





The complete time for Roughing 13 Minutes and Finishing pass took 1 Hr and 13Minutes...The stepover and tolerance were kept high so the quality was not come out great.. but this is in my hand.. The main was i know how to create efficient 4th axis toolpath..

If i decrease the stepover and tolerance values..you will see the quality, details and real beauty of it..