v3.0.0 - Dual Nozzle Support, CAD Overhaul, Mobo REV04

Hey all! This is a huge release with lots of new features. There are many other tweaks and updates that are already queued up, so expect to see incremental releases as we make changes!

Summary

V3 of the LumenPnP comes with support for Dual Nozzles. All CAD expects two sets of pneumatics by default, and the REV04 Marlin config and OpenPnP config support this as well. V3 also comes with a number of updates that make it easier to put together and do maintenance on, namely the fact that the entire X axis is easily removable from the Y gantries using only a few screws.

V3 is the first version of the LumenPnP that has a REV04 motherboard, which fixes bugs found in REV03, along with adding some new features. Sensorless homing is now supported on the X and Y axis, and the vacuum sensors have been upgraded to a monolithic sensor that handles all of the signal processing on board. Many EMI and ESD protection features have been added as well.

CAD Updates

Removable X Axis

• The entire X axis subassembly is now completely removable from the Y gantries using only four screws.

Cable Chain replaces Umbilical

• A cable chain now routes all pneumatic tubing and cabling to the head from the front left leg.
• A new part has been added that bolts into the front left leg that supports the cable chain, and the X gantry has been modified to accept the other end of the chain as well.

Improved Nozzle and Camera Spacing

• Both nozzles have been shifted in the +Z direction by 13mm in order to create more clearance for components, now supporting parts up to 20mm tall by default.
• The bottom camera has been lowered in the -Z direction by 30mm to not only increase the maximum diameter part visible, but also allow the bottom camera focal plane to be at the nominal Z height for nozzle tips. (Closes #484)

Improved Component Mounts on Staging Plate

• A dedicated part for mounting the pneumatic Y splitters has been added.
• Valve and pump mounts have been redone to reduce the number of holes used in the staging plate.
• The nozzle tip rack has been raised to stay compatible with the raised nozzles, and a new retention feature was added to better retain the N75 nozzle tip.
• The staging plate foot is now easily removable, and smaller one has been added for the build plate.

Motherboard Protection

• A back cover has been added to prevent any potential shorts from fallen components. (Closes #56 and Closes #572 )
• A front cover has been added to help protect the board and make pressing the Boot and Reset buttons easier.

Back Leg Improvements

• The back leg has new cutouts to protect the cable port on the Y motor.
• The back legs have been remodeled to include better strength when printed in the ideal orientation for minimizing overhangs.

Dual Nozzle

• The BOM has been updated to reflect a dual nozzle configuration.
• Prints have been adapted to support two pneumatic lines, and an extra motor on the X gantry.
• Preliminary OpenPnP Dual Nozzle configuration files have been made.
• Second Z gantry is now mapped to a virtual axis based on the first Z gantry. (Closes #539)

Misc

• X and Y limit switches have been removed in light of introducing sensorless homing. (Closes #564)
• The front X gantry print now has indexing bumps that help align the Z axis linear rails to be parallel.
• The 8mm strip feeder has been tuned to better grip tape of various types.
• A pass of all the CAD was performed to remove the need of tools, mainly utilizing captive nuts in prints.
• The part hierarchy in the assembly FreeCAD file now matches the assembly process.
• The diffusor print for the bottom ring light has been improved to reduce the chance of glare.

REV04 Motherboard

Improvements

• The USB hub has been removed. Customer interviews revealed that the chance of not getting both cameras to work through the hub was more trouble than it was worth.
• The 5 volt bus from USB will now power the STM32, meaning serial communication and programming can happen without connecting to a 24v source.
• The surface mount vacuum sensors, analog signal processing pipeline, and I2C ADC have been replaced with a monolithic vacuum sensor that communicates over I2C. These sensors do not have a selectable address, so they're accessed through an I2C multiplexer.
• Fiducials have been added to the bottom side of the PCB for potential future THT soldering applications.
• The Diag pins on the X and Y axis TMC stepper drivers have been connected to the X and Y limit switch pins. All axis have the support for sensorless homing using a configuration jumper on the back side of the board.
• A blade fuse has been added on the power input of the board.
• Unique part count has been reduced, and uncommon resistor values have been swapped out for common values where possible.
• Power is now provided through a 2.1mm barrel jack. Optionally, the footprint supports a terminal block as well.
• The Boot button has been broken out to a second interface by way of a 2 pin header to support a more easily accessible button.
• One of the spare I2C multiplexer downstream ports has been broken out for connecting multiple peripherals that might have address collisions.
• ESD protection has been added on the USB lines.
• EMI protection has been added for the stepper output lines.
• The USB-C connector has been replaced with a USB-B connector.
• Strain relief cutouts have been added to the PCB to help protect the vacuum sensors.

Bug Fixes

• The incorrect configurable jumper on the bottom of the board has been corrected.
• The upside down Y2 motor connector has been flipped upright.
• Traces directly underneath cut solder/cut selectable jumpers have been moved so that a slightly too-deep cut doesn't sever them.
• A level shifter was added to the servo signal lines so that they're driven at 5v.

Full Changelog: v2.2.0...v3.0.0

v2.2.0 - PCB Staging Plate, Vacuum Sensor Interposer, CAD Adjustments

v2.2.0 is centered mainly around the switch to a PCB staging plate, and the addition of an interposer board for the vacuum sensors to increase their signal swing. A few CAD changes are also included in this release:

• Chamfers were reintroduced to the Z gantry to add more clearance for the belt system.
• Back legs have been unified into a single back leg part that works for both the left and right side.
• Slots for aluminum extrusion in the back leg have been widened to facilitate an easier fit.
• Assembly has been updated to include these changes.

Full Changelog: v2.1.4...v2.2.0

v2.1.4 - CI Improvements, Repo Cleanup

Hey all!

This release has many housekeeping and CI improvements:

• Updated CI to export webpage BOM
• Added wire harness Wireviz source files
• Cleaned up repo, consolidating part info
• Removed gigabytes of old STL data in git history