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Cobod BOD2-444 Instruction Manual

3d construction printer
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Instruction Manual
Original Version
BOD2-444
3D Construction Printer
Generation: 02

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Summary of Contents for Cobod BOD2-444

  • Page 1 Instruction Manual Original Version BOD2-444 3D Construction Printer Generation: 02...

  • Page 2: Table Of Contents

    1 Contents Document version ..........................4 Identification ............................. 5 Supplier information .......................... 5 Declaration of Conformity ......................... 6 Product description ........................... 7 General .............................. 7 3.1.1 Function description ........................7 3.1.2 Machine construction ........................ 7 3.1.3 Process description ........................10 3.1.4 Proper use..........................
  • Page 3 Placing of instructions ........................27 Operating manual ............................ 28 Normal function..........................28 6.1.1 Connection to computer ......................28 6.1.2 Manual operation ........................29 6.1.3 Automatic operation ....................... 31 6.1.4 User interface .......................... 31 Error situations ..........................37 Signals to be observed ........................38 Accessories ............................

  • Page 4: Document Version

    7.3.7 7 – Extruder inner parts ......................45 Alarm list ....................Error! Bookmark not defined. Service ..............................47 Service intervals ..........................47 8.1.1 1 – Maintenance task No. 1 ............Error! Bookmark not defined. 8.1.2 2 – Maintenance task No. 2 ............Error! Bookmark not defined. 8.1.3 3 –...

  • Page 5: Identification

    2 Identification 2.1 Supplier information Manufacturer: COBOD International A/S Address: Dronningens Tværgade 26 DK - 1302 København K Phone +45 70 60 55 33 E-Mail: ad@cobod.com Instruction Manual - Original Version Page 5 of 50...

  • Page 6: Declaration Of Conformity

    2.2 Declaration of Conformity Instruction Manual - Original Version Page 6 of 50...

  • Page 7: Product Description

    3 Product description 3.1 General Before the machine is commissioned, this instruction manual must be thoroughly read and understood! This warning symbol indicates that special precautionary measures must be taken. If the safety precautions are not observed, it may lead to hazardous conditions and result in personal injury or damage to property.
  • Page 8 Figure 1: Model of printer Instruction Manual - Original Version Page 8 of 50...
  • Page 9 Z1-axis Y2-axis Main E-box X-axis Power connection and circuit breaker X-carriage E-Box Emergency stop Status lamp Z1-carriage X-carriage Z2-axis Material hopper Hose management Mixing shaft Z2-Carriage Z3-axis U Axis Z3-carriage Nozzle Z4-axis Camera Mount Z4-carriage IP Cameras Y1-axis Figure 2: Exploded view, printer parts Instruction Manual - Original Version Page 9 of 50...

  • Page 10: Process Description

    3.1.3 Process description The machine is intended for automated extrusion of concrete materials in layers. The shape of the layers is directed by a predefined digital model. • Fresh concrete or mortar is fed to the hopper. Either manually or by an external pumping device. •...

  • Page 11: Before The Commissioning

    Before the commissioning of the machine, it must be checked that all parts have been installed according to the documentation and instructions from COBOD International A/S. Before the commissioning of the machine, all relevant personnel must be instructed in the documentation of the machine –...

  • Page 12: Machine Information

    3.2 Machine information Description Unit Value Measurements (length x width x height) 10.1 x 12.6 x 10.5 Weight [kg] 5023 Power consumption Voltage 3x400VAC + PE 50/60 Hz Frequency [Hz] Short circuit current, I kmin Short circuit current, I 1200 kmax Max.

  • Page 13: Safety Information

    3.3 Safety information 3.3.1 Signs The machine is fitted with several mandatory and warning signs. The meaning of these is described in the following. Protection Description Symbol Mandatory: When entering the printing area. Helmet When working in the area, always wear approved safety helmet.

  • Page 14: Safety Functions

    3.3.2 Safety functions Before operating the machine, the operator must seek information about the safety functions and protection equipment of the machine. The use and operation of the machine must only be initiated when all safety functions are fully present and in an operable condition! Defective safety functions and protection equipment may lead to loss of safety and hazardous situations.
  • Page 15 Displays and alarms When activating an E-stop, the status will appear on the operator monitor: ”Emergency stop of the machine is activated” Operating conditions The work of the emergency function is unchanged throughout any operation modes of the machine. Maintenance and test The emergency stop function must be activated and tested before commissioning after each installation or reinstallation of the machine.
  • Page 16 Components included in the safety function. Input part Logical part Output part Encoder. Safety controller. Servo drives. If the speed limit of 250mm/sec is Intelligent controller monitoring the Disconnects the power supply to the exceeded by the X-axis or the print safety function.
  • Page 17 If the application requires a speed higher than 250 mm/sec. for the X-axis and print head, the perimeter guarding together with an interlocked door must be installed. When entering the guarded zone, opening the interlocked door, the speed of the X-axis and the Print head is automatically reduced to 250mm/sec and is then monitored by the speed monitoring as long as the door to the guarded zone is open.

  • Page 18: Definitions

    4 Definitions 4.1 Technical terms and abbreviations In the following, the technical terms and abbreviations used in this instruction manual are described. Terms Explanation A person having received the necessary training to carry out a task in a safe and Instructed person responsible way 3DCP...

  • Page 19: Handling

    5 Handling This section describes how the machine is to be operated in various situations. Where specific personal qualifications are required, this will be described. Installation and dismounting of the machine must be carried out by qualified and trained personnel. To prevent accidents, all safety instructions must be observed.
  • Page 20 To ensure the safe intended use of the printer, it needs to be installed and assembled according to the following instructions. Steps for installation: 1. Mapping and Anchoring 4. Mounting X-Axis 2. Mounting Z-Axes 5. Connecting cables 3. Mounting Y-Axes 5.4.1.1 Mapping and Anchoring This section covers installation of Anchors, serving as a base for securing Z axes to the ground plane.
  • Page 21 Procedure Figure 3: Center distance measures for BOD2 1. Locate first center point (Z1). Mark it. 2. Align marked spot with center hole of the drill guide. 3. Place Angle Laser on drill guide and make sure laser aligns with the grooves. 4.
  • Page 22 5.4.1.2 Mounting Z-axis The following section will explain how Z-axes must be handled while placing and securing it onto installed anchors. Each of the Z-axes is marked at the bottom (Z1- Z4) and must be placed on dedicated anchors (see Figure 4Figure 1). After secured and resting on anchors, Z-axes must be leveled to be perpendicular to the ground.
  • Page 23 5. Slowly lower the axis while ensuring the anchors fit into the base holes of the axis. 6. While crane is still holding the axis, secure the bolts with nuts and washers as in Figure 5. 7. Make sure axis is fully resting on the anchors before lowering the crane completely. 8.
  • Page 24 5.4.1.4 Mounting X-axis Tools needed • 1 x Crane or telescope forklift (min 1000 kg at 12 meters) • 2 x 24 mm wrench • 1 x 4 mm Allen key • 16 x M5x16 bolts and washers • 4x End-pieces •...

  • Page 25: Electrical Installation

    5.4.2 Electrical installation The connection of the machine must only be made by an authorized electrician. During the installation, the law of the country must be followed. For the proper connection and information of voltage and power consumption, see the electrical diagram. Tools needed •...

  • Page 26: Connections

    5.4.3 Connections For water connection refer to m-tec user manual: https://m-tec.com 5.5 Storage Before storage, the printer must be disassembled into 8 separate parts: • 1 X-beam (including X- and Y carriages) • 2 Y-beams • 4 Z-beams (Including Z carriages and E-box) •...

  • Page 27: Repacking

    Transport on truck must be stacked according to figure 1, and tightly secured using straps. 5.7 Placing of instructions Personnel should refer to this manual. If in doubt, please contact COBOD International before handling or transporting this machine. Instruction Manual - Original Version...

  • Page 28: Operating Manual

    6 Operating manual In the following it is described how the machine is operated in an appropriate and safe way. The safety instructions described in this instruction manual must be observed. 6.1 Normal function Operation of the machine can be either in a warehouse or on a construction site. Operator should always be located next to the machine, outside the printing area by a desk with full view of the machine.

  • Page 29: Manual Operation

    5. Open a browser window (i.e. Google Chrome) and connect to Duet3D Web interface via default IP: 192.168.0.250. If the above steps are performed correctly, the browser window should display the Duet Web Interface. 6.1.2 Manual operation The machine can be controlled manually using the Duet web interface. Figure 13: Duet web interface - manual movement The print head and axes can be moved manually using the buttons under the “machine control”...
  • Page 30 • Distance is in millimeter • To change the amount on a button, right click on the button and insert a new value, i.e. 200 mm, 500 mm 1000 mm U-axis movement: • The U axis is the rotational movement on the printhead. •...

  • Page 31: Automatic Operation

    Prepare a model in any CAD/CAM software. Model must consist of center lines b. Export model as STP or IGS file format c. Import STP or IGS to COBOD slice, set parameters and output G-code (see section 6.1.4.4). 2. Prepare printer a.
  • Page 32 For all operations it is recommended to use a laptop or tablet with the web-interface to control the machine. Small movements and adjustments can be performed on the touch panel. 6.1.4.1 Duet touch panel The touch panel is mounted on front of the main E-box. Figure 15: Duet touch panel Use the touch panel to manually move the machine, find the IP of the machine to connect, and access and print files from the local file storage.
  • Page 33 3. Upload and Print. Choose G-code file to be uploaded to printer. Print starts immediately after upload. 4. Status bar indicating state of machine – idle, printing, busy. 5. Emergency Stop – stops machine and restarts control board in the middle of any operation. 6.
  • Page 34 6.1.4.2.3 Settings 1. Subsetting tabs – User interface, System Editor, tools, Machine properties, List items 2. Software and firmware information 3. Button to upload firmware, control files, etc. 4. Settings related to communication and reconnecting rules. 5. Apply made changes or reset to factory Defaults. 6.1.4.3 G-code commands G-code is the industry standard for CNC equipment, and the specific flavor of G-code for BOD2 is similar,...
  • Page 35 6.1.4.4 COBOD Slice COBOD Slice is a software used to prepare 3D models from various CAD software to print with BOD2 printer. It generates G-code files, which in turn can be read and interpreted by the printer’s web interface and control board.
  • Page 36 1. Main menu a. File i. New Project – Start a new project with default slicing parameters ii. Open Project – Open an existing .COBOD project. iii. Save – Save .COBOD project iv. Save as – save .COBOD project as v.

  • Page 37: Error Situations

    a. Import Centerlines – Import a 3D model of a supported file type. Model must represent centerlines of the object. b. Nozzle Width – Width of the current printer nozzle in mm c. Layer height – Height of each layer in mm d.

  • Page 38: Signals To Be Observed

    7. Pump controller cable (optional) 6.5 Disposal of waste materials The BOD2 printer is open to all materials with compatible aggregate sizes and consistency. COBOD International does not develop, produce or supply any concrete or mortar materials. For disposal of waste materials, please refer to supplier documentation and local law.

  • Page 39: Maintenance And Cleaning

    7 Maintenance and cleaning The daily tidying-up and cleaning of the machine and its surroundings is made by the operator or specially trained cleaning staff. During this work, the same requirements for the use of tools and personal protective equipment apply as for the operational work. 7.1 Precautionary measures Before the work is initiated, this instruction manual must be read and understood by the personnel.

  • Page 40: Test Axis Movement

    Task Task Test axis movement Test end-stops Test Load-cells Test pump controller Test all E-stops Test downwards pinch safety Test safety door Inspect extruder pump Inspect hoses Inspect mixing shaft Inspect cables Inspect E-chains Grease tooth-rack 7.2.1 1 – Test axis movement Use the Web interface “Machine Control”...

  • Page 41: Test Pump Controller (Optional: Only If Pump Controller Is Attached)

    Press the green “start” button on the main E-box to reset. Lamp should turn GREEN. WARNING: If an E-stop fails to stop the machine (lamp does not light red), stop all operation immediately, turn off the machine and contact your local reseller or COBOD International directly.

  • Page 42: Test Safety Door (Optional, If Safety Door Is Installed And Connected)

    4. Using the manual movement control to move the printer z-200 (200 mm down) 5. The printer should go into error mode the second it hits the joist. If this does not happen, please terminate all operations and contact your local reseller or COBOD International directly. 6. To reset printer position: a.

  • Page 43: Inspect Hoses

    7.2.9 9 – Inspect hoses Inspect material feeder hoses for wear and tear. 7.2.10 10 – Inspect mixing shaft Inspect mixing shaft for damage or bending. 7.2.11 11 – Inspect cables Inspect external cables for visible damage or wear. 7.2.12 12 – Inspect E-chains Inspect E-chains for visible damage or wear.

  • Page 44: All Parts Of The Printhead

    Task No. Task All parts of the printhead Material hose Mixer/pump Printing area Other equipment Excess / waste material Extruder inner parts U-rails Tooth rack Signal lamp / lights Safety door latch Carriages Beams 7.3.1 1 – All parts of the printhead After all operation involving fresh concrete (not for dry-runs etc.).

  • Page 45: Printing Area

    7.3.4 4 – Printing area After all operation involving fresh concrete (not for dry-runs etc.). Thoroughly clean printing area, removing all excess materials from floor / ground. 7.3.5 5 – Other equipment After all operation involving fresh concrete (not for dry-runs etc.). Thoroughly clean all additional equipment like buckets, shovels etc., and leave to dry outside printing area.
  • Page 46 7.3.13 13 – Beams Using high pressure water hose or similar, clean all beams / truss modules. Pay special attention to cable trays. 7.4 Errors Error Symptom Procedure Signal lamp is red, printer will not move 1. Check all E-stops are disengaged. Press start button on E-box 2.

  • Page 47: Service

    A service visit should be performed twice yearly. 8.2 Customer service Manufacturer: COBOD International A/S Address: Dronningens Tværgade 26 DK - 1302 København K Phone...
  • Page 48 E-Mail: ad@cobod.com Instruction Manual - Original Version Page 48 of 50...

  • Page 49: Disposal Of The Machine

    9 Disposal of the machine Oil and other liquids must be drained off the machine and treated separately according to local regulation. Switchboards, motors, cables and other electronics must be demounted and treated separately according to the local regulations. Metal parts are disposed of as scrap iron. Instruction Manual - Original Version Page 49 of 50...

  • Page 50: Logbook

    10 Logbook Instruction Manual - Original Version Page 50 of 50...

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