Professional Documents
Culture Documents
Original Version
BOD2-444
3D Construction Printer
Generation: 02
1 Contents
1.1 Document version ............................................................................................................................. 4
2 Identification ............................................................................................................................................. 5
2.1 Supplier information.......................................................................................................................... 5
2.2 Declaration of Conformity ................................................................................................................. 6
3 Product description ................................................................................................................................... 7
3.1 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................................................................................................................................ 10
3.1.5 Improper use ........................................................................................................................... 10
3.1.6 Modification ............................................................................................................................ 10
3.1.7 Before the commissioning ....................................................................................................... 11
3.1.8 Limits of machinery ................................................................................................................. 11
3.2 Machine information ....................................................................................................................... 12
3.3 Safety information ........................................................................................................................... 13
3.3.1 Signs ......................................................................................................................................... 13
3.3.2 Safety functions ....................................................................................................................... 14
4 Definitions ............................................................................................................................................... 18
4.1 Technical terms and abbreviations ................................................................................................. 18
4.2 References ....................................................................................................................................... 18
5 Handling ................................................................................................................................................... 19
5.1 Transport and storage ..................................................................................................................... 19
5.2 Precautionary measures before the operation ................................... Error! Bookmark not defined.
5.3 Unpacking ........................................................................................................................................ 19
5.4 Safe disposal of packing material .................................................................................................... 19
5.5 Installation and assembly of the machine ....................................................................................... 19
5.5.1 Mechanical assembly............................................................................................................... 19
5.5.2 Electrical installation................................................................................................................ 25
5.5.3 Connections ............................................................................................................................. 26
5.6 Storage............................................................................................................................................. 26
5.7 Repacking......................................................................................................................................... 27
Instruction Manual - Original Version Page 2 of 50
5.8 Placing of instructions ..................................................................................................................... 27
6 Operating manual .................................................................................................................................... 28
6.1 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
6.2 Error situations ................................................................................................................................ 37
6.3 Signals to be observed ..................................................................................................................... 38
6.4 Accessories ...................................................................................................................................... 38
6.5 Disposal of waste materials ............................................................................................................. 38
7 Maintenance and cleaning ...................................................................................................................... 39
7.1 Precautionary measures .................................................................................................................. 39
7.2 Maintenance made by the operator ............................................................................................... 39
7.2.1 1 – Test axis movement ........................................................................................................... 40
7.2.2 2 – Test end-stops.................................................................................................................... 40
7.2.3 3 – Test Load cells .................................................................................................................... 40
7.2.4 4 – Test pump controller (OPTIONAL: only if pump controller is attached) ........................... 41
7.2.5 5 – Test all E-stops ................................................................................................................... 41
7.2.6 6 – Test downwards pinch safety ............................................................................................ 41
7.2.7 7 – Test safety door (Optional, if safety door is installed and connected).............................. 42
7.2.8 8 – Inspect Extruder pump ...................................................................................................... 42
7.2.9 9 – Inspect hoses ..................................................................................................................... 43
7.2.10 10 – Inspect mixing shaft ......................................................................................................... 43
7.2.11 11 – Inspect cables .................................................................................................................. 43
7.2.12 12 – Grease tooth rack ............................................................................................................ 43
7.3 Maintenance and cleaning made by the cleaning personnel.......................................................... 43
7.3.1 1 – All parts of the printhead................................................................................................... 44
7.3.2 2 – Material hose ..................................................................................................................... 44
7.3.3 3 – Mixer pump ....................................................................................................................... 44
7.3.4 4 – Printing area....................................................................................................................... 45
7.3.5 5 – Other equipment ............................................................................................................... 45
7.3.6 6 – Excess / waste material ..................................................................................................... 45
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.
The BOD2 is designed as a stand-alone unit consisting of several integrated units and components:
• Four Z-columns (legs), height = 10 m, 4 servomotors, drivers included.
• Two Y-axis, length = 10 m, 2 servomotors, drivers included.
• One X-axes, width = 10 m, 1 servomotor, drivers included.
• One print head, 2 servomotors, drivers included.
(One for turning the nozzle and one for controlling the material flow)
• Control cabinet with supply disconnector, electrical equipment, 3D print controller and safety PLCs.
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.
• From the hopper, the concrete is extruded through a nozzle, and placed in a predefined layer
pattern.
• Layers are applied on top continuously until the desired geometry is printed.
• The machine can be controlled manually or automatically.
The machine may only be used under the operating conditions foreseen in this instructions manual. Any
other use beyond such operating conditions is deemed not conform to the instructions manual and the
manufacturer cannot accept any liability what-so-ever for subsequent loss or damage.
Proper use shall be deemed to include:
• The observance of all references of this instruction manual.
• The observance of service intervals and maintenance routines.
The manufacturer / supplier will not be liable for any subsequent loss or damage resulting from improper
use of the machine.
Improper use shall be deemed to include:
• The use of substances that may damage machine parts. Including substances that may create
explosive or poisonous gases posing a risk to personnel or property.
• Improper or missing maintenance of the machine.
• Improper installation of machine or its sub-components.
• Use of the machine for other operations than the stated purpose.
3.1.6 Modification
Any alterations or additions to the machine must be filed in the technical documentation of the machine. If
necessary, the Declaration of Conformity must be updated and signed again. The responsibility for this rests
with the owner of the machine.
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 – including instruction manual, maintenance instructions, diagrams etc.
The service life of the machine is 20 years of a daily 8-hour operation. This is based on the presumption that
all service and maintenance instructions described in this instruction manual are observed carefully.
The BOD2 is intended for use on construction sites and must be installed inside (typically in a tent).
Printing material is a premix of concrete and cement-based mortars.
Temperature limits: 5 °C to +50 °C.
3.3.1 Signs
The machine is fitted with several mandatory and warning signs. The meaning of these is described in the
following.
Mandatory:
When entering the printing area.
Helmet
When working in the area, always wear approved
safety helmet.
Mandatory:
When entering the printing area.
Safety shoes
When working in the area, always wear approved
safety shoes
Mandatory:
Safety glasses When working with fresh concrete or dry mix
concrete in- or outside printing area
Mandatory:
Protective gloves When working with fresh concrete or dry mix
concrete in- or outside printing area
Mandatory:
Respiratory protection When working with fresh concrete or dry mix
concrete in- or outside printing area
Warning:
Control Cabinets.
Electricity
Only experienced and skilled personnel may open
the control cabinets.
Warning:
Crushing of hands
Transmission parts, toothed rack on each axis.
Warning:
When moving the X-, Y- axis and print head
Crushing downwards, between print head and floor.
When print head is moved towards one of the two
“end” positions on the X-axis.
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.
In case defective safety functions and protective equipment is found, do the following:
• Stop the machine immediately.
• Make sure the machine cannot restart by disconnecting the supply sources to the
machine.
The following safety and protection devices are installed on the machine:
Emergency stop-function
The emergency stop function is a supplementary safety function, with the purpose of preventing a source of hazard
from arising caused by the improper use of the machine. As an example, a source of hazard could result in personal
injury, damage to the machine or ongoing work, or it may arise because another safety function is failing.
After actuation and before disengaging the E-stop devices, the machinery shall be inspected in order to detect the
reason for actuation.
Components included in the safety function.
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.
Speed monitoring of the movement of the X – axis and the Print head (optional)
The speed monitoring of the movement of the X – axis and the print head is a safety function, with the purpose of
preventing them going faster than 250 mm/sec. If the limit is exceeded, the machine is stopped.
The speed monitoring is optional and comes together with the perimeter guarding which also is optional.
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. As soon as the door is closed the speed is
automatically increased. See also Interlocked door.
When the door is open, the status will appear on the operator monitor:
”Door open, running with reduced speed”
Operating conditions
Works:
- only together with perimeter guarding and interlocked door;
- in automatic and manual mode when interlocked door is open.
This safety function is to protect the operator against the hazardous fast moving parts (Speed > 250mm/sec), the
X-axis and the movement of the print head.
The perimeter guarding is optional and comes together with the speed monitoring, which also is optional.
When the door is open, the status will appear on the operator monitor:
”Door open, running with reduced speed”
Operating conditions
The safety function operates unchanged in any operating conditions of the machine.
The safety function must be activated and tested before commissioning after each installation or reinstallation of
the machine.
Test by opening the door, speed must be reduced to 250 mm/sec. When door is closed, speed is increased again.
As a minimum, the safety function must be visually checked and activated at least once a day.
Also see section 7 of this instruction manual.
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 3D Concrete Printing
The device that attached on the carriage, handles extrusion and depositioning of
Print head
material
The small piece that sits on the end of the print head, that shapes the final form of
Nozzle
the extruded material. Can be 3D printed or machined.
Origo The starting position of the printer, defined as [X,Y,Z,E,U] = [0,0,0,0,0]
4.2 References
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.
The machine is built of components from various suppliers. Some of these parts are of a size, shape and
weight that require special handling. Follow the instruction manual from the manufacturer or supplier on
how to apply lifting equipment and the appropriate lifting points.
Only instructed and certified personnel have the permission to move machine parts using a
fork lift truck or crane.
Only appropriate and certified equipment must be used for the lifting of machine parts.
5.2 Unpacking
When unpacking the machine, it is to be controlled if damage to the machine has occurred during
transport. Damage affecting the functionality or safety of the machine must be repaired before the
machine is put into operation.
Both are reusable items and should not be disposed of, unless damaged. If damaged or unusable, dispose
as wooden waste according to local law.
Tools needed
Tools needed
Procedure:
Tools needed
• 1 x Crane or telescopic
forklift (min. 1000 kg at 12
meters)
• 1 x 6mm Allen key (or bit)
• 16 x M8 bolts + washers
• 1 x Laser measuring device
Procedure:
1. Before starting, make sure Z-axes and Z-carriages are leveled and aligned.
2. Lift Y-axis using the crane hook in the middle of the truss.
3. Carefully place the axis on top of the Z-carriage as in Figure 6
4. Measure the distance from the end of the Y-axis to the Z-carriage.
5. Adjust the axis sideways until centered (within 1-2mm)
6. Mount the brackets that holds the Y-axis in place as in Figure 6.
7. Repeat for remaining Y-axis.
Tools needed
Procedure
1. Make sure, that safeguards are not installed in the ends of the Y-axes.
2. Lift the axis so it is levelled horizontally as in Error! Reference source not found..
3. Align the wheels and cogs on X-axis with the rails and racks on the Y-axis on both sides.
4. Carefully push the wheels in place (see Figure 8).
5. Push the entire X-axis into the middle of the Y-axis before you loosen the crane straps.
6. Mount all end-pieces and safeguards with two M16x100 bolts, nuts and washers
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
• 1 x Large flathead screwdriver
Procedure
Connect power cable to socket located on bottom of E-box. Connect to external power source.
Circuit breaker is located on machine E-box. The circuit breaker also serves as service switch and must be in
a locked position during repair work.
5.5 Storage
Parts must be stored assembled in modules and raised from ground (with i.e.: pallets or joists) in such a
manner that it is possible to access under using fork lift or wrap lifting strap around. Printhead can be
stored on a regular EU-pallet or similar. All cable ends must be covered and tied to the beams to avoid
damage. All accessories must be stored on pallets and protected from weather.
Packing of Z and Y beams:
Packing of X beam:
5.6 Repacking
Transport of the BOD2 printer must be done in 8 parts
Personnel should refer to this manual. If in doubt, please contact COBOD International before handling or
transporting this machine.
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.
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.
If installed on a building site, the machine must be protected from rain and wind, in order to achieve the
best printing results.
• Power is turned on with the circuit breaker located on the machine e-box on column Z1.
• Before operation, start the machine by pressing the green “start” button on the E-box.
Connection directly to a laptop:
1. Use a regular laptop or tablet with an ethernet cable port. Connect to the printer using the
provided ethernet cable. Connect it to the bottom of the e-box and connect the other end to the
operator computer.
2. Set your computer ethernet to static IP address: 192.168.0.100
3. Open a browser window (i.e. Google Chrome) and connect to Duet3D Web interface via default IP:
192.168.0.250.
4. In case the above steps do not work:
a. The IP address of the printer can be found on the
touch-screen located on the e-box.
b. Press “console”.
c. The printer IP should be visible on the screen.
d. Set your computer ethernet to static IP with the same first 3 places and set the 4th to a
number other than the printer (between 2-199)
e. Example: IP on printer is 165.024.222.10, Set your computer IP to 165.024.222.15
5. Connect to cameras: Open two browser windows. Connect to IP: 192.168.0.200 in one window, and
192.168.0.201 in the other and login using the below credentials
a. Username: admin
b. Password: cobod2019
If the above steps are performed correctly, the browser window should display the Duet Web Interface.
The print head and axes can be moved manually using the buttons under the “machine control” panel in
the web interface.
X-axis movement:
• Positive direction to the right, when standing in front of the machine.
• 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
Y-axis movement:
• Positive direction moving backwards (away), when standing in front of the machine.
• 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
Z-axis movement:
• Positive direction upwards.
WARNING!
TO AVOID DAMAGE TO THE EXTRUDER PUMP, NEVER RUN THE EXTRUDER IN A DRY STATE I.E. WITHOUT
CONCRETE, OIL OR WATER IN THE HOPPER.
If a dry run is required, please remove the mixing shaft inside the material hopper before continuing.
• Feed amount is material extruded in milliliters (estimated).
• Feedrate is flow-rate in ml/s.
• Extrude will move pump Counter Clockwise (seen from top) and push material out using the
chosen parameters for feed amount / feedrate.
• Retract will move the pump Clockwise (seen from top) and pull material back.
• To change a number, right click on the button, and insert the updated value.
The BOD2 printer has two options for controlling the machine.
1. Using the touch panel mounted on the E-box
2. Using a web interface controller
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.
Duet web interface is the preferred control option for BOD2. In this section you will find a short description
of the control interface. A full documentation of the interface can be found at:
https://duet3d.dozuki.com/Wiki/Duet_Web_Control_Manual
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.
G92 Xnnn Ynnn Znnn: Set current position to Xnnn, Ynnn, Znnn. Defines the current position of the axes.
G92 X0 Y0 Z0 U0
M220 S150
Set speed to 150 % of normal speed (defined by print file). All axes including extruder will increase the
speed by 50%.
M221 S150
Extrude at 150% of normal extrusion (defined by print file). This will not affect other axes.
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. Export toolpath – Export toolpath to directory.
vi. Quit
b. Display
i. View mode
ii. Show / Hide features
iii. Zoom
c. Tools
i. Measure curves – Measures the length of a selected curve in mm.
ii. Save view to image – Saves the current viewport view to an image.
iii. Options – Set color, mesh defaults, units and more.
2. Import and slice settings
6.4 Accessories
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.
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.
Before the work is initiated, this instruction manual must be read and understood by the personnel.
In case specific tasks require the use of personal protective equipment, this requirement is to be observed
by all occupational groups.
Tasks to be made by the operator are described in this section. The instructions are meant as minimum
requirements to be carried out according to the following plan.
The operator must have read and understood this instruction manual before the maintenance of the
machine is initiated.
When specific tasks require the use of personal protective equipment, this requirement must be complied
with.
For the documentation purpose of the maintenance and cleaning tasks, the keeping of a logbook or similar
is recommended. If the regular maintenance and cleaning of the machine cannot be demonstrated, the
manufacturer’s warranty may lapse.
Special precautionary measures to be taken during a maintenance and cleaning task will be described
under each single task. For general maintenance and cleaning tasks, the general guide lines are followed for
the safe work at the machine. This includes the use of personal protective equipment, that machinery and
components are put in a safe condition before the task is initiated, and that the manufacturer instructions
are complied with.
Operation
required
Monthly
Weekly
Before
When
No.
Use the web interface “Machine Control” panel (see section 6.1.2).
1. Open the two latches left / right on material hopper and lower the material hopper on its hinge.
2. Observe the signal lamp. This should turn RED immediately and cut the energy from all motors.
3. Reattach the hopper and close the latches.
4. Press green “Start” button on E-box to reset the error-state.
1. One at a time – for each E-stop button located on the machine (1 on each Z axis, 3 on printhead, 1
in control room, 1 on safety door (if connected)
a. Push the button, observe that signal lamp turns RED.
b. When lamp is red, unlatch the E-stop button by turning it Clockwise.
c. 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.
WARNING: Never leave the override key in keyhole or turned on. Remove it immediately and
store it safely.
7.2.7 7 – Test safety door (Optional, if safety door is installed and connected)
While machine is in operational mode (signal lamp is green).
WARNING: Never close the safety door while personnel are inside the working area
Cleaning tasks to be made by the cleaning personnel is described in this section. The instructions are meant
as a minimum requirement and are to be carried out according to the plan below.
The cleaning personnel must have read and understood this instruction manual before any maintenance
and cleaning of the machine is commenced.
If specific tasks require the use of personal protective equipment, this must be complied with.
For the documentation purpose of maintenance and cleaning tasks, the keeping of a logbook or similar is
recommended. If the regular maintenance and cleaning of the machine cannot be demonstrated, the
manufacturer warranty may lapse.
Special precautionary measures to be taken during a maintenance and cleaning task, is described under
each single task. For regular maintenance and cleaning tasks, the general instructions for the safe work at
the machine are to be followed. This includes the use of personal protective equipment, and that machines
and components are put into a safe condition before the task is initiated and that the manufacturer
instructions are complied with.
operation
required
Monthly
Weekly
After
As
1 All parts of the printhead X
2 Material hose X
3 Mixer/pump X
4 Printing area X
5 Other equipment X
6 Excess / waste material X
7 Extruder inner parts X
8 U-rails X
9 Tooth rack X
10 Signal lamp / lights X
11 Safety door latch X
12 Carriages X
13 Beams X
• Material hopper (inside and outside): Use the excess valve located on bottom.
• Extruder pump: run clean water through pump until outlet water is clean.
• Nozzle and Nozzle clamp: Dismount and clean separately.
• Extruder outlet: Spray from underneath while pump is running.
• Mixing shaft: Take out mixing shaft and clean separately.
Thoroughly clean material hose, using specified foam balls and high-pressure water outlet on m-tec pump
(see m-tec manual)
7.3.8 8 – U-rails
Inspect all U-rails (located on X, Y and Z axes).
Remove all dust / oil / dirt gathered using high pressure water hose or similar.
Remove all dust / dirt gathered using high pressure water hose or similar. Lubricate racks if necessary.
Using pressurized air, clean out all dust / dirt gathered. Lubricate latch if necessary.
7.3.12 12 – Carriages
Using high pressure water hose or similar, clean all carriages.
7.4 Errors
Error
Symptom Procedure
No.
001 Signal lamp is red, printer will not move 1. Check all E-stops are disengaged. Press
start button on E-box
2. Check that material hopper is installed and
closed. Correct, and press start Button on
E-box.
3. Check that printhead is not loaded with
any external weight, or driven into the
ground
002 Printhead has crashed into the ground, To reset printer position:
Signal lamp is red
1. Turn off printer using the Circuit Breaker
on main E-box.
2. Insert “override” key in key-hole located
above circuit breaker on main E-box.
3. Turn key clockwise 90 deg. to override
safety.
4. Turn on machine.
5. Manually move Z-axis upwards (Z+200)
using web control.
6. Turn off machine
7. Turn key Counter Clockwise 90 deg and
remove it from keyhole
8. Turn on printer and press green “start”
button on main E-box.
003 Material does not feed from extruder 1. Check material consistency in material
hopper. Add a little water to material, until
consistency is more fluid. Manually
extrude until material is coming out of the
nozzle.
2. Extruder pump is not connected to
extruder motor. Insert the mixing shaft
and try again.
004 Can’t connect to printer (web control) 1. Check, that ethernet cable is correctly
inserted into both printer and computer
2. On duet touch-panel, press “console” to
see the IP of the machine. Check that you
are connecting to the correct IP.
3. Check ethernet settings. If connected
directly through an ethernet cable, IP
8 Service
The servicing of the machine must be carried out by trained personnel only. Various tasks may require
various skills and training. The instructions of this section are meant as a minimum requirement and must
be carried out according to the below plan.
The maintenance staff must have read and understood this instruction manual before the maintenance of
the machine is commenced. If specific tasks require the use of personal protective equipment, the
requirement must be complied with by all occupational groups.
For the documentation purpose of maintenance tasks, the keeping of a logbook or similar is recommended.
If the regular maintenance of the machine cannot be demonstrated, the manufacturer’s warranty may
lapse.
Special precautionary measures to be taken during a maintenance task will be described under each single
task. For general maintenance and cleaning tasks, the general guide lines are followed for the safe work at
the machine. This includes the use of personal protective equipment, and that machines and components
are put into a safe condition before the task is initiated and that the manufacturer instructions are
complied with.
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.