Introduction: GantryWorks Y-Gantry System
We are GantryWorks, a small undergraduate team working at Falmouth University. This project is part of our undergraduate degree at Falmouth University. This project presents a dual motor paracord-based Y-Gantry system, with a wide range of applications. It’s powered by a Raspberry Pi Pico and operates via dual spooled motors, guided by encoders for precise movement. Originally envisioned as part of a multi-axis gantry, this Y-axis system has proven ideal for vertical navigation along scaffold structures. It features WiFi-less communication up a complex technology stack to a stylised frontend for controlling it with various built in services and algorithms.
Attachments
Supplies
Raspberry Pi Pico - 1
Encoded DC Motors (12v 40rpm) - 2
Rotary Encoders - 2
Heltec ESP32 V3 Development Board - 2
L293D Motor Driver - 1
Capacitors (assorted) - 4
Pushbutton + Resistor - 1
PLA Filament (+ access to 3D printer) - ~ 1kg
Grub Screws - As Needed
Screws/Fastenings (M3 + M5) - As Needed
Paracord(2mm-5mm) - 2 Equal Lengths
Optional
Buzzer
LED
Mounts
PCB
Endstop sensors (x2)
Step 1: 3D Printing
To begin, download the STL files for all mechanical parts: INSERT GIT LINK HERE
Recommended Slicers:
- Orca Slicer
- Cura
Material: PLA (environmentally friendly, compostable under industrial conditions)
Supports: Required for spool housings and overhangs
Ensure you print the correct final versions of each:
- Gantry main body
- Spool flanges
- Motor mount brackets
- Rope guides
- Encoder mounts
Attachments
Step 2: Assembly
Using screws or appropriate fasteners, mount each JGY motor securely onto the robot backplate, using the corresponding motor cutouts for alignment.
Note: Motors should be installed symmetrically on either side of the gantry.
Step 3: Assembly: Flanges and Spools
Affix the flange to each motor shaft using grub screws, then attach spools to the flanges using provided holes as shown in the 3D print.
Step 4: Assembly: Encoders
Attach rotary encoders to either side of the spool using encoder mounts.
Note: Ensure encoder idlers are aligned with the spool paths.
Attachments
Step 5: Assembly: Rope Setup
String and secure the paracord, ensuring each rope securely wraps around the rotary encoders. These should be in line with the spool shafts on the printed design.
Note: Make sure the encoder rotates as the rope moves in and out. Ropes MUST be under tension during testing.
Step 6: Electronics
Now that the hardware is implemented, the next step is to install and wire the electronics. A diagram is provided below to help with this step.
Step 7: Electronics: Power Supply
Power Input and Regulation
- JST connector brings external power (14.8V LiPo recommended).
- LM7805CT regulator steps down to 5V for logic components.
- Capacitors stabilize voltage (C1–C3).
Step 8: Electronics: Microcontroller
Raspberry Pi Pico (U1):
- Main microcontroller running motion logic and telemetry.
- Connects to button (KEY1), buzzer (BZ1), motor driver, and ESP32 development board.
Step 9: Electronics: Motor Driver
Dual H-Bridge motor driver IC (L293D)(U4).
- Controls 2 motors (M1, M2) via GPIO signals.
- Takes power from +VBAT and +5V rails.
- Motor inputs (IN1–IN4) are connected to GPIOs from the microcontroller.
- Outputs (OUT1–OUT4) drive the motors.
Step 10: Electronics: Motors and Encoders
Motor and Encoder Outputs:
- J1 & J2: Connect to 2 motors and their encoders.
- J3 & J4: Connect to two encoders individually.
- Each motor has encoder A/B channels, power, and ground. (Use GPIOs 8-15 for A/B channel inputs)
Step 11: Electronics: Indicators
LED, Buzzer and Programmable Button:
- LED (LED1) with resistor shows power status.
- Buzzer sounds alerts or motion feedback.
- A programmable pushbutton switch (KEY1)
Step 12: Software
Software can either be programmed by yourself or you can purchase access to our subscription-based service. Our software includes a stylish Next.js frontend, with various bespoke analytics and complete control of the gantry in its working area with an advanced technology stack.
