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.

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)

To begin, download the STL files for all mechanical parts: INSERT GIT LINK HERE

Recommended Slicers:

1. Orca Slicer
2. 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:

1. Gantry main body
2. Spool flanges
3. Motor mount brackets
4. Rope guides
5. Encoder mounts

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.

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.

Attach rotary encoders to either side of the spool using encoder mounts.

Note: Ensure encoder idlers are aligned with the spool paths.

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.

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.

Power Input and Regulation

1. JST connector brings external power (14.8V LiPo recommended).
2. LM7805CT regulator steps down to 5V for logic components.
3. Capacitors stabilize voltage (C1–C3).

Raspberry Pi Pico (U1):

1. Main microcontroller running motion logic and telemetry.
2. Connects to button (KEY1), buzzer (BZ1), motor driver, and ESP32 development board.

Dual H-Bridge motor driver IC (L293D)(U4).

1. Controls 2 motors (M1, M2) via GPIO signals.
2. Takes power from +VBAT and +5V rails.
3. Motor inputs (IN1–IN4) are connected to GPIOs from the microcontroller.
4. Outputs (OUT1–OUT4) drive the motors.

Motor and Encoder Outputs:

1. J1 & J2: Connect to 2 motors and their encoders.
2. J3 & J4: Connect to two encoders individually.
3. Each motor has encoder A/B channels, power, and ground. (Use GPIOs 8-15 for A/B channel inputs)

LED, Buzzer and Programmable Button:

1. LED (LED1) with resistor shows power status.
2. Buzzer sounds alerts or motion feedback.
3. A programmable pushbutton switch (KEY1)

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.