quelab changes

ChineseHotEnd.scad

@@ -0,0 +1,29 @@
+module grooveRing(spread) {
+radGroove = 12.1/2;
+widthGroove = 4.5;
+  #difference() {
+    cylinder(h=widthGroove+1.6*spread+1*0,r=10,$fn=24);
+    translate([0,0,-.1]) cylinder(h=6,r=radGroove+spread*0.6,$fn=32);
+  }
+}
+
+module ChineseHotEnd() {
+spread = 0.2*0;
+radCyl = 16.12/2;
+widthCap = 5.1;
+heightNut = 8.5;
+diamNut = 10;
+radNutEdges = 11.7/2;  // tips of hexagons used for $fn=6 cyl, not face diam
+  difference() {
+    union() {
+      translate([0,0,-widthCap-spread]) {
+        cylinder(h=40+spread,r=radCyl+spread,$fn=48);
+        translate([0,0,-heightNut-.5]) cylinder(h=9.9,r=radNutEdges+1.0*spread,$fn=6);
+      }
+
+    }
+    translate([0,0,spread]) grooveRing(spread);
+  }
+}
+
+ChineseHotEnd();

Makefile

@@ -3,6 +3,9 @@ effector.stl retractable.stl power_supply.stl extruder.stl frame_extruder.stl \
 glass_frame.stl m5_internal.stl plate_3x.stl plate_1x.stl \
 switch_holder.stl hotend_fan.stl
 
+aaronGcode:	frame_top.gcode frame_motor.gcode carriage.gcode \
+	extruder.gcode effector.gcode
+
 .SECONDARY:
 
 # Explicit wildcard expansion suppresses errors when no files are found.
@@ -15,7 +18,7 @@ include $(wildcard *.deps)
 	openscad -m make -d $*.deps -o $@ $<
 
 %.gcode: %.stl
-	slic3r -o $@ $<
+	slic3r --load QuelabKosselConfig.ini -o $@ $<
 
 # Replace tabs with spaces.
 %.tab: %.scad

QuelabKosselConfig.ini

@@ -0,0 +1,114 @@
+# generated by Slic3r 0.9.10b on Mon Mar 31 08:54:58 2014
+avoid_crossing_perimeters = 0
+bed_size = 195,195
+bed_temperature = 0
+bottom_solid_layers = 3
+bridge_acceleration = 0
+bridge_fan_speed = 100
+bridge_flow_ratio = 1
+bridge_speed = 35
+brim_width = 0
+complete_objects = 0
+cooling = 1
+default_acceleration = 0
+disable_fan_first_layers = 1
+duplicate = 1
+duplicate_distance = 6
+duplicate_grid = 1,1
+end_gcode = G1 X12.0 F4000       ; home (almost) x - stops extruder crashing into frame if at very top of Z height\nG28 Y0       ; move the print to the front.\nM84     ; disable motors\nM104 S0 ; extruder heater off\nM140 S0 ; bed heater off
+external_perimeter_speed = 70%
+external_perimeters_first = 0
+extra_perimeters = 1
+extruder_clearance_height = 20
+extruder_clearance_radius = 20
+extruder_offset = 0x0
+extrusion_axis = E
+extrusion_multiplier = .82
+extrusion_width = 0
+fan_always_on = 0
+fan_below_layer_time = 60
+filament_diameter = 1.75
+fill_angle = 45
+fill_density = 0.4
+fill_pattern = honeycomb
+first_layer_bed_temperature = 0
+first_layer_extrusion_width = 0
+first_layer_height = 0.30
+first_layer_speed = 20%
+first_layer_temperature = 0
+g0 = 0
+gap_fill_speed = 20
+gcode_arcs = 0
+gcode_comments = 0
+gcode_flavor = reprap
+infill_acceleration = 0
+infill_every_layers = 1
+infill_extruder = 1
+infill_extrusion_width = 0
+infill_first = 0
+infill_only_where_needed = 0
+infill_speed = 70
+layer_gcode = 
+layer_height = 0.35
+max_fan_speed = 100
+min_fan_speed = 35
+min_print_speed = 10
+min_skirt_length = 0
+notes = 
+nozzle_diameter = 0.5
+only_retract_when_crossing_perimeters = 0
+output_filename_format = [input_filename_base].gcode
+perimeter_acceleration = 0
+perimeter_extruder = 1
+perimeter_extrusion_width = 0
+perimeter_speed = 60
+perimeters = 3
+post_process = 
+print_center = 97.5,97.5
+raft_layers = 0
+randomize_start = 0
+resolution = 0
+retract_before_travel = 10
+retract_layer_change = 1
+retract_length = 1.2
+retract_length_toolchange = 3
+retract_lift = .05
+retract_restart_extra = 0
+retract_restart_extra_toolchange = 0
+retract_speed = 18
+rotate = 0
+scale = 1
+skirt_distance = 6
+skirt_height = 1
+skirts = 2
+slowdown_below_layer_time = 15
+small_perimeter_speed = 30
+solid_fill_pattern = rectilinear
+solid_infill_below_area = 50
+solid_infill_every_layers = 0
+solid_infill_extrusion_width = 0
+solid_infill_speed = 60
+spiral_vase = 0
+start_gcode = G28 ; home all axes
+support_material = 1
+support_material_angle = 45
+support_material_enforce_layers = 0
+support_material_extruder = 1
+support_material_extrusion_width = 0
+support_material_interface_layers = 0
+support_material_interface_spacing = 0
+support_material_pattern = honeycomb
+support_material_spacing = 1.8
+support_material_speed = 60
+support_material_threshold = 40
+temperature = 0
+threads = 5
+toolchange_gcode = 
+top_infill_extrusion_width = 0
+top_solid_infill_speed = 30
+top_solid_layers = 3
+travel_speed = 135
+use_relative_e_distances = 0
+vibration_limit = 0
+wipe = 0
+z_offset = 0

README.md

@@ -1,13 +1,24 @@
 Release status
 ==============
 
-Most of these parts are now stable and won't change much more.
+These are Mr-What's tweaks to Johann's mini-kossel drawings
+circa Feb. 2014.
+The main changes are:
 
-How to print Mini Kossel
-========================
+   * Attach the carriage to a base that can mount Delrin wheels
+     that ride directly on the extrusion, instead of the
+     linear bearing rails.
 
-* 3x plate_3x.stl (about 3x80g = 240g of plastic)
-* 1x plate_1x.stl (about 50g of plastic)
+   * Added support material to make printing easier on Quelab's
+     public RepRap printer (Hackerspace in Albuquerque, NM)
+
+   * Simplified some parts.
+
+   * Changed effector head to carry a different shaped hot-end.
+
+   * Attempting to use pressure sensors on top of the NEMA-17 motors
+     instead of the probe.  This will require new, very tight tolerance
+     print bed mounts.
 
 Links
 =====
@@ -16,28 +27,13 @@ Links
 * Mailing list: http://groups.google.com/group/deltabot
 * Project history: http://deltabot.tumblr.com
 
-Pay it forward
-==============
-
-Johann is offering free printed parts for Mini Kossel:
-
-* I'm going to make some Mini Kossel printed parts kits.
-* I'm going to give them away for free (as in beer).
-* Some kits may include some non-printed parts.
-* Free international shipping is included.
-* No delivery schedule, maybe only one kit per month.
-
-But there's no such thing as a free lunch. If you want to receive a
-free kit, you must swear by your geek honor:
-
-* To complete your Mini Kossel and tune it well.
-* To print two (2) Mini Kossel kits and also give them away for free.
-* To make your recipients agree to the same rule.
+Upstream Project
+================
 
-After giving away the 2 free kits, you may sell printed parts for any
-price you want.
+Johann offers some free printed parts, on the condition that
+once you get a printer working, you give away two (2) sets
+of free parts to others.  After that, you are free to sell
+printed parts.
 
-If you're interested, please email johann@rocholl.net and let me know
-your favorite PLA color and mailing address. If you want to get your
-printed parts first, explain why you're more qualified than others to
-start giving away high quality printed parts soon.
+See Johann's main source project for more details.
+    https://github.com/jcrocholl/kossel

basePlate.scad

@@ -0,0 +1,84 @@
+// complete top (bottom) assembly, fused with vertexB drawing.
+// take a slice of this to generate DXF drawing for laser cut
+
+use <vertexC.scad>;
+
+m3rad = 2.94/2-.1;
+vertexTrad = 181.3;  // radius for vertical extrusion centers
+extTrad    = 109.6;  // radius for horiz extrusion centers
+
+fuzz = -0.1;  // fuzz (contraction) for laser cut holes
+
+slop = 0.3;  // extra fuzz to add for slop in mounts
+
+//projection(cut=true)
+translate([0,0,-0.2]) {
+  difference() {
+    union() {
+      for (a=[0,120,240]) {
+        rotate([0,0,a   ]) translate([0,-vertexTrad,-1]) vertexCframe(5,fuzz+slop,motorHole=true);
+        // dialte a bit to make parts fuse.
+        // initial numbers are close to exact
+        rotate([0,0,a-30]) translate([extTrad-.295,0,5])
+          cube([15+.5,300+1,15],center=true);
+
+        // this should allow us to draw both the motor shaft area,
+        // and have an island drawing the idler holder holes.
+        // delete whichever one(s) you do not want on LaserCut
+        rotate([0,0,a]) translate([0,-vertexTrad+32,-2])
+           hull() for(b=[-1,1]) translate([17*b,0,0])
+              cylinder(r=7,h=9,$fn=48);
+      }
+
+      hull() {
+        for (a=[0,120,240]) rotate([0,0,a])
+           translate([0,-64,-1]) cylinder(h=6,r=85,$fn=6);
+      }
+    }
+
+    // drill more holes in plate
+    translate([0,0,-1]) {
+
+      // drill edge holes -- these can use extra slop
+      for(a=[0,120,240]) rotate([0,0,a]) translate([0,extTrad,-4])
+         for (b=[-140:70:140]) translate([b,0,0]) m3hole(22,fuzz+.15+slop);
+
+      // holes for belt tensioner idler
+      //    should be 22mm in from front of 20mm extrusion
+      // for frogCarriage20v, using openbuilds wheel kit with spacer
+      %translate([0,-vertexTrad+10+11,4]) cube([2*12,22,5],center=true);  // diagnostic for spacing from extrusion
+      for (a=[30,150,270]) rotate([0,0,a])
+         for(b=[-1,1]) translate([vertexTrad-32,12*b,-3])
+            cylinder(r=m3rad+.1,h=27,$fn=11);
+
+      if (1) {
+         // decorative holes
+         translate([0,0,-1]) cylinder(r=35,h=17,$fn=120);
+         for(d=[0,60,120,180,240,300])
+           rotate([0,0,d]) translate([75,0,-1])
+             cylinder(r=30,h=17,$fn=96);
+
+         for(d=[30,150,270]) rotate([0,0,d])
+           translate([118,0,-1])
+             hull() for(a=[-1,1]) translate([0,a*30,0])
+               cylinder(r=12,h=17,$fn=80);
+
+         for(d=[30,90,150,210,270,330]) rotate([0,0,d])
+           translate([90,0,-1]) cylinder(r=8,h=17,$fn=60);
+
+         //for(d=[30,150,270]) for (a=[-1,1]) rotate([0,0,d+a*24])
+         //  translate([118,0,-2]) cylinder(r=8,h=17,$fn=60);
+
+      } else {
+         // a big ring might be better for under print bed
+         //cylinder(r=90,h=18,$fn=120);
+      }
+
+    }
+
+  }
+}
+
+////%translate([-350/2,130,0]) cube([350,20,20]);
+//%translate([0,0,20]) cylinder(r=9*25.4/2,h=4,$fn=180);
+//%translate([0,0,30]) cylinder(r=250/2,h=3.3,$fn=180);

beltCatch.scad

@@ -0,0 +1,58 @@
+beltThick  = 1.45 + 0.2;  // thickness of belt from back to tooth tip
+// the doubled belt part must be very tight, or teeth will slip.
+beltThick2 = 2.35 + 0.1;  // thickness of DOUBLED over belt, teeth interlocked
+
+module beltCatch(height,full=false)
+{
+  postRad = 2.7;  // radius of main post
+  // post is a little thin to safely support a screw.
+  // move pilot screw hole to an outer brace
+  //difference() {
+    hull() {
+      cylinder(h=height,r=postRad,$fn=32);
+      translate([-postRad,0,0]) cube([0.6,2.0*postRad,height]);
+    }
+  //  translate([0,0,height-4]) cylinder(h=5,r=.6,$fn=11);  // pilot hole for optional lock-in screw
+  //}
+
+  difference() {
+    union() {
+      difference() {
+        cylinder(h=height,r=postRad+beltThick+3,$fn=48);
+        translate([0,0,-1]) cylinder(h=height+2,r=postRad+beltThick,$fn=48);
+        translate([-10,0,-1]) cube([10,20,height+2]);
+        translate([-10*.7071,10*.7071,-1]) rotate([0,0,-45]) cube([10,20,height+2]);
+      }
+      translate([-postRad-beltThick-3,-.1,0]) hull() {
+        translate([-2, 0,0]) cube([5,3  ,height]);
+        translate([ 1,15,0]) cube([2,1,height]);
+      }
+      hull() {
+        translate([-postRad-beltThick+beltThick2, 2.0*postRad+beltThick+.5,0])
+          cube([2,8.35,height]);
+        rotate([0,0,43]) translate([postRad+beltThick,0,0]) cube([3,1,height]);
+      }
+    }
+
+    // chop off (unnecessary) bottom curve part of catch
+    translate([-12 ,-15,-1]) cube([24,15-postRad-beltThick-0.2,height+2]);
+    translate([-2.5,-15,-1]) cube([ 5,15-postRad-0.2          ,height+2]);
+
+    if (!full) {
+      // chop off most of far brace for close quarters
+      translate([postRad+1,-8,-1]) cube([10,20,height+2]);
+      translate([-2,-7,-1]) rotate([0,0,-45]) cube([5,10,height+2]);
+    }
+
+    // pilot hole for optional lock-in screw
+    translate([1,1.7*postRad+.7*beltThick+3,height-4])
+      cylinder(h=5,r=.8,$fn=6);
+
+  }
+}
+
+union(){
+  beltCatch(6.3);
+  translate([-6.4,-4.5,-2.5]) cube([10.1,20.4,2.7]);
+}
+%translate([0,-20,0]) mirror([0,1,0]) beltCatch(6,full=true);