Difference between revisions of "BreepBroop"

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[[File:BreepBroopLighting.jpg|thumb|500px|The BreepBroop in it's current state]]
 
[[File:BreepBroopLighting.jpg|thumb|500px|The BreepBroop in it's current state]]
 
===General===
 
===General===
−
The BreepBroop (nickname) is a standard [http://reprap.org/wiki/Mendel RepRap Mendel]. It's the original design, and was printed during the main build rush after the Mendel came out. [[user:chorca|Chorca]] printed the parts on [[user:f00bard|Mack]]'s [[mackerbot|MakerBot]] over a period of about a month. It is all ABS aside from the frame vertexes which were purchased from the [http://forums.reprap.org/ RepRap Forums], from Joshua Updyke in particular.
+
The BreepBroop (nickname) is a standard [http://reprap.org/wiki/Mendel RepRap Mendel]. It's the original design, and was printed during the main build rush after the Mendel came out. [[user:chorca|Chorca]] printed the parts on [[user:Mack|Mack]]'s [[mackerbot|MakerBot]] over a period of about a month. It is all ABS aside from the frame vertexes which were purchased from the [http://forums.reprap.org/ RepRap Forums], from Joshua Updyke in particular.
−
This style of Mendel is rarely made anymore due to it's complexity. The much simpler [http://reprap.org/wiki/Prusa Prusa Mendel] is more commonly built, due to the large reduction of printed parts and hardware, and the simpler pulley and bearing systems used. [[user:digitalman2112|Digitalman2112]]'s RepRap is a Prusa.
+
This style of Mendel is rarely made anymore due to it's complexity. The much simpler [http://reprap.org/wiki/Prusa Prusa Mendel] is more commonly built, due to the large reduction of printed parts and hardware, and the simpler pulley and bearing systems used. [[Phineas|Digitalman2112's RepRap]] is a Prusa.
  
 
===Electronics===
 
===Electronics===
−
The BreepBroop originally used a [http://reprap.org/wiki/Generation_3_Electronics/Tech_Zone_Remix Techzone Gen3] electronics set, which needed a good amount of touch-up and had some issues. Chorca replaced some of these boards:
+
The BreepBroop originally used a [http://reprap.org/wiki/Generation_3_Electronics/Tech_Zone_Remix Techzone Gen3] electronics set, which needed a good amount of touch-up and had some issues. Chorca replaced this.
−
* Two Techzone Stepper Controllers were replaced with self-etched [http://store.makerbot.com/stepper-motor-driver-v3-3.html Stepper Driver v3.0] (link goes to the 3.3, which is the released version)
+
 
−
* The Extruder controller was removed as it's function was replaced by one of the stepper drivers, and the heaters (bed and extruder) are driven by two Omron [http://www.ia.omron.com/product/family/1434/index_fea.html E5GN] Temperature Process Controllers
+
* Currently using a RAMPS 1.2 board donated by [[user:digitalman2112|Digitalman2112]]
−
* Endstops are not used.
+
* Bed heater is hooked into an [http://www.mouser.com/Search/ProductDetail.aspx?R=G3NE-210T-US-DC5virtualkey65300000virtualkey653-G3E-210T-US5 Omron 15A SSR], which is controlled by the DC heater output from the RAMPS. It modulates the SSR, and detects the temperature via a thermistor kapton-taped to the bed.
−
* Temperature is controlled by thermocouple, which is why there are Omron controllers as opposed to a simple RepRap heater control (The Extruder Controller had issues maintaining accurate temps with thermocouples, later traced to a noisy power supply)
+
* With the RAMPS, the steppers are now all drive via the Pololus onboard the RAMPS board.
 +
* Arduino MEGA on loan from [[user:digitalman2112|Digitalman2112]]
  
 
===Mechanical===
 
===Mechanical===
−
Most mechanical functions of the BreepBroop are according to the original build specifications. Few modifications have been made:
+
Most mechanical functions of the BreepBroop are according to the original build specifications. A few modifications have been made:
−
* Using a Wade's extruder on the X carriage
+
* Using a Wade's extruder on the [http://www.thingiverse.com/thing:6278 OpenX carriage].
−
* Wade's extruder is using a Herringbone gear set from [http://www.thingiverse.com Thingiverse]
+
* Hot end is a [http://www.lulzbot.com LulzBot] [http://www.lulzbot.com/en/hot-ends/1-budaschnozzle.html Budaschnozzle 1.0].
−
* Hot end is a [http://www.makergear.com MakerGear] Power Resistor heater and BigHead nozzle.
+
* Bed has been modified to a 1/8" thick aluminum plate, using a 110v silicone mat heater from [http://www.mcmaster.com McMaster Carr] (Part number: 35765K482), controlled by an SSR.
−
* Bed has been modified to a 1/8" thick copper plate, using a 110v silicone mat heater from [http://www.mcmaster.com McMaster Carr] (Part number: 35765K482)
 
  
 
===Software===
 
===Software===
Line 26: Line 26:
  
 
===Print Status===
 
===Print Status===
−
The printer is not printing. After a total rebuild of the hot end and reassembly, we are still having major issues. It was able to successfully print a Wade's extruder gear, however, the PLA was burning and oozing out of the top of the nozzle slightly. The X axis is cracked near the belt clamp area and binding badly. The Y axis also has a lot of wobble due to the weight of the copper plate. There are no endstops so homing is a major issue. The extruder constantly strips because of the shallow hobbing and due to the fact that the thermocouples are difficult to use in getting an accurate temperature reading, it is hard to figure out what the temperature currently is.
+
The printer is now working great.
 +
 
 +
After a rebuild with a new X carriage (which works very well), a new extruder ([http://www.thingiverse.com/thing:6713 Greg's Accessible Wade's]), the Lulzbot Budaschnozzle hot-end, a new bed, SSR for controlling it, and RAMPS kit with a Mega, things are beginning to come together.
 +
 
 +
I found that I had a little lash on my X axis after all that, and after some helpful advice in the #reprap chat on FreeNode, I found that Nophead's pulleys for the belts are NOT for XL-toothed belts, the kind I got from McMaster. They are for T5 belts, more common in Europe. I therefore printed a new pulley for the X axis, and the issue is gone! I need to do the same for the Y axis, which I somewhat dread because it means disassembling the bed once again (and having to re-level it).
 +
 
 +
However, the print quality right now is superb. Some of the issue I was having with printing seemed to be due to the white PLA I was using. Once I ran out of that and switched to green, many problems disappeared. I also noticed that I'm getting a grey plastic ooze coming out of the budaschnozzle in some spots, but that seems to have largely stopped as I've begun using green PLA.
 +
 
 +
I've printed a full set of frame vertexes with feet which I plan to install shortly (about the same time I replace the Y pulley) and I need to start getting the printer more self-contained (small onboard power supply, RAMPS enclosure, etc.
  
 
==Current Work==
 
==Current Work==
  
 
===Electronics===
 
===Electronics===
−
The electronics system is a mess, and is very hard to operate. There have been great strides in ease of use, mainly with the [http://reprap.org/wiki/RAMPS RAMPS] platform. This integrates all components onto one shield for the Arduino MEGA, reducing footprint and making everything a lot easier to run.
+
Swapped out all the electronics mess with a RAMPS [http://reprap.org/wiki/RAMPS RAMPS] platform. This integrates all components onto one shield for the Arduino MEGA, reducing footprint and making everything a lot easier to run.
 
The following are current plans for work:
 
The following are current plans for work:
−
* Replace all electronics with RAMPS board ([[user:digitalman2112|Digitalman2112]] has graciously donated a complete RAMPS kit with Pololus to my cause. I have assembled it and am borrowing an Arduino MEGA from him to use for testing)
+
* Get a second SSR and set it up for the new heater block
−
* Swap thermocouples for thermistors to use with RAMPS ([[user:digitalman2112|Digitalman2112]] has a set of thermistors which we will attempt to use for this)
+
* Incorporate a thermal fuse to prevent runaway of the heater
−
* Purchase small [[Wikipedia:Solid_state_relay|SSR]] to handle the tiny load of the heated bed, and soon the extruder heater
+
* Build a box for the RAMPS, and install a onboard power supply to help self-contain the unit
  
 
===Mechanical===
 
===Mechanical===
−
The hotend needs to be replaced and the Wade's upgraded. The X axis needs to be redone, preferably with a Prusa-style carriage to reduce weight and complexity.
 
 
The following are current plans for work:
 
The following are current plans for work:
−
* Replace hot end with LulzBot pre-built [http://www.lulzbot.com/en/hot-ends/1-budaschnozzle.html Budaschnozzle]
+
* <del>Replace copper bed with aluminum bed to lower stress on Y axis and prevent wobble</del> This is actually not due to the wobble of the bed, but due to using the wrong kind of pulley on my machine. The pulleys that Nophead has made and which are widely used on thingiverse are NOT the correct type for american XL-style belt tooth profiles. His are made for european T5 belts. The proper pulley for XL belt is [http://www.thingiverse.com/thing:7454 Here]
−
* Replace X carriage with Prusa-style carriage
 
−
* Swap smooth rods for smoother rods on X axis and use oil-impregnated bushings to ride along the rails for greater accuracy
 
−
* Replace copper bed with aluminum bed to lower stress on Y axis and prevent wobble
 
−
* Fix hobbed bolt on Wade's extruder (Run tap on bolt for longer, cut deeper grooves to get better traction on filament)
 
−
* Replace herringbone gears with original gears OR print new extruder such as Greg's Accessible Extruder and use it instead
 

Latest revision as of 00:49, 19 March 2012

Information

The BreepBroop in it's current state

General

The BreepBroop (nickname) is a standard RepRap Mendel. It's the original design, and was printed during the main build rush after the Mendel came out. Chorca printed the parts on Mack's MakerBot over a period of about a month. It is all ABS aside from the frame vertexes which were purchased from the RepRap Forums, from Joshua Updyke in particular. This style of Mendel is rarely made anymore due to it's complexity. The much simpler Prusa Mendel is more commonly built, due to the large reduction of printed parts and hardware, and the simpler pulley and bearing systems used. Digitalman2112's RepRap is a Prusa.

Electronics

The BreepBroop originally used a Techzone Gen3 electronics set, which needed a good amount of touch-up and had some issues. Chorca replaced this.

  • Currently using a RAMPS 1.2 board donated by Digitalman2112
  • Bed heater is hooked into an Omron 15A SSR, which is controlled by the DC heater output from the RAMPS. It modulates the SSR, and detects the temperature via a thermistor kapton-taped to the bed.
  • With the RAMPS, the steppers are now all drive via the Pololus onboard the RAMPS board.
  • Arduino MEGA on loan from Digitalman2112

Mechanical

Most mechanical functions of the BreepBroop are according to the original build specifications. A few modifications have been made:

Software

Chorca is currently using the following:

Print Status

The printer is now working great.

After a rebuild with a new X carriage (which works very well), a new extruder (Greg's Accessible Wade's), the Lulzbot Budaschnozzle hot-end, a new bed, SSR for controlling it, and RAMPS kit with a Mega, things are beginning to come together.

I found that I had a little lash on my X axis after all that, and after some helpful advice in the #reprap chat on FreeNode, I found that Nophead's pulleys for the belts are NOT for XL-toothed belts, the kind I got from McMaster. They are for T5 belts, more common in Europe. I therefore printed a new pulley for the X axis, and the issue is gone! I need to do the same for the Y axis, which I somewhat dread because it means disassembling the bed once again (and having to re-level it).

However, the print quality right now is superb. Some of the issue I was having with printing seemed to be due to the white PLA I was using. Once I ran out of that and switched to green, many problems disappeared. I also noticed that I'm getting a grey plastic ooze coming out of the budaschnozzle in some spots, but that seems to have largely stopped as I've begun using green PLA.

I've printed a full set of frame vertexes with feet which I plan to install shortly (about the same time I replace the Y pulley) and I need to start getting the printer more self-contained (small onboard power supply, RAMPS enclosure, etc.

Current Work

Electronics

Swapped out all the electronics mess with a RAMPS RAMPS platform. This integrates all components onto one shield for the Arduino MEGA, reducing footprint and making everything a lot easier to run. The following are current plans for work:

  • Get a second SSR and set it up for the new heater block
  • Incorporate a thermal fuse to prevent runaway of the heater
  • Build a box for the RAMPS, and install a onboard power supply to help self-contain the unit

Mechanical

The following are current plans for work:

  • Replace copper bed with aluminum bed to lower stress on Y axis and prevent wobble This is actually not due to the wobble of the bed, but due to using the wrong kind of pulley on my machine. The pulleys that Nophead has made and which are widely used on thingiverse are NOT the correct type for american XL-style belt tooth profiles. His are made for european T5 belts. The proper pulley for XL belt is Here
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