Voron based ToolChanger - 400x400x400mm AWD

[cjkennedy72]

20 hours ago, claudermilk said:

Looks like you have a lot of overextrusion on the top layer.

@claudermilk I agree 100%, and started going back through tuning on my 2.4R2 this week, while I have been home. Those were printed the last time I had more than 4 days home and I didn't feel it was enough to affect anything, plus they are under a big piece of aluminum.

[Dirk]

It's amazing to see how you change one design into another and adjust as per what you have on hand.

I'll be honest and say I have lost the thread between where you were building the monolith and where you are now.

The most important is that you don't forget it. 

I know you don't have a lot of time and the time you have can be used to do more interesting things...

But can you maybe give an oversight image /cad of what you have already done and what needs still to be done?

If I have understood well, you have decided to use your own XY connection instead of theo monolith one. I don't know how and if it's going to work out well... But I'm sure you checked that

[cjkennedy72]

@Dirk

I can understand the confusion... I think I have thought through the design and modeled components more than anything else so far. Here is a quick summary, which is about as good as I can pull together today. My flight is at 8:45AM tomorrow morning. So, get a haircut, pack, all the usual pre-business trip BS.

Informal Design Inputs and Concept:
Voron Trident based Frame with dimensions based on 400x450x450mm
Gantry - Modified Monolith based AWD

XY Joint - deprecated Monolith Hexvort joints remixed/modified to move the linear rail to the bottom of the 2020 extrusion, resize to an MGN12H and fill the gap between the frame and X extrusion that was present for the side mounted rails of the original.
MGN12H everywhere but the top-rail mounted X axis. This needed to be an MGN9H to work with the Funssor E3D Cloned tool changer kit
Disassembled the tool changer and redesigned the top-rail mount and belt mounts to prevent the tool changer forcing the belt path to rise across the X Axis
Bed Mounting:
I have added 5mm thickness to the Z linear rail components and resized the interface for MGN12H. For the extrusions under the bed, I created the mounts above to use ball nuts instead of buying a kinematic kit or using the stock mount design. I have also added 25mm to the piece that goes from the extrusion to the Z rail components (the part the GE5C goes into) to make a total of 30mm of additional printed structure to account for 3/5ths of the extra Y travel. 

I currently believe I will be able to off-set the other 20mm in where I put the holes in the bed. If not, I will change the mounts above to attach to the side of the bed extrusions and cantilever them 20mm in the needed direction, which should be toward the back. This was done to help fit a 400x400 bed on a frame built for 400x450mm. I also flipped the bed carriages so they are pushing up instead of pulling up and added a thick 20mm spacer and top piece to support the extrusion from both sides. I have not posted this component yet, but I have them finished. (They are likely to be reprinted to spare @claudermilk's sensitivity to over-extrusion... )

I am going to use the two holes in the Monolith front stepper components to mount the extrusion needed to hold the tools not in use. I have to work on this part still. The way my brain works, I need to get it assembled so I can see and measure where the extrusion and tool holders need to be. I can visualize it, but until I get to where I can move the toolhead to the front and see how it will be positioned on the printer, I would be making a best guess.

Sorry, my CAD skills are getting better over time, but I am VERY rusty. I was proficient with AutoCAD about 30 years ago while I was in college to be an Architect. However, that was not the field I went into and well... unused skills fade quickly. Ironically, Architect is in my title at work, but its Cloud/Network/Computer related. I'll leave it at that. It's hard to explain what I do unless you are in the same segment of the Information Technology industry.

I would love to put together a full F3D file with everything as it should be, but the time needed will exceed my desire to produce that asset. I will stick everything in a Git repo at some point so others can use any of my ideas, but that is pretty low priority presently.

Little irony.. while typing this I received a notification to check in for my flight tomorrow.
 

Edited May 5, 2024 by cjkennedy72

[cjkennedy72]

Well, I am home for two weeks in a row, so far... but, it could change at any given time during a work day.
So...I have made some decent progress and thought I would share where I am so far.. 
1. The frame, gantry (less the X-Axis Linear Rail that I need to go cut down from 500 to 450), and Z motion components are assembled and everything lines up when I measure. Pic for posterity:

 

Since I decided to add 50MM of travel to the Y-Axis to allow extra room for tool mounts and swaps, I had to make some modifications to the Trident bed mounts. I had previously posted some 2020 mounted v-core3 style bed mounts, but since I need to offset 50mm I have done two things, well three:

1. I shortened the frame extrusion under the bed that goes from front to back by ~45mm

2. I created a simply reinforced 25mm extended mount for the frame extrusion that runs across the X-Axis

3. I took the front 2 v-core style mounts for the front and cantilevered them 15mm and made them to mount to the side of the extrusion with a plate coming across the top to reinforce it. 

Between the extension to the front between the Z motion components and the 2020 extrusion and the center of the mount where the 12mm ball screw will sit is ~50mm.

 

Here are those parts... the new bed mounts have to have the magnets and 5mm posts installed still:

I am going to reprint the mounts as the corners turned out kinda ugly. Guess I should have used a few supports

 

[cjkennedy72]

I have been playing around in Fusion360... I really do not like the way I have the actual tools assembled on this. ITS UGLY!

So... I thought I would try something else. I looked through several ready to print designs that might work, but most everything I found in a form that would work was either also ugly, wouldn't work for the mounting plate of the toolchanger, or used 3010 fans, which I think I have 3. So, inspired by many designs, I have redesigned my toolheads. 

I am printing the hotend and extruder mounts now. I will be using the Sailfin design. I looked at most everything I could find that was a 3d-printable design, and liked this best when I put a model onto my design in CAD. Of course, each will get an EBB.... mostly 36s, but I think I might have to use 2 42s if I do all 6 tools that I have plates/holders to match.

Here are the screenshots of the F360 designs. If you look closely, you will see I used hotend mount's side extensions to brace the bottom of the fan cowl.

I will post a fully assembled toolhead in the next day or so. I am waiting on parts to print in ABS. Plenty of PLA was sacrificed as this design evolved...

 

[Dirk]

6 hours ago, cjkennedy72 said:

ITS UGLY!

Add a CPAP to it. It will make it look better - alien-like

[cjkennedy72]

2 hours ago, Dirk said:

Add a CPAP to it. It will make it look better - alien-like

 

I don't think there is much of anything to make this look better:
 

 

On 3/16/2024 at 10:53 AM, cjkennedy72 said:

Here is a repost of one of the finished tool plates with everything mounted except the EBB36:

[cjkennedy72]

Okay... I am pretty stoked about how this turned out! 
 

 

Now to finish assembling the first Sailfin extruder and mount it!

More soon!

 

PS. I finally cut the MGN9H and mounted it last night. I just disassembled the tool changer to mount it... fun times are coming soon!

 

Edited June 2, 2024 by cjkennedy72

[claudermilk]

It resembles a Dragon Burner now.

[cjkennedy72]

2 minutes ago, claudermilk said:

It resembles a Dragon Burner now.

I said I was inspired by what I as finding. I just couldn't get the OG designs for the Dragon Burner or any others to work for me... They all called for a 3010 somewhere.

AND... Still WAY better than my first try! 

[Dirk]

It sure looks better than the Alien toolhead you had in the pictures.... I believe in a toolchanger a small toolhead would be beneficial, but since you have such a huge build volume, it will matter not so much I guess...

General progress is also great.

[cjkennedy72]

Starting to work on the mount for tools...

BTW @Dirk, I measured and I have only added 13mm to the depth of the tool heads if I had used the included J-Heads and mounts with the designed bowden setup.

  

[cjkennedy72]

Hey everyone! Missed being active around here, but life just has left little time to spend on the Interwebs... 

If you thought this was a dead thread... well, I have actually been making quiet progress when I get a few minutes here and there, so thought I would add a couple pics and progress.

Since my last post, I have... 

Redigned the front bed mounting components to accomodate the fact that although I ordered a 400x400 bed a long time ago, I never actually measured it. It has been wrapped in plastic waiting on me. Well.. its actually 430x430... and already had nice corner holes, so, I didn't want to drill more holes in it.

So, I made appropriate adjustments and everything is mounting up nicely. I will post a pic once i get a moment to shrink the file-size.

I also was able to get the belts on! I moved the toolhead mount around a bit since nothing is connected to the motors yet and the motion feels smooth, no catching or belt slack as I move it about. I haven't fully tensioned the belts yet of course, so hopefully this is a good sign.

Additionally, I have my electronic's bay ready to receive components:

 

So that leaves not pictured:
The start of the docking rail at what would normally be the "Front" of the bed. When I measured with the bed in place and before I put on belts, it was lining up nicely to be inside the make forward movement, but clear of the bed, so no loss of printable area.

More to come! I have been putting more time into this project as things start to calm down at work. However, as I move forward, I have hit a few setbacks, like the bed, and have had to rethink a few things... regardless, hopefully she will be spitting 6 color prints before the year is out.

BTW.... Some cool stuff happening with other's  builds. I try to creep in and see what you all are working on if I get a spare moment.