Camper Part 34: Cosmetic Quicky

Yesterday was a 'camper' day as I decided to start trying to improve the cosmetics a little.

As is evident in this picture from last year when I was removing the stickers, some paint had lifted off the passenger door.  (look carefully in the crease line).  As I recall it wasn't on the latest stickers, but some time earlier in the life of the vehicle.

This made the vehicle look tatty, so having located a better door, I went and collected and fitted it yesterday (picture when I manage to download it off the phone).  This had the advantage of not waiting for paint to dry and the new door comes off a much newer vehicle so hopefully less time before rust sets.

Opto Issues

The issues with the optos are ongoing.  I replaced the connection pins with wires on all three my opto circuits, but it appears the one I damaged last time is fubar.

As for the other two:

• The TechZone optos have the LED enabled until the opto is blocked then it switches off
• On mine, they're never turn off, no matter what I block them with.

Help!!

Mendel Mayhem: Completing the bot

Having gotten the X-axis running last time, the job tonight was to finish off the job.

I started by wiring up the Y & Z stepper motors. Luckily with the Zapp Automation stepper motors and the Azdle mounting for my TechZone electronics, I was able to wire the steppers directly, no extending of cables. (The extruder stepper will be another matter).

I then starting playing with moving the axes around using the RepRap host software. This reminded me that I had tweaked the config for the ScrapStrap (which had a belt drive for the Z-axis), so I set about trying to remember how to reset the config. I decided that the best was to get the latest from Sourceforge (now at 20100806 - I had previously installed 201000702).

Upgrading RepRap Host
As I wanted to reset my config, I upgraded as follows:

• Extracted the latest software 20100806 to a temp folder.
• Replaced the raprap.bat with the one I modified last time (to make it work in a different sub-folder)
• Copied in my RepRap.ico file I had created
• Deleted the contents of my install folder (having backed it up)
• Copied in the new installation (and deleted the temp folder)

This means that I reverted by firmware config as well, so I had to reprogram the firmware. This was achieved as follows (any folder locations refer to sub-folders off Reprap\mendel\firmware\FiveD_GCode):

• Copied configuration.h.dist to configuration.h in the FiveD_GCode_Interpreter and Extruder folders (I compared to my old config and was reminded that I commented my changed with my initials - glad I followed a guideline I insist all my coders at work follow)
• Load the FiveD_GCode_Interpreter/FiveD_GCode_Interpreter.pde sketchbook
• Modified the configuration.h tab to match my setup (guessed most of it as I don't know what applies yet - it seems to be pretty much setup for the v3 electronics which the TechZone stuff is - For the hardware, I left it as standard for now, as it should be) and saved.
• Selected the Tools->Board->Sanguino board and then Sketch->Verify/Compile
• Connected the board to the PC.
• Selected Upload to I/O Board and done!!

For the Extruder controller:

• Copied the configuration.h.dist to configuration.h in the Extruder folder
• Moved the USB board to the extruder controller, remembered to invert it (ground is on the opposite side). Mine is now marked with a black marker.
• Loaded the Extruder/Extruder.pde sketchbook.
• Modified the configuration.h tab to match my setup (left it all standard as I didn't see anything relevant to change) and saved.
• Checked the temperature.h tab as I am running a thermistor. I wasn't sure is the default table is correct or not, so I left it be for now.
• Selected the Tools->Board->Arduino Diecimila, Duemilanove or Nano w/ ATmega 168 board and then Sketch->Verify/Compile
• Connected the USB cable to the PC
• Selected Upload to I/O Board and done!!!
• Disconnected the USB and moved it back the main board

Next step, testing the config. I reloaded the RepRap host software and it all worked fine.

Next step was to get on with mounting the end-stops and checking that it can home itself. This is when I discovered one of the issues with the TechZone electronics. In their efforts to reduce the size of the components, they gave no consideration to the retention of the standard mounting locations and as such I managed to damage one of the circuits while trying to make this work. This caused me to suspend work for the evening as I now need to get into some soldering etc, which is a change of focus so will be done on another day...

Mendel Mayhem: Frame continued

I got bored inside, so here I am again. My wife popped out to the shed to see what was happening, and got a guided tour of the assembly to date.

Installing the Y-axis
It took very little time to get the Y-axis installed, completed with belt. I then quickly installed the X-axis belt while I thought I knew what I was doing. As said before, the bed is going in later.


Fitting the electronics
Having a moving cartesian frame and a seperate set of mounted electronics will only drive one insane, so the next step was...

And it works!!!! Well ok, I only connect the X-axis, but at least I'll be able to sleep tonight (sort of).

Mendel Mayhem: Frame

As I have previously assembled my TechZone electronics on a thick sheet, the next step is the frame.

Frame sides

The lower vertex pieces supplied by Nophead have feet so I needed to ensure I took heed of this from the off (I don't know which he used, so no link, sorry These are Nophead's own design, frame-vertex_with_simple_foot_4off located in the alternative-parts repository).

I did a loose assembly initally, but tightened one end of each threaded bar. Then laying the assembly flat on the worktop I adjusted them to the jigged value. For locating the Z-leadscrew brackets, motor bracket & tensioner, it is useful to note that the lying the assembly flat on the worktop allows you to have these pointing up perpendicularly.

So another hour got me from this:

To this:

I also decided to use these 3M stick on rubber feet that I found somewhere (I'm a bit of a hoarder if you hadn't realised yet). The picture on the right shows one fitted to the Mendel's foot. They should help a bit with regard to the reduction of noise/vibration transmission to the worktop.

Frame ends (i.e. the bits that join the two sides together)
Starting to read this I just see that they recommend feet like the ones I fitted. Great minds and all...

In reality this is the assembly of the main framework (without axes), so quite time consuming with all the calibration. As you'll see if you look carefully at the first picture, I was so happy to be done after 1.75 hours that I had forgotten to align the Y-axes motor and idler brackets.

This is going to be an epic segment as I need to get all the cross pieces in.

On sorting these out I found that my large mudguard washers on the motor bracket were preventing the M8 washer from getting past. Loosening the M4 bolt a bit so the washer could 'wiggle' allowed the two to pass each other. Another 15 minutes had passed, so 2 hours in total for the frame assembly.

X-axis installation

Following the instructions on the 'Mendel Frame' page of the wiki, I noted the following (depicted in the pictures below):

• The cap screws for the Z-lead screw bearings are easier to fasten if they point upwards. The picture will show that I only switch to this for the 3rd screw on each side as the bolts for the Z-bar bracket prevent my socket from fitting.
• The instructions mention that that X-axis should be approximately levelled before adding the belt. I achieved this by using the J3 measuring jig as shown.
• I double checked the spacing of the top brackets by measuring and comparing to the leadscrew brackets at the bottom. (Still need to test full travel).

That was another hour, I think I'm calling it a day for now. The next step in the instructions is the lower circuits, but that doesn't apply with the Techzone electronics, the next instalment should see the Y-axis, bed and electornics (on the side) installed.

Mendel Mayhem: Y-axis continued

Chassis

Now that I have the requisite thick sheet parts I'll get on with assembly.

I started with the bearing blocks as the template supplied by Nophead for the squashed froglet doesn't have the slotted holes for aligning them. You do the alignment first and then drill the holes accordingly.

Everything seems to line up properly so it went quite quickly in the end (about an hour, with some fiddling about when I had to drill the extra holes, etc).

Mendel Mayhem: Squashed froglet

As stated in yesterday's segment, this morning I tackled the Thick Sheets.

When I finished last night I updated my Reprappers forum topic to update on my progress. Nudel recommended Nophead's froglet made from Dibond (which I have some of as I bought too much in anticipation of making a heated bed and am selling extras). He also told me that the standard thin sheets (opto plates) don't work with the Techzone electronics so saved me some wasted effort.

The standard thick sheet parts comprise:

• Squashed Frog (chassis)
• Purge plate
• Bed
• Electronics mounting plates (2-off)

I went and re-read of Nophead's 'Making Mendel' post to confirm my approach.

I have already made Azdle's Mounting Plate for Tech Zone Remix Electronics as described here, and will make the bed later as I want to make a heated bed, so this morning I cut up a Dibond FR sheet to make the Nophead's Squashed Froglet and a purge plate as shown below.

That's about another hour, so with that done, I'll be able to continue the Y-axis build, but first I'm off to walk the dogs before it rains (It is still summer - sort of - in England afterall.)