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Preparing x-gantry

Create x-linear-axis subassembly

Prepare x-gantry-back

Install fasteners

  • Remove any stringing from the print with a heat gun

  • Insert 4x m5-hex-nut into the following region

  • Insert 5x m5-hex-nut into the following region

    • Add a drop of blue-loctite into each of these pockets to permanently secure each nut in place

Check top-camera focus

  • Use top-camera-focus-jig to check focus of top-camera

  • Connect top-camera-focus-jig to a laptop and open a native camera viewing application

  • Remove lens-cap from top-camera

  • Install the top-camera fully into the top-camera-focus-jig, plugging the USB cable into the camera module afterwards

  • In Photo Booth, change the selected camera to LumenPnP Top to view the camera feed from top-camera

     

If the datum-board is sharp and nicely focused continue onward

If the datum-board is blurry and out of focus, follow instructions below

  • Loosen set-screw on side of lens body

  • Rotate camera lens until live view shows datum-board as focused as possible

  • Once the camera is refocused, tighten set-screw to preserve the adjustments

  • Remove the top-camera from top-camera-focus-jig and immediately replace lens-cap

Install top-camera and top-ring-light into x-gantry-back

  • Install top-camera into x-gantry-back

  • Install top-ring-light into top-light-mount

  • Install top-light-mount onto back of x-gantry-back

  • Secure top-light-mount in place with 2x M3x12-self-tapping-flat-head

Prepare NEMA-17-stepper-motor for x-linear-axis

  • Set timing-pulley height on NEMA-17-stepper-motor shaft with x-pulley-spacer-jig

  • Tighten the first set-screw into the flat region found on the NEMA-17-stepper-motor shaft, before tightening the second set-screw

    • Tighten each set-screw to 0.5 N/M

Install NEMA-17-stepper-motor onto x-motor-mount

  • Orient NEMA-17-stepper-motor onto x-motor-mount so that the motor's connector is facing the backside of the print as shown in the image below

  • Bolt NEMA-17-stepper-motor onto x-motor-mount with 4x M3x8-bolt

    • Tighten these bolts to 0.5 N/M

Install XY-limit-switch-board onto x-motor-mount

  • Install XY-limit-switch-board onto x-motor-mount and secure it with 2x m3x12-self-tapping-flat-head-screw

    • Tighten each screw in place with the electic torque driver

Install belt-tensioner-arm onto x-idler mount

  • If you have not already done so, assemble 1x belt-tensioner-arm

    For reference building this sub-assembly, visit the Y Gantry OHAI page

  • Install 1x M5-lock-nut into x-idler-mount

  • Install belt-tensioner-arm onto x-idler-mount

  • Bolt belt-tensioner-arm to x-idler-mount with 1x M5x40-socket-head-bolt

    • Avoid over tightening the bolt! belt-tensioner-arm should be able to pivot smoothly without much resistance.
    • Ensure the belt-tensioner-arm is installed correctly on x-idler-mount (IE not backwards)
      • The acorn nut should be resting against the x-idler mount when installed correctly

Install alu-extrusion onto x-motor-mount

  • Insert alu-extrusion into x-idler-mount, using light force as necessary

  • Insert 2x M5-t-nut into alu-extrusion

  • Secure alu-extrusion in place with 2x M5x10-socket-head-bolt

    • Tighten these bolts to 0.5N/M

Install M3-t-nut-bar

Inspect the M3-t-nut-bar to ensure that each hole has M3 threads

  • Slide M3-t-nut-bar into top-side track of alu-extrusion

Install x-idler-mount onto alu-extrusion

  • Insert 2x M5-t-nut into alu-extrusion

  • Slide x-idler-mount onto alu-extrusion

  • Use x-gantry-spacer-jig to slide x-idler-mount onto alu-extrusion the required amount

    • The WIP x-linear-axis should be sitting on x-gantry-spacer-jig snug - not overly tight - when x-idler-mount is at the correct depth

  • Secure x-idler-mount in place with 2x M5x10-socket-head-bolt

    • Tighten these bolts to 0.5N/M

Install linear-rail-525mm

  • Roughly position linear-rail-525mm onto top-side of alu-extrusion

  • Place a linear-rail-2020-alignment-jig on both ends of linear-rail-525mm

    • Do not cover any bolt holes with the jig

  • Visually center linear-rail-525mm between x-motor-mount and x-idler-mount

  • Slide the M3-t-nut-bar to line up with the rail's bolt hole pattern

  • Starting from the x-motor-mount side, lightly snug a M3x8-bolt into every other bolt hole on linear-rail-525mm

    • Move the linear-rail-carriage out of the way as needed

  • Torque the rail mounting bolts to specification in sequence beginning with the bolts at the center of the rail and working towards each end.

    • A torque wrench set to 0.5N/M must be used when tightening these bolts

  • Remove the linear-rail-2020-alignment-jig from both ends of linear-rail-525mm

  • Slide the linear-rail-carriage back and forth a few times, checking to see that it travels smoothly and consistently

Install GT2-belt and x-gantry-back

  • Route a 1.5m-long piece of GT2-belt through x-gantry-back

    Belt routing step-by-step

    • Start by running the belt through the left-side slot on x-gantry-back and leave 75mm of extra belt poking out
    • Run it through the extrusion towards the x-motor-mount
    • Wrap it around the timing-pulley
    • Run it back through the extrusion towards the x-idler-mount
    • Wrap it around the idler-pulley
    • Run it back through the extrusion towards the x-motor-mount again
    • Have the belt exit through the right-side slot on x-gantry-back

  • Slide the x-gantry-back onto the linear-rail-carriage while pulling slack out of the GT2-belt

  • Bolt x-gantry-back to the linear-rail-carriage with 4x M3x16-bolt

    • Tighten each bolt to 0.5 N/M
    • Push x-gantry-back inward towards the linear-rail-carriage while tightening the mounting bolts to align it

    Ensure that x-gantry-back sits flush against linear-rail-carriage without any visible gaps

  • Use belt-clamp with 2x M5x10-bolt to clamp the left-side of the GT2-belt to the x-gantry-back

    • Tighten each M5x10-bolt to 0.5 N.M

Tension belt

  • Pull the right-side GT2-belt tightly towards x-motor-mount

  • Use belt-clamp with 2x M5x10-bolt to clamp the right-side GT2-belt to the y-gantry

    • Tighten each M5x10-bolt to 0.5 N.M

  • Rotate the M3x16-bolt clockwise on belt-tensioner-arm installed on x-idler-mount to tension the GT2-belt

    • This will cause the belt-tensioner-arm to pull the idler-pulley away from x-idler-mount adding desired tension to the GT2-belt

  • Trim the loose GT2-belt on either side of the x-gantry-back

    • For the x-motor-mount side of the x-gantry-back print, trim loose GT2-belt until flush against belt-clamp
    • For the x-idler-mount side of the x-gantry-back print, trim loose GT2-belt until approx. 15mm of GT2-belt remains past belt-clamp

Confirm progress

  • Check that finished x-linear-axis matches the image shown below before proceeding

Create x-gantry-front subassembly

Prepare NEMA-17-stepper-motor for z-axis

  • Set timing-pulley height on NEMA-17-stepper-motor shaft with jig

    • The 1st set-screw tightened must contact the flat region of the motor’s shaft

      • Tighten both set screws to 0.4 N/M

Prepare z-belt-subassembly

  • Prepare z-gantry-backplate-right

    • Drill out the limit switch striker bolt hole on z-gantry-backplate-right with a 2.5mm drill bit

    • Install 1x M3x16-flathead-bolt into z-gantry-backplate-right to a depth that roughly matches the image shown below

      • This screw depth will be precisely adjusted in later steps

  • Install both z-gantry-backplate-left and z-gantry-backplate-right onto gt2-belt-loop

    • Place a gt2-belt-loop onto the z-belt-alignment-jig
    • Place z-gantry-backplate-left and z-gantry-backplate-right onto the z-belt-alignment-jig to align them correctly on the gt2-belt-loop
    • Twist z-gantry-backplate-left upwards to pull the completed z-belt-subassembly off of the z-belt-alignment-jig
    • Use a dull knife or other tool to push the gt2-belt-loop all the way down into the cavity of each z-gantry-backplate-####

    TO DO: Add info about LOCTITE 435 Usage

Install M5-lock-nut into x-gantry-front

  • Use an arbor press to install an M5-lock-nut into backside of x-gantry-front

Install 2x linear rail onto x-gantry-front

  • Install 2x linear-rail by aligning them against the bumps found on x-gantry-front

    • Uses 3x M3x12-self-tapping-button-head per linear-rail
    • Tighten each bolt in place with the electic torque driver

Install z-axis-limit-switch

  • Secure with 2x M3x12-self-tapping-button-head
    • Tighten each screw in place with the electic torque driver

  • Make sure each limit switch clicks and feels normal when actuated

Install z-axis belt drive components

  • Secure idler-pulley onto x-gantry-front with 1x M5x25-bolt, tightened enough that the pulley can rotate freely without resistance

  • Check that the pulley can only rotate - it should not be able to move up and down if the bolt is tightened correctly

  • Begin by placing z-belt-subassembly onto x-gantry-front

    • The z-gantry-backplate-right should fit over the right linear-rail-carriage, and the same goes for the left-side

    • The gt2-belt-loop should wrap around the idler-pulley

  • Install the NEMA-17-stepper-motor by angling it into the z-belt-subassembly

    • The limit switch connector will be at a 45º from the motor’s connector when everything is in the proper position.

  • Bolt NEMA-17-stepper-motor onto x-gantry-front with 4x M3x8-bolt

    • Leave the bolts loose for now

  • Tension gt2-belt-loop by pulling the motor upwards before tightening the mounting bolts to 0.5 N/M

    • The belts should feel much firmer now - to test manually move the z-axis back and forth while inspecting the belts for sag when changing directions

    • You should be able to pluck the belt like a bass string

  • The x-gantry-front should now match the image shown below:

Install 2x z-gantry

  • Loosely attach a z-gantry onto the left-side linear-rail-carriage with 4x M3x8-bolt per side

  • Align z-gantry parallel to linear-rail by lightly pressing it outward, while tightening the mounting bolts

    • Tighten bolts to 0.5 N/M, moving in a star pattern

  • Repeat this process to attach the second z-gantry to the right-side linear-rail-carriage

Install NEMA11-hollow-shaft-stepper

  • Bolt NEMA11-hollow-shaft-stepper onto left-side z-ganty

    • Attach with 4x M2.5x8 bolts
    • Torque each bolt to 0.3 N/M

Install toolhead components

  • Slide nozzle-mask onto nozzle-holder as shown in the image below

  • Place rotary-pneumatic-adapter into rotary-pneumatic-adapter-socket

    • Attach the custom socket to a torque driver if you have not already done so
    • Set the torque driver to 0.5 N/M for the following steps

  • Install nozzle-holder and rotary-pneumatic-adapter onto NEMA11-hollow-shaft-stepper

    • Begin by loosely threading nozzle-holder w/attached nozzle-mask onto the NEMA11-hollow-shaft-stepper (on the side closest to the idler-pulley)
    • Install rotary-pneumatic-adapter onto NEMA11-hollow-shaft-stepper (on the side closest to the motor's cable connector)
    • Place a 16mm wrench onto the flats found on nozzle-mask
    • Tighten the toolhead components onto the NEMA11-hollow-shaft-stepper by torquing the rotary-pneumatic-adapter

  • Repeat above process to attach a rotary-pneumatic-toolhead-assembly to the left-side z-gantry

Install x-gantry-front onto x-linear-axis

  • Use 4x M5x40-bolt to attach x-gantry-front onto x-linear-axis

    • Move each toolhead out of the way as needed
    • Torque each bolt to 0.8 N/M

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Gundam test x-gantry

  • Ensure that the Gundam motherboard is unplugged from 24vDC power
  • Check that x-gantry fits correctly on x-gantry-spacer-jig
  • Slide a M5x25-bolt into the x-gantry from either side of x-gantry-spacer-jig to prevent it from falling during testing
  • Bolt down the test jig’s drag chain onto x-gantry-back with 1x M5x16-bolt
  • Connect the test jig’s xy-limit, z-limit, x-motor, and z-motor cables into x-gantry
  • Connect the Gundam motherboard to 24vDC power and then press reset on Gundam motherboard
  • Connect the motherboard to the Gundam test software

  • Begin testing the x-gantry by running various macros:

    • Check X-Home

      • If the toolhead is moving very slow, the stepper drivers may not have initialized properly - try restarting the motherboard again

    • Check X-Movement Speed

      • Ensure that no weird sounds are heard, if so consult with team for debugging steps
      • Adjust the tightness of the belts and each tensioner-bar as needed to pass this test

    • Test Z-Home

      • Check that the z-belt is adequately tensioned and adjust if necessary - you shouldn’t be able to twist the belt too much
      • Adjust the M3x16 bolt either up or down as needed, until the z-gantry's are aligned vertically after homing
        • This can be checked by sliding a brass shim across the top of the motor while checking to see if it sits higher/lower than the top surface of the adjacent motor
        • Repeat this test and continue adjusting the M3x16 bolt until the alignment appears to be perfect

    • Test Z-Movement Speed

If issues arise, continue rerunning tests and reworking the x-gantry

Once everything is passing, proceed with the following steps

  • Remove x-gantry from Gundam
    • Disconnect Gundam motherboard from 24vDC power
    • Unplug the test jig’s xy-limit, z-limit, x-motor, and z-motor cables from x-gantry
    • Unscrew drag-chain mounting hardware from x-gantry
    • Remove the 2x M5x25-bolt used to keep x-gantry on x-gantry-spacer-jig

QC Checklist

Inspect the completed x-gantry for the following criteria:

  • GT2-belt has been trimmed to appropriate length (flush on 1 side, 15mm on the other)
  • Top-light-mount is attached with two screws
  • Camera lens cap is present
  • The wire connectors on both NEMA-11-stepper-motor units face away from each other, sitting adjacent to their respective cable strain relief points
  • Each nozzle-holder has been lubricated and fit-tested with a nozzle
  • Z-belt-loop feels appropriately tensioned when plucked
  • Each z-gantry moves smoothly when actuated back-and-forth by hand
  • 1x M5-hex-nut is installed in x-gantry-back for use in cable-splay attachment
  • NEMA-17-stepper-motor wire connector faces towards z-limit-switch
  • Linear-rail is centered atop alu-extrusion
  • x-idler-mount and x-motor-mount are secured to alu-extrusion with 2x M5x10-bolt per side
  • Tensioner-arm is installed on x-idler-mount in the correct orientation (IE acorn-nut facing touches print)
  • Timing-pulley is tightened down and at proper height
  • GT2-belt lays flat and is roughly centered in the alu-extrusion channels
  • GT2-belt has been correctly tensioned
  • X-gantry-toolhead moves smoothly when actuated back and forth by hand

If all checks pass, place completed x-gantry on shelf for peer-review and pack-out.