Preparing x-gantry

This set of work instructions is out of date!

What's shown here is for v3.0.5 of the LumenPnP. Instructions for the latest version of x-gantry still need to be written for LumenPnP v3.1.#.
Please note however, the QC Checklist is up to date.

Assemble the x-gantry-linear-axis

Prepare the x-motor-mount

Install 2x M5 Hex Nuts into x-motor-mount
Use an M5x16 bolt to align the hex nut with the hex pocket
Before continuing, add a small drop of Loctite to the side of the hex nut
You can then proceed to pull the hex nut fully into the hex pocket by tightening the bolt
Repeat this process for the second hex nut, when finished your x-motor-mount should match the images shown below:

Install NEMA 17 stepper motor onto x-motor-mount

Set timing-pulley height on NEMA 17 stepper motor shaft with jig
- The 1st set screw tightened must contact the flat region of the NEMA 17 motor’s shaft
- Tighten both set screws to 0.6 N/M
Bolt NEMA 17 motor onto motor mount with 4x M3x8 bolts
- Tighten these bolts to 0.4 N/M
- The motor connector should face towards the 2x pressed in M5 hex nuts when installed

Assemble x-axis tensioner and install onto x-idler mount

The pieces you will need are shown below
Press an M3 hex nut into the belt-tension-arm, followed by an M3x16 bolt
Thread the M3x16 bolt all the way through the belt-tension-arm, and then thread an M3 acorn nut onto the ends of the bolt.
- Tighten the nut onto the bolt with pliers and an Allen wrench!
Install the idler-pulley with an M5x25 bolt and a nyloc M5 hex nut
- Avoid over tightening the bolt, the idler-pulley should be able to spin freely without resistance.
Install belt-tension-arm onto x-idler-mount
- Bolt the pieces together at the pivot point on x-idler-mount with an M5x40 bolt and a nyloc M5 hex nut.
- Avoid over tightening the bolt, the 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

Assemble x-motor-mount and x-idler mount onto alu-extrusion

needs work

Prepare the x-gantry’s toolhead-assembly

Top-camera-assembly preparation

Use the top-camera-focus-jig to pre-focus top-cameras
Connect top-camera-focus-jig to a laptop and open a native camera viewing application
Remove the top-camera lens cap
Loosen the set screw found on the side of the lens body that locks the focus
Install the top-camera fully into the top-camera-focus-jig, plugging the USB cable into the camera module afterwards
In Photobooth, change the selected camera to PnP Top to view the camera feed of the top-camera. The setup should now look like the following image
Rotate the camera lens until the live viewport shows the datum board as focused as possible

Camera view before and after focusing shown above
Once the camera is focused, tighten the set screw to lock in the adjustments
Put a red dot on the camera PCB with a sharpie to denote that the camera has passed testing
Remove the top-camera from the top-camera-focus-jig and immediately replace the lens cap.

Assemble the top-camera-assembly

Installing top-ring-light into top-light-mount
- Place the ring light facing downwards into the top-light-mount.
- The LEDs will shine down, and the white plastic wire connector will face upwards.
Place top-camera-mount above top-light-mount, ensuring that the tab from the top-light-mount fits onto the side opposite the arms on the top-camera
- These two prints will pinch the top ring light in place
Install top-camera into top-camera-mount.
- Make sure the connector on the back side of the camera is between the two arms of the top-camera-mount.
Secure the whole stack in place with four M2.5x20mm screws in the outer four holes
- Do not put the screws through the inner holes with metal circles around them
- Tighten the screws enough so that all parts are tightly held together, however be cautious as these screws are threading directly into the plastic

X-gantry-back hex nut installation

Insert 2x hex nuts into x-gantry-back for later drag-chain-assembly attachment
Add a small amount of Loctite to the sides of the hex nuts to ensure they stay installed in transit to the customer

It is recommended to use a wide tool that can easily press down on the entire hex nut without allowing it to rock. This helps insert the hex nut into the print straight on.

However, be sure to switch to a narrow tool that can fully press hex nuts into the pockets
Insert 2x backside hex-nuts into x-gantry-back
Place the x-gantry-back-nut-plate jig onto the arbor press to hold x-gantry-back in a proper position during the following steps

Press the hex nuts into x-gantry-back until they are flush with the surface

The 2x adjustable sliding M5 hex nuts are not installed at this time because they can be loose and it would be inappropriate to fix them in place with Loctite
Insert all the remaining top-side hex nuts into x-gantry-back
Fully insert the 4x M5 hex nuts used for belt-clamp attachment

If the pockets for the 2x hex nuts used for attaching the top-camera assembly loosely fit the hardware, use Loctite to prevent to secure them

Insert the 2x hex nuts used for tension adjustment deep into the print, stopping once the threads are fully visible from the intersecting bolt hole

Install tensioner bar onto x-gantry back

X-gantry-front preparation

Install hex nuts into x-gantry-front, being sure to utilize the x-gantry-front-nut-plate fixture when installing hardware into the backside of the print.
Press an M5 nyloc hex nut into the backside of x-gantry-front

Install the 8x M3 hex nuts into the backside of the x-gantry-front, use a narrow tool to ensure that these pieces are fully inserted into the 3D print.

Insert the 2x hex nuts used for tension adjustment deep into the print, stopping once the threads are fully visible from the intersecting bolt hole

Install tensioner bar onto x-gantry-front

x-gantry-toolhead assembly

Install linear-rails by aligning them against the bumps on x-gantry-front
- Uses 3x M3x14 bolts per rail
- Tighten each bolt to 0.5 N/M
Install z-axis limit switch onto x-gantry-front
- Mounts with 2x M3x8 bolts and 2x M3 hex nuts on backside (should be already installed by now)
- Make sure each limit switch clicks and feels normal when actuated
Install idler-pulley onto x-gantry-front
- Use 1x M5x25 bolt and torque with a 4mm hex driver
- Check 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
Prepare z-belt-subassembly
- Prepare z-gantry-backplate-left
- Drill out the limit switch striker bolt hole on z-gantry-backplate-left with a 2.5mm drill bit
- Install an M3x16 Flathead bolt into z-gantry-backplate-left to a depth that roughly matches the image shown below
  - This screw depth will be precisely in later steps
- 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-ganry-backplate
Set timing-pulley height on NEMA 17 stepper motor shaft with jig
- The 1st set screw tightened must contact the flat region of the NEMA 17 motor’s shaft
  - Tighten both set screws to 0.4 N/M
Install NEMA 17 stepper motor and belts onto the x-gantry-front subassembly
- Begin by placing the gt2-belt-loop w/attached z-gantry-backplates onto the x-gantry-front subassembly
- The z-gantry-backplate-right should fit over the right linear rail’s carriage, and the same goes for the left side
- Install the NEMA 17 stepper motor by angling it into the belt-loop
- The limit switch connector will be at a 45degree angle from the z-axis stepper motor’s connector when everything is in the proper position.
- Bolt NEMA 17 stepper motor onto x-gantry-front with 4x M3x8 bolts
- Leave the bolts loose for now
- Tension belt-loop by pulling the stepper motor upwards before tightening its 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
Attach z-gantry-left and z-gantry-right onto each respective linear rail carriages + z-gantry-backplate with 4x M3x8 bolts per side
- Align each z-gantry to be parallel with the linear-rail by lightly pressing it outward with your hand, away from the mid-plane of the x-gantry-subassembly
  - As these bolts are tightend ensure that the z-gantry doesn’t collide with the z-idler’s bolt head
- Tighten bolts to 0.3 N/M, moving in a star pattern
Prepare pneumatic-toolhead-assembly
- Install a nozzle-holder and rotary-pneumatic-adapter onto NEMA11-hollow-shaft-stepper
  - Use a torque driver w/custom rotary-pneumatic-adapter-socket and 8mm wrench to tighten these components onto the motor shaft
  - Set the torque driver to 0.5 N/M for this step
  - Use the 8mm wrench to hold the nozzle-holder stationary while applying torque from the rotary-pneumatic-adapterside
  - The rotary-pneumatic-adapter should be installed closer to the motor's cable connector
- Install 2x pneumatic-toolhead-assembly onto x-gantry-front-subassembly
- Bolt pneumatic-toolhead-assembly onto left side z-ganty
  - Attach with 4x M2.5x8 bolts
  - Torque each bolt to 0.3 N/M
- Repeat above process to attach a pneumatic-toolhead-assembly to the right side z-gantry

X-gantry final assembly

Precut GT2 belt to ### length
Run gt2-belt through x-gantry-linear axis and connect both ends to x-gantry-back
Fully depress the x-axis belt tensioner arm before tightening down the belt with 2x belt-clamps with 2x M5x10mm socket head screws per clamp.
Use brass bar to route the belt through the extrusion and ends of the axis
Install x-gantry-front-subassembly onto x-gantry-linear-axis, connecting it to previously installed x-gantry-back

Step #1 - Hold the x-gantry-back subassembly against the x-gantry-linear-axis subassembly for the following steps to happen easier
Step #2A - Fully insert 2x M5x40 bolts through the upper counterbored M5 bores in x-gantry-front
Step #2B - Happening basically simultaneously with the previous step, align 2x roller-space and 2x v-wheels onto the previously inserted M5x40 bolts

Step #3 - Move the x-gantry-front-subassembly backward into the x-gantry-back-subassembly, paying attention to keeping the upper 2x v-wheels aligned on the x-gantry-linear-axis’s 2020-v-groove extrusion

Note

Rotate everything upside down for the following steps

Step #4A - Lower 2x v-wheels up until they rest loosely against the 2020 v-groove extrusion, they should also each be aligned so that each wheel is concentric to the raised nubs on the x-gantry’s tensioner-bars.
Note that the 2x tensioner-bar pieces may not be vertically aligned very well by this point, so this process may be tricky

Step #4B -
- Adjust the vertical alignment of the 2x tensioner-bar pieces
- This is done by tightening or loosening the 4x M3x30 adjustment bolts until you can peer straight through the lower counterbored M5 bores in x-gantry-front and past the hex-nut slot found on x-grant-back
- This may take a few minutes so be patient!
- Tighten and loosen all 4x M3x30 bolts as a set, taking care to never make a single bolt more than a few turns away from any other bolt
- Fully insert 2x M5x40 bolts into the lower counterbored M5 bores in x-gantry-front, through both v-wheels, and stopping within two hex-nut slots found on x-gantry-back
- Manipulate the z-gantry pieces as needed to avoid interference with the bolts
- Tension x-gantry v-wheels and x-axis belt tensioner arm
- Tighten the 4x M3x30 bolts until the toolhead-assembly can smoothly move along the x-gantry-linear-axis, without resistance
- Grab the toolhead-assembly and try twisting it in many directions, if you feel any play or looseness tighten the appropriate M3x30 bolts until the play dissipates
- Tighten the 2x lower M5x40 bolts to 0.1 N/M to lock-in the calibrated v-wheel tension
- Tension the belt to 0.03 N/M ** need to confirm **

Test x-gantry on Gundam jig

Ensure that the Gundam motherboard is unplugged from 24vDC power
Check that the x-gantry fits correctly on the x-gantry-spacer-jig
Slide a bolt into the x-gantry on 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-subassembly with 2x M5x16 bolts
Connect the test jig’s z-limit-switch, x-motor, and z-motor cables to the x-gantry being tested on the x-gantry-spacer-jig
Connect the Gundam motherboard to 24vDC power and then press reset on the 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, if needed, provided the z-gantries are not 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 arrise, 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 z-limit-switch, x-motor, and z-motor cables from the x-gantry being tested on the x-gantry-spacer-jig
- Unscrew the drag-chain mounting hardware from the x-gantry being tested on the x-gantry-spacer-jig
- Remove the 2 M5x25 bolts used initially for keeping the x-gantry from falling off the x-gantry-spacer-jig

Install top-camera-assembly

Install top-camera and Light subassembly onto x-gantry
- Use two M3x14mm screws to mount the top-camera and Light subassembly onto the back of the X Gantry Back.

QC Checklist

Inspect the completed x-gantry for the following criteria:

GT2-belt has been trimmed to appropriate length (flush on 1 side, ~1/2" - 3/4" on the other)
Camera is installed with two bolts
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
2x M5-hex-nut are installed in x-gantry-back for use with drag-chain attachment
NEMA-17-stepper-motor wire connector faces towards drag-chain mounting location on x-gantry-back
Linear-rail is centered atop aluminum-extrusion
x-idler-mount and x-motor-mount are secured to 600mm-alu-extrusion with 2x M5x10-bolt per side
2x M5-hex-nut are installed in x-motor-mount for use with the x-motor-cable-guide
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 600mm-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, bring the completed x-gantry to the shelf for peer-review and pack-out.