VertX

manu's Vertical X-Axis and X-carriage-struder

Release status: experimental

Description	a direct-drive extruder/x-carriage for the V9 hotend (for the moment) and its whole vertical x-axis
License	GPL
Author	User:Emmanuel
Contributors
Based-on
Categories	Development
CAD Models	http://www.thingiverse.com/thing:10711
External Link

Inspiration

• EMAKER_Huxley
• Huxley-eg
• The Gen X Skb-Kiparis remix I discovered on this thread : http://forums.reprap.org/read.php?94,84403,93044#msg-93044
• Orca and the v9
• And all the existing reprap stuff that certainly influenced me

I wanted to design a vertical carriage with linear bearings, but mixed with the ideas behind the V9 (direct drive, no damn PTFE, no mouting block) to make it even simpler. And thus came this "carriage-struder":

Benefits

• a very compact/accessible extruder ! (65mm wide x 50mm deep x 75mm tall)
• only 2 pieces
• with LM8UU (optionally locked by zip-tie)
• active cooling with a little fan, mounted on only one point : just rotate if you need to access at the inside
• "Double pulley driven" x-carriage (inspired from the Madkit's double resolution mod)
• Bearing holders tend less to snap, thanks to the printing orientation
• in case of snaping/removing the filament, the idler will bump on the body of the x-carriage without damaging the brass insert of the direct drive

And for the x-axis

• the whole x-axis may be assembled without removing any Z-rods (except to put the linear bearing on it)
• the x-carriage can move over a distance of ~235mm (bigger print area ?^^)

Sells/Prusa Mendel (~28mm between the z rods)

Axis V1 (beta)

I estimated how many vitamins are needed, but that may change. If you upgrade from a classic Sells Mendel, you already have a long belt and most if any of the vitamins required.

Italics are for the "Don't bend the belt backward option" which is recommended.

Item (and approximate weight/time	Quantity/File	Vitamins
x-carriage-struder 24.7gr 80min@35-120mm/s	1 manu_x-carriage-struder	4 LM8UU 4 M3x8-10 (motor) 1 M4x20 (for the fan) 2 M4x60 (+ 2springs) (1 M3-4x10 for the optoflag) Double resolution: 2 624zz (and 2 M4x16-20 + 2-4 M4 mudgard washer)
x-carriage-idler 4gr 13min@35-120mm/s	1 manu_x-carriage_idler	1 624zz + 1 M4x20 (to hold the bearing in the idler) 1 M4x40 (rotation axis)
x-carriage-spring-pusher 1.6gr 5min@35-120mm/s	1 manu_x-carriage_pushspring	optional, for comfort to push on the two springs (hmm finally it feel better without, I'll remove it later)
x-end-motor 40gr 90min@35-120mm/s hexafill 0.2	1 manu_x-end-motor or 1 manu_x-end-motor_bis	2 M8 nuts and 2 LM8UU 4 M3x8-10 (motor) 2 M3x15 (clamping the smooth rods) add 1 624zz + 1 M4x30 + 1-2 mudgard washer
x-end-idler 30gr, 60min@35-120mm/s hexafill 0.2	1 manu_x-end-idler or 1 manu_x-end-idler_bis	2 M8 nuts and 2 LM8UU 2 M3x15 (clamping the smooth rods) 1 624zz + 1 M4x30 + 1-2 M4 mudgard washer add 1 624zz + 1 M4x30 + 1-2 M4 mudgard washer
Total : ~ 100gr. and ~233min		Add some zip-tie and as many washers/nuts as needed

First print

Maybe for the next revision

Vertical Axis V0.6

First move/heat test --Emmanuel 16:08, 29 August 2011 (UTC)

<flickr>6104725870</flickr>

It move ! more pictures/videos on flickr : http://www.flickr.com/photos/watsdesign/6093138294/in/photostream

As expected in a "double-resolution" configuration it only make half of the distance with the old E_Step_MM and we must double it in the firmware.

I also tested the heat-resistance of the x-carriage-struder, and thanks to the little fan it can handle 270°C (the resistance couldn't heat more) without any deformation and while the upper part of the v9 is only a little warm (can be touched without problem). Thus I suppose that it can also extrude ABS.

First assembly

<flickr>6090296087|center</flickr>

X-carriage-struder v4

X-ends v6

There is also a version of the x-ends with one added bearing to avoid to bend the belt backward in a "double-resolution" configuration, if you fear for the belt's life (as Droftarts suggested).

X-end-idler :

X-end-motor :

There is a video of a print of the x-end-motor : <videoflash type="youtube">1AA38w8l-1M</videoflash>

Detail of the mounting of the opto-switch :

Axis V0.5

A LOT of modification were made (quite time consuming)... but it's on its way ! (some more pics on flickr)

X-end-idler v5

Only ~30gr (15gr saved from the v2) and ~45min to print (at 40-120mm/s with Marlin)

<flickr>6083753400|center</flickr>

<flickr>6083752324|center</flickr>

<flickr>6083753038|center</flickr>

X-end-idler v2

33mm between the rods was finally too much, it seems to be ~28mm

<flickr>6083737416|center</flickr>

<flickr>6083195165|center</flickr>

X-carriage v2

I inverted the angles of the LM8UU seats for the V3 (to avoid removing the carriage when pushing on the filament by hand by example)

<flickr>6083736386|center</flickr>

<flickr>6083194353|center</flickr>

V0.4

X-ends also integrate something for the opto/microswitch

And as AhmetCemTuran suggested, the bearings seats of the X-carriage_v2 are now at an angle to snap them without removing the smooth rods :)

V0.3

Yay !

V0.3a

Buback suggested to put the motor face to face to center the overall mass :)

V0.2

And the x-ends that will have to be tested too. The spacing between the Z rods are for a Sells Mendel, to replace the classic x-axis (don't checked for a Prusa but if different that may not be difficult to adapt and re-export)

V0.2.2

<flickr>6080067127|left</flickr>

<flickr>6080604538|left</flickr>

<flickr>6060884422|left</flickr>

<flickr>6070660239|left</flickr>

V0.2.1

V0.1

When looking back at the eMaker, maybe two LM8UU can be enough ?

Orca (horizontal rods)

V1b

Not tested yet and could be refined (rounded edges, some details, inverting the bearing parts that drive the belt to hang it close to the linear bearing and thus make it more compact)

But it's supposed to be a drop-in replacement of the actual x-carriage :