COssel

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Revision as of 22:34, 8 February 2014 by Cdaringe (talk | contribs) (BOM: Added .xlsm BOM link)
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cOssel

Release status: working

Cossel main.jpg
Description
Delta robot 3D printer with extrusion frame
License
Author
Contributors
Based-on
Categories
CAD Models
inwork
External Link


Overview

cOssel is an iteration of Johann's Kossel. Design intents are equip a dual head end effector and to move the linear rails to an open design. It also uses 20x20 instead of 15x15. All other tweaks are minor. This design otherwise entirely copies Johann's delta-bot intent. Default configuration is setup for Dual Extruders, heated bed, and EE fan.

Non-contact Autoleveling

cOssel attempts to enable a low-power, non-contact autoleveling sensor as an alternative to using a retractable mechanical switch as used in other Rostock/Kossel deltas. This feature is still experimental as most IR sensors have not been proven repeatable, thus is still unfit for use. Video: Infrared Leveling

Assembly

Pre-install nuts for easier extrusion install

The assembly process should take a short weekend to complete. Make sure that you have a standard tool set, including ball-end metric allen keys.


Main Vertical Assembly

Base Connections


Upper Assembly

Carriages

End Effector

End Stops

The following images show the terminal block on the board. I ended up removing the terminal blocks from the boards to reduce interference from the carriage assembly as it approached the Z_MAX home position.

Rod Ends

It is assumed that your push rods have already been cut to size by yourself or a vendor. If not, cut your rods to length.

  1. Place the rod end ball standing vertically on a stable surface.
  2. Place the rod end socket loosely over the ball end ball.
  3. Space a pair of needle nose pliers around the perimeter of the socket.
  4. Press firmly down and click the socket over the ball.
  5. Prepare the epoxy solution.
  6. Apply dab of mixed epoxy onto threaded 4mm dia, 20mm long set screw
  7. Thread set screw into rod end as deep as it will go
  8. Apply another dab of epoxy onto the set screws, this time, more generous
  9. Gently place the set screws into the carbon fiber tube.
  10. Firmly press both opposing rod ends together along the tube axis.
  11. Set rod to try. Ensure that rod ends are parallel with each other.

Filament Delivery

Spool Assy

Extruders

Frame - External

Bed

Wiring

Fan I/O

The RAMPS_1.4 board does not by default have sufficient IO to power three heaters and additional fans for the extruder heaters. Products exist already to serve this need, but I decided to build my own. I added a constant 12V drop for a always-on stepper driver cooling fan (so long as PS-ON is on), and a PWM circuit for a single extruder cooling fan. I shall use only one fan for both extruders.


BOM

The BOM for COssel is large, thus has been collapsed to not overflow the page. Expand the table below for a flat Bill of Material for procurement! The BOM is also formally maintained here in Microsoft Excel format (.xlsm): cOssel BOM.

Part Total Qty Vendor MFG PN Vendor PN Notes Link
2020_cap 16 Misumi HFC5-2020 HFC5-2020 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [1]
2020-134mm 1 Misumi HFS5-2020-134 HFS5-2020-134 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [2]
2020-200mm 3 Misumi HFS5-2020-200 HFS5-2020-200 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [3]
2020-300mm 7 Misumi HFS5-2020-300 HFS5-2020-300 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [4]
2020-371mm 7 Misumi HFS5-2020-371 HFS5-2020-371 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [5]
2020-50mm 2 Misumi HFS5-2020-50 HFS5-2020-50 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [6]
2020-800mm 3 Misumi HFS5-2020-800 HFS5-2020-800 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [7]
bearing_608z 4 Amazon 608z 608z Easily sourced [8]
bearing_624z 6 Amazon 624z 624z Easily sourced [9]
bed_glass 1 (no vendor data entered) 300mm beds appear to be scare at the moment. Looking into sources. 250mm from TrinityLabs may need to be an interim substitue.
belt_gt2_1700mm 3 OpenBuilds Order by the foot. 304.8 mm / ft! [10]
bracket_heater_sppt_wood 1 Ponoko Wooden piece. Laser cutting files on GitHub & ponoko [11]
bracket_hot_end_groovemount_dual 1 Ponoko Wooden piece. Laser cutting files on GitHub & ponoko [12]
bracket_power_supply_stablity_xy 1 Ponoko Wooden piece. Laser cutting files on GitHub & ponoko [13]
bracket_tee_2020 9 Misumui HBLFSN5 HBLFSN5 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order. [14]
cable_ribbon_10_conductor_15ft 2 SparkFun Used for bulk-running the opto +V, SIG, & GND to the board. Also used for clean motor runs and I/O to the EE. Note, some have suggested this is too thin of wire gauge. User to decide [15]
drive_filament_dia 2 RepRap Sources Mk7-like with 8mm bore to be compatible with phidgets geared steppers. [16]
epoxy_two_part 1 Amazon For gluing the rod ends to the carbon tubing [17]
extruder_maker_gear 2 MakerGear Make sure to configure your order for 1.75 barrel. [18]
fan_40mm_12VDC 2 Amazon Most 40mm 12VDC fans should do the trick [19]
fitting_one_touch_4mm 4 Amazon KQ2S04-M5A KQ2S04-M5A 5mm thread req'd and 4mm OD tube receptable req'd [20]
gear_drive_belt_gt2 3 OpenBuilds 20 tooth or less is critical to prevent the belt from hitting the carriage [21]
motor_nema_17 3 Ultimachine Std reprap motor [22]
motor_nema_17_geared_5.18_1 2 Phidgets Extra torque required for long bowden path to hot end [23]
nut_extr_m4 79 Misumi HNTTBS5-4 HNTTBS5-4 Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order.
nut_extr_m5 (open_rail_kit_excess) 69 OpenBuilds Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.
nut_m3 35 Fastenal Nylon lock preferred [24]
nut_m3_jam 13 Fastenal Jam [25]
nut_m4 8 Fastenal Nylon lock preferred [26]
open_rail_bearing 24 OpenBuilds Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.
open_rail_nut_m5 14 OpenBuilds Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.
open_rail_scrw_m5_std_wheel_mnt 12 OpenBuilds Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.
open_rail_shim 9 OpenBuilds Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.
open_rail_shim_eccentric 6 OpenBuilds Stock availability can be shaky. May need to adapt a different eccentric nut. [27]
open_rail_spacer_bearing 12 OpenBuilds Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.
open_rail_wheel_delrin 6 OpenBuilds Wheel kit [28]
open_rail_wheel_sst 6 OpenBuilds Wheel kit [29]
open_rail-700mm 3 OpenBuilds Order the 1000mm's and cut to length [30]
pcb_arduino_mega 1 Ultimachine Note: The RAMPS stack below includes a MEGA 2560. Make sure not to double buy! [31]
pcb_fan_extension_board 1 Geeetech Or make your own! cdaringe opto-extension board [32]
pcb_heater 1 Ultimachine Prusa Heater [33]
pcb_opto 3 Ultimachine Std opto's [34]
pcb_RAMPS_stack 1 Ultimachine Single Z, not dual Z configuration. [35]
pcb_sd_ramps_extension_board 1 Geeetech Strongly recommended as pausing issues occur when printing via USB [36]
power_supply 1 Thermaltake TR2 TR-700 TR2 TR-700 ATX PS. Quiet, reliable. [37]
rod_carbon_330mm 6 Hobby-Lobby Must be cut to size. 3x 1000 rods will satisfy a std build [38]
rod_ends 12 Amazon 5347 5347 4mm OD receptable, 3mm thru-hole ball-ends [39]
rod_threaded_8mm-271mm 1 Grainger 5/16" rod is ~8mm too. You can buy 5/16" rod at hardware stores (i.e. Home Depot) for a couple of bucks. [40]
rp_base_vertex 3 RP RP RP Files on GitHub
rp_block_bed 3 RP RP RP Files on GitHub
rp_bracket_axle_spool 3 RP RP RP Files on GitHub
rp_bracket_lateral_sppt 4 RP RP RP Files on GitHub
rp_bracket_lateral_sppt_mirrored 4 RP RP RP Files on GitHub
rp_bracket_pwr_spply_tab 2 RP RP RP Files on GitHub
rp_bracket_RAMPS 1 RP RP RP Files on GitHub
rp_extruder_join_lower 1 RP RP RP Files on GitHub
rp_extruder_join_upper 1 RP RP RP Files on GitHub
rp_fan_mount_motor_drivers 1 RP RP RP Files on GitHub
rp_flag_carriage 3 RP RP RP Files on GitHub
rp_idler 1 RP RP RP Files on GitHub
rp_idler_boss_bearing_8mm 2 RP RP RP Files on GitHub
rp_idler_mirrored 1 RP RP RP Files on GitHub
rp_idler_strut 2 RP RP RP Files on GitHub
rp_mount_fan_ee 1 RP RP RP Files on GitHub
rp_opto_mount 3 RP RP RP Files on GitHub
rp_plate_slider 3 RP RP RP Files on GitHub
rp_ram 3 RP RP RP Files on GitHub
rp_upper_vertex 3 RP RP RP Files on GitHub
scrw_finish_#6 1 Fastenal Thermal switch is not required, but strongly recommended for safety
scrw_m3_10 8 Fastenal Pan head & SST preferred when applicable.
scrw_m3_12 18 Fastenal Pan head & SST preferred when applicable.
scrw_m3_15 14 Fastenal Pan head & SST preferred when applicable.
scrw_m3_20 17 Fastenal Pan head & SST preferred when applicable.
scrw_m3_25 2 Fastenal Pan head & SST preferred when applicable.
scrw_m3_35 2 Fastenal Pan head & SST preferred when applicable.
scrw_m3_50 4 Fastenal Pan head & SST preferred when applicable.
scrw_m3_set 5 Fastenal Only order this if your timing pulleys and filament drive gear do not come with their own. They nearly always do.
scrw_m4_10 47 Fastenal Pan head & SST preferred when applicable.
scrw_m4_12 12 Fastenal Pan head & SST preferred when applicable.
scrw_m4_15 25 Fastenal Pan head & SST preferred when applicable.
scrw_m4_25 4 Fastenal Pan head & SST preferred when applicable.
scrw_m4_8 22 Fastenal Pan head & SST preferred when applicable.
scrw_m4_set_20 12 Fastenal Rod End Mounts [41]
scrw_m5_10 (open_rail_kit_excess) 67 OpenBuilds Do not order directly for hardware. Hardware comes kitted with your rail. [42]
spring_m3_extruder 4 Home Depot Only 1x spring kit reqd [43]
spring_m4 7 Home Depot Only 1x spring kit reqd [44]
switch_thermal 1 Amazon Amico KSD301 Amico KSD301 Recommended for safety [45]
tab_felt 3 (no vendor data entered) This is a thermal barrier between the bed and the bed clamp. Simply household cloth shall suffice.
tubing_4mm_bowden_1000mm 2 MakerShop Any common RepRap 4mm tube shall suffice [46]
wire_raceway_10in 1 McMaster-Carr The 6'6" is enough for your full build [47]
wire_raceway_25in 1 McMaster-Carr The 6'6" is enough for your full build [48]
wire_raceway_5in 2 McMaster-Carr The 6'6" is enough for your full build [49]
wire_raceway_8in 1 McMaster-Carr The 6'6" is enough for your full build [50]
wire_wrap_10ft 1 McMaster-Carr Pick a color! You may use 8+ ft. [51]
wshr_4mm 8 Fastenal SST preferred
wshr_m3 69 Fastenal SST preferred
wshr_m4 115 Fastenal SST preferred
wshr_m4_fender 6 Fastenal SST preferred [52]

Images