Rostock MAX

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Revision as of 09:35, 8 November 2012 by Johnoly99 (talk | contribs) (Bill of Materials)
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Rostock MAX

Release status: working

Description
Rostock MAX is a delta robot 3D printer based upon Johann's origional.
License
Author
Contributors
Based-on
Categories
CAD Models
See BOM for links to files
External Link




Rostock MAX by SeeMeCNC.com


Introduction

Rostock MAX is based upon Johann's origional Rostock Delta Printer Prototype. It features T-Slot extrusion for the linear motion ( cheapskate ) and laser cut acrylic OR plywood framework. The lower wrap piece around the bottom hides the electronics, but it's removeable to show off all the acrylic/plywood and electronics if you want.


Photos

250px Rostock max small.jpg Upperidlerrensioner.jpg Withrambo.jpg Blinkyside.jpg Morepowah.jpg IMAG1184.jpg 250px Concept for triple hot-end 250px 250px 250px 250px


Videos

http://youtube.com/seemecnc


Bill of Materials

The following BOM is for completing a Rostock MAX. You may substitute many of the hardware pieces for metric equivalents if you have easier access to them, we tried to make sure that it would accept both where possible.


Feel free to add any other items not listed below here, by you the users

Electronics

RAMBo by UltiMachine is what is being used on the prototypes. RAMPS 1.4 has been used as well. You only need 4 stepper drivers, 3 limit switch inputs, and two heating circuits (if using a heated bed) so any board capable of those requirements should be acceptable.

450W ATX PSU is used to run all electronics, the lower acrylic panels have mounts for a standard ATX PSU, as well as RAMPS 1.4, RAMBo and universal mounting holes for other electronics.

Firmware

The Rostock MAX uses Delta based firmware. The firmware can be found at https://github.com/johnoly99/Marlin-for-rostockmax-rambo. That firmware can also be used on RAMPS or other electronics. It is Marlin RC2, But has Johann's delta mods, Tonokip's RAMBo mods, and johnoly99's MAX mods.

All of the settings relating to the delta geometry is located in the first marlin.pde file. The settings in the version linked above are maintained to work on the Rostock MAX, but changing the delta geometry could make it work on other 3 column parallel delta bots as well.

Assembly

STEP 1 ...

Motors

4 NEMA 17 stepper motors are needed. There is one motor for each of the three delta arms, and one for the extruder. You can substitute NEMA 11 thru 17 motors on the extruder, but the arms need more torque to lift the carriage.

Motors used in SeeMeCNC kits are

42BYGHW811

Other motors that should work well are

42BYGHW804

If you use other motors, be sure to list them and their performance here please.

NEMA 17's uses M3 X.5-10mm mounting screws.

Endstops

Uses 3 mechanical endstops located at the TOP of each column. Endstops are actuated and adjusted by screws located on the cheapskate slides.

Belts and Pulleys

The three columns use 74" long (~1900mm long) GT2 2mm pitch x 6mm wide open ended belt. 15 tooth machined aluminum pulleys are used on the prototype to increase torque and positioning accuracy.

Calibration

Because the Rostock MAX (as well as other deltas) use the X Y and Z axes to drive the columns up/down, the steps per mm MUST be the same for all 3 axes as well as the acceleration values. For the Rostock MAX, the default steps per mm using the 15 tooth timing pulleys and the Rambo electronics are 53.333 for the X Y and Z, and 292.000 for the extruder. All these values are based on 1/8 stepping, so you can modify these values for your own electronics.


The First step is to make sure each tower/arm is moving parallel to the table. To do this, home the machine by sending G28. Then, jog the platform down to about 5mm above the print surface, at the center. Take a measurement using calipers or something as precise as you can between the top of the platform and the print surface. Now jog the platform towards the Z column, the one in the very back. Get it close to the column, but not all the way to the arms being straight up and down. Now, take a measurement again with the calipers or such. If the platform is HIGHER at the column, then move the endstop screw up by that amount, and if the platform is lower, then move the endstop screw down by that amount. Repeat this process for the other two columns, and then go once more around the three columns. This should be good enough at this point.

The next thing to calibrate is the sweeping motion of the platform across the print surface. To do this, once again home the machine out with G28. Now, jog the platform down to about 5mm above the surface. Using your calipers etc... make a measurement as you did above. Now make slow (~1000mm/min) moves from X0 Y0 to X100 Y0 and measure the platform again. If the platform is raising "up" as it travels away from the center (X0 Y0) then you need to decrease the #define DELTA_SMOOTH_ROD_OFFSET. If it's lowering down, increase the #define DELTA_SMOOTH_ROD_OFFSET. Start by making .5mm changes to the value, and decrease the amount of the change as you get closer to perfect parallel movement.

Slic3r Settings

Print test rmax.jpg

The following settings were used to calibrate retraction on the hollower pyramid thing at http://www.thingiverse.com/thing:29429. Filament used was Makerbot 1.8mm Silver ABS. Use these settings for a good general baseline for printing. You can increase the print speed, but you may need to increase hotend temps as you increase speed above 35mm/sec. 235C+ is looking to print well at 35mm/sec speeds



.3 layer height

2 perimeters

0% infill (hollow)

30mm/sec speeds for everything except for external perimeters at 80%

300mm/sec travel speed

228C extruder temp

slow down if print time is below 25 seconds

minimum print speed set to 6mm/sec

10mm retraction @ 55mm/sec retraction speed

0 Z lift

0 extra length on restart

3mm minimum travel after retraction

Further reading

Rostock MAX B.O.M.}
Quantity Description Notes
Reference STL's of ALL PARTS File:10-11-12 ROSTOCK MAX RELEASE BY PARTDADDY SEEMECNC.zip These are .stl files of all parts for reference if needed
Qty. 1 Set DWG of only LASER PARTS File:DWG 10-11-12 ROSTOCK MAX LASERFILES BY PARTDADDY SEEMECNC.zip These parts are may have modifications as time goes on, but they are a good baseline
Qty. 3 32" long 1" T Slot Have found that 20mm Misumi and 80/20 1" or 80/20 metric work equally as well
Qty. 24 608ZZ Ball Bearings Standard 608 Skate Bearings
Qty. 16 M3-.5 x 10mm L Pan Head Phillips nema motor mounting screws
Qty. 6 M3-.5 x 6mm L Pan head Phillips For attaching the motor pulleys
Qty. 1 Electronics Control RAMPS, RAMBo, Sanguino etc... At the moment, printrboard doesn't have enough memory to support delta firmwares
Qty. 4 Nema 17 Size Stepper Motors 42BYG811 or 42BYG804 or similar, 3 for the vertical axes and one for the extruder
Qty. 1 Optional Heated Bed This is a must have for ABS. You can use a Phebe, Prusa PCB, or fab your own. Laser files have mount for Phebe from SeeMeCNC
Qty. 1 Hotend Laser files have the mounts etc... for use with SeeMeCNC's own hotend
Qty. 1 Extruder Laser files have the mounts etc.. for use with SeeMeCNC's "Steve's Extruder" setup for bowden drive
Qty. 1 ATX PSU The mounts are on the laser files for a standard ATX PC power supply, If using a heated bed, use at least 400w
Qty. 3 15 Tooth Motor Pulley GT2 2mm pitch timing belt pulley, origional uses 40 tooth, you can use anything from 15 on up
Qty. 3 GT2 2mm pitch x 1905mm open-ended is fine, and neoprene works fine
Qty. 12 CNC Machined U-joints from SeeMeCNC
Qty. 18 Idler Bearing Spacers from SeeMeCNC
Qty. 12 Cheapskate Eccentric tensioner Cams from SeeMeCNC
Qty. 18 Cheapskate Fixed Bearing Spacer from SeeMeCNC Qty. 6 2-56 X 5/8" Screws For Endstops
Qty. 6 2-56 Nuts For Endstops
Qty. 100 6-32 Nylon Locknuts
Qty. 65 6-32 X 1" Flat Head screws
Qty. 6 6-32 X 5/8" Socket Head Cap Screws (SHCS)
Qty. 21 6-32 X 2" SHCS from SeeMeCNC
Qty. 9 6-32 X 1 3/4" SHCS
Qty. 25 1/4-20 T Slot nuts For sliding in the t slot channels
Qty. 25 1/4-20 X 1/2" Button Head Screws For t slot nuts
Qty. 6 10-32 X 5/8" Pan Head Screws NYLON for mounting feet
Qty. 6 10-32 Nylon finish nuts For mounting feet
Qty. 6 Rubber Feet You can use any kind of rubbery foot on the bottom, we use our rubber feet
Qty. 26 #4 SAE Flat Washer
Qty. 12 #4 X 1/4" Sheet Metal Screw (SMS)
Qty. 12 #4 X 3/8" SMS
Qty. 27 4-40 Blind T-Nuts These are the kind that press in from the back side and have barbs that keep them from turning
Qty. 4 4-40 X 1 1/4" Pan Head Screws
Qty. 12 4-40 X 3/4" Pan Head Screws
Qty. 12 4-40 X 1/2" Pan Head Screws
Qty. 4 6-32 X 1/2" Nylon Pan Head For mounting the ATX PS
Qty. 50 #6 SAE Flat Washer
Qty. 30 Acetal Bearing slip-on covers These are the tapered acetal pieces that slip over a 608 to ride on the t slot extrusion
Qty. 6 1/8" dia. X 3 1/8" L axle/dowel These are the axles that hold the U-joints to the carriages/platform
Qty. 3 3/8" OD X 9/64 ID X 1" aluminum bushing These are used to space the hotend plate up off the platform for more Z travel
Qty. 2ft 2mm ID X 4mm OD Teflon Tubing This is the material for the Bowden Tube
Qty. 2 4mm PTC fittings These connect the bowden tube from the extruder to the hotend
Qty. 6 Parallel Delta Arms From SeeMeCNC
Qty. 6 Folding Belt Clamps These can be printed or purchased from SeeMeCNC
Qty. 3 Carriage U-Joint Mounts These are in the .stl files, can be purchased from SeeMeCNC
Qty. 1 Platform You can use the origional Johann platform, or the injection molded SeeMeCNC Platform halves (2 halves from SeeMe)
Qty. 20 1/8" ID X 1/4" OD Spacers These are used as standoffs under the heated bed mount and electronics (SeeMeCNC supplies acetal spacers)
Qty. 1 Switch for PSU You can use a switch between the green wire and a ground wire on a PS to turn it on/off
Qty. 1 1/8" Stickralon(tm) Polycarbonate Build plate Stickralon is a polycarbonate material found by SeeMeCNC to be awesome as use for a build surface!
Qty. 4-6 Small Binder Clips Also called bulldog clips, used to hold the build plate on
Qty. 12 small zip ties for fastening wiring and making it cleaner
Qty. 2 Spool Axles For supporting the filament spool on the extruder mount (lasercut or printed)
Qty. 1 Hot-End Spacer 1/2" ID X 3/4" OD X 1/4" thick wood/aluminum spacer for the hotend where it mounts to the upper part of the platform
Qty. 1 1/8" PVC or flexible material for bottom wrap 6 1/8" wide by 48" long, can be PVC signboard, plywood, polycarb, anyting flexible enough to wrap around and enclose the electronics if you want to
Qty. 4 10-32 X 1/2" Nylon Thumb Screws Used to hold the decorative PVC warp on the base of the machine