IN DEVELOPMENT BigBox Dual X Carriages (Direct)

Discussion in 'Guides, Mods, and Upgrades' started by Greg Holloway, Oct 13, 2016.

  1. Greg Holloway

    Greg Holloway Administrator
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    BigBox_IDEX_Direct.png

    This is not the official release and is only for beta testing.


    This is a development thread. Please try to stay on topic and avoid questions like "I see you have a mirrored Titan, when can I get one?" as they will go unanswered and will not serve to help anyone.

    Hardware

    You will need in addition to what you should already have...
    • 2 x NEMA 14 Motors (34mm).
    • 1 x Stepper Driver.
    • 1 x 1700mm Motor Cable.
    • 2 x Additional LM8LUU Bearings.
    • 1 x 20T GT2 Pulley.
    • 1 x Endstop.
    • 2 x M4 20mm Grub Screw.
    • 1 x Single-Ended Dragchain.
    • 2 x Meters of GT2 6mm Belt.
    • 1 x 40x40x20 Blower Fan (requires 2 in total).
    You will need a range of M3 screws and square nuts I do not have quantities or lengths at this time. I recommend batch buying a selection of lengths from 6mm up to 20mm.

    Firmware

    For now there is no firmware, I am using a heavily modified version of Marlin RC6, which is being used for other purposes.

    Start with a fresh version of either RC6 or RC7. You'll need to edition configuration_adv.h to enable Dual X and use the 6th stepper driver slot for the additional axis. I will try and edit a stock version when I have some time. You're a clever bunch, I'm sure you'll figure it out.

    Slicer Profiles

    You'll have to script your own. Adapt it from a BigBox Dual profile.

    Points to note

    • There is a loss of build space in both X & Y.
    • M218 offsets work only in Y & Z, X must be done in the slicer for some reason.
    • There is no need to level the two heads so they are at the same height!
    • To get the best the bed needs to move forward ~30mm.

    Obstacles

    To get the best from the Dual X system the bed needs to move forwards ~30mm. There are two ways to do this.

    1. Modify the bed assembly either with printed parts or something else and move the bed PCB forwards 30mm.
    2. Fit alternative laser-cut parts which move the whole Z-Axis forwards 30mm. DXFs will be available soon.
    I have a machine which has been built with option 2 and the whole Z-Axis has moved forwards 30mm. Advantages include the option for a dump/purge zone either at the front of the printer or at the rear.

    The left side requires an additional dragchain for the extra motor.

    STLs

    https://www.thingiverse.com/thing:2039361

    Printing the Parts.


    Quantities are in the file names. Some parts do require supports. The left & right fan housing should print fine without support. The STLs have been orientated for best printings.

    BigBox Dual X Carriages with Duet Wifi (and Duex)


    https://forum.e3d-online.com/index.php?threads/bigbox-dual-x-carriages-with-duet-wifi-and-duex.2207/

    BigBox IDEX Bowden

    https://forum.e3d-online.com/index.php?threads/bigbox-dual-x-carriages-bowden.2480
     
    #1 Greg Holloway, Oct 13, 2016
    Last edited: Feb 10, 2017
    JohnEsc, EASI3D, gearmesh and 9 others like this.
  2. Mark Curry

    Mark Curry Well-Known Member

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    • 2 x NEMA 14 Motors. What length please Greg?
    Great work!

    Cant help but think twin y rods either side would polish it off for rigidity.. (rod sag)
     
  3. Kanedias

    Kanedias Well-Known Member

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  4. PsyVision

    PsyVision Moderator
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    I'm all over this #firesupprinter
     
  5. Tom De Bie

    Tom De Bie Well-Known Member

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    Why not use 10 or even 12mm rods...
     
  6. Greg Holloway

    Greg Holloway Administrator
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    I did look into this but there is no space for the larger bearings inside the frame without major changes.
     
  7. PsyVision

    PsyVision Moderator
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    I've printed bearing_clamp_top, bearing_clamp_bottom, x_carriage_left_bearing_clamp and x_carriage_right_bearing_clamp without supports:

    [​IMG]

    Next up are motor_left and motor_right. It looks as though these may benefit from some support.
     
    #7 PsyVision, Oct 13, 2016
    Last edited: Oct 13, 2016
  8. Mark Curry

    Mark Curry Well-Known Member

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    Looks delicious Psy... black doesn't do it for me either.

    Thought you would be up and running already;)
     
  9. Alex9779

    Alex9779 Moderator
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    As far as I can see there is enough space on each carriage for the IR sensor... The sensor is approx 18mm high and the space between the bottom of the carriage and the nozzle is about 23mm.
    @dc42 so it should be possible to mount an IR sensor on each carriage and I am really looking forward that RRF will support that kind of setup...
     
  10. Alex9779

    Alex9779 Moderator
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    Greg told us in the other thread: #157
     
  11. Falc.be

    Falc.be Well-Known Member

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    You fotgot the extra stepper driver needed
     
  12. Miasmictruth

    Miasmictruth Well-Known Member

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    Anyone know a US source for 1700mm or longer stepper cables, or where to get the cable ends to make my own I cant seem to find anything that long.
     
  13. PsyVision

    PsyVision Moderator
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    The motors printed nicely with a bit of support:

    [​IMG]

    Carriages and fans tonight.
     
  14. Alex9779

    Alex9779 Moderator
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    I know the specs, they are labelled with "UL-1007 26AWG" you should find those to make them longer, I am still struggeling finding the right connector and PINs to make a whole cable on my own. I mean the connectors on the motors, for connection to the boards I have them...
     
  15. PsyVision

    PsyVision Moderator
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  16. PsyVision

    PsyVision Moderator
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    I had an idea about moving the bed forward... designing new corner nut traps and corner tops that move the metal standoffs forward 3cm. It might make the bed a bit front heavy but might be a suitable temporary fix.
     
  17. Greg Holloway

    Greg Holloway Administrator
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    I've got a ~2 day print running testing the new setup.

    2016-10-14 08.26.48.jpg

    What you can see are the perimeters being printed in Edge Dark Crystal and the infill is PLA Glow in the Dark.

    design.jpg

    The design is that of a bomb, the internal is hollow so I can put an LED light inside. The hope is that the light shines through and when switched off the bomb glows and becomes a night light. I'll be putting it onto thingiverse once I have finished it.

    sliced.jpg

    The slicing is done with a single profile. You have to set the X offset in the slicer. You can see this in effect as the infill is off to the right.

    Marlin works oddly when dealing with Dual X configurations. You have to specify the separation distance between the two nozzles when they are homed. This is about 333mm. It then calculates the correct position for X based on that number. Naturally it doesn't work and you still need to set an X offset. Which you can't.....

    The M218 code, which usually accepts a value for X, does not function for X offsets. However it does still work for Y and Z. It's a very odd setup in my opinion! Maybe this is being altered in RC7....

    The wiper at the rear has to have the rubber off to the side as the head doesn't go far back enough to do the standard dump. The STLs for it are attached. Those with the bed in it's original position will need a wiper at the front.
     

    Attached Files:

    JohnEsc and PsyVision like this.
  18. PsyVision

    PsyVision Moderator
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    That's really cool Greg. Are you finding dual prints any quicker and with less dumped filament?
     
  19. Falc.be

    Falc.be Well-Known Member

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    do I detect a different heated bed there ?
     
  20. Greg Holloway

    Greg Holloway Administrator
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    Print times are similar, the Dual X does not really cut that down. You can tweak the numbers to reduce the Ram|Purge and prime cycles, but that will work on any profile or setup.

    The dual x has three primary functions..

    1. No need to align the nozzles to each other.
    2. no potential dragging of the idle nozzles on the print.
    3. two direct extruders

    There is a trade off to these primary advantages as you will lose build volume.

    Yes, but it is not relevant to the Dual X upgrade.
     

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