More Upgrades – X axis Linear Rails

Finally got a few hours over Christmas to knock up the X axis linear rails upgrade for the printer.

Printer seems to run nicely and i’ve printed a few small things….I’ll work on quantifying any improvements next as, right now it only ‘seems’ better, and print quality improvements are really marginal. The biggest difference was on the Y axis bed, and I suspect there are now easy further improvements to be had………

Photos Below

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Side view showing the new Carriage (designed by someone else)
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The new idler mount – this was needed as existing thingverse ones don’t have space for the rail at the top
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Top down view of the new rail carriage
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side view of the new idler and it’s tension adjustment screws

First signs of life and possible ‘bugs’

Everything’s gone superbly up to now…The printer’s levelled all lovely like.

The bed moves back and forth as it should.

So, lets try a first brand new print , as I already have one printed months ago, which I broke due to not enough infill…It’ll be a good ‘benchmark’

Wanhao D9 Idler mount from Thingverse

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Err, doesn’t look great does it….The first layer went down lovely, then at some point during these first 6 or so layers, a shift happened, there’s some blobbing, and, well, it ain’t too pretty.

First thoughts are many expletives, followed by a ‘ah well, that was a fun experiment’ resignation.

The rails aren’t perfectly frictionless in their moving, but they aren’t bad either..I’ve seen worse on automated production lines….Could I be experiencing STICTION????

If so, that’s gonna be some mechanical engineering stuff i’m going to have to figure out…Whilst ‘fun’ trying to calculate stuff with excel, wikipedia and various internet forums (are the MGN12 ideal for this job? – who knows?)…..I don’t fancy being bored, typing crap out on a computer (yes, i’m blogging, typing stuff out on a computer, hopefully not crap), I want to get stuck into tinkering, printing…..

I try another print and just stand and watch……

I luckily and quickly notice an odd ‘cyclic’ type of motion happening with the pattern laying down, almost a tiny figure of 8 type of motion happening on the print head with respect to the bed…..

I have a look underneath to see what’s causing it, maybe the bearings are wobbling, or i’ve not tightend the rails properly?

In summary –

Tighten the belt holder holding nuts when you re-assemble the thing! these ones shown below…..

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Yes, tightening these two solved my odd pattern issues and layer shifting

MGN12H rails small tweaks to perfect…

Ok, the rails are on and working a treat, kind of…

The right angled fittings I purchased to secure the 20×20 extrusion to the 40×40 have some little tabs on them, I can’t find any readily available way of securely making this connection with off the shelf parts so i’ll have to grind down one side’s tabs…

The slight amount of pressure this tab is putting on the extruision is enough to twist it and stop the MGN rails from running smoothly!

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A secure 20×20 extrusion. But slightly twisted due to the small lump
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View from below…if I add a little drop down to the right hand carriage, it’ll be easy to re-use the existing limit switch by mounting it on the side of the 2020

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Close ups of the existing limit switch and the protrusions on the right angled mounting block.

Overall, minor things , but shows you should plan things a little in advance and test fit stuff before ‘going for it’

Fortunately this is nothing a quick angle grind and carriage print can’t fix….which means re-assembling the original printer to print a new bit, D’oh!

MGN12 rails update – Fitted and The printer moves!

Finally bit the bullet and stopped printing stuff long enough to shove the rails on the printer……..

And, the carriages fit perfectly!

The movement of the blocks is very nice and smooth  – though right now, no real notable difference from the V-wheels……

Continue reading “MGN12 rails update – Fitted and The printer moves!”

It’s alive! – kind of. MGN12 Rails update

Well, the MGN12H linear rail carriages fit into the new carriage adaptors I quickly knocked up in Tinkercad perfectly!

And, don’t they look lovely in Purple (great filament from 3D Filaprint)

Now, to dismantle the printer and see if the print bed tray fits…………

That’s the problem with printing stuff to upgrade a printer, iterating takes time and stuff gets dismantled waaay too much! I need a second printer :-p

MGN12H crappy linear rail bearing blocks

What’s more sensible than spending $9USD on a basic, possibly non working chinese no-name bearing block?

……..Spending hours and a few quid trying to do ’em up!

Parts I’ll need…

  • 3/32 Drill Bit (or possibly 2.4mm if it needs some play) …………..[edit, turns out a 2.4mm is too small! Looks like 2.5 is the go]
  • 3/32 Ball bearings (bound to loose a few)
  • Something to drill with
  • something to clamp down the carriage without damaging it

After a few minutes with the calipers and Tinkercad, I give you………. Continue reading “MGN12H crappy linear rail bearing blocks”

Chinese ‘cheap’ clone linear rails MGN12 Beware and a teardown

The Cheapy ‘Hiwin’ clone rails and blocks arrived a while back and they haven’t really dissapointed. By that, I mean, I kinda got what I was expecting. Still, only a small premium paid and 3 workable carriages / rails……

Continue reading “Chinese ‘cheap’ clone linear rails MGN12 Beware and a teardown”

D9 Linear rails upgrade – Bed

d9 202 wide base by 120 deep

I’ve found a solution to having a fairly stable base that’s wider than the 60mm square wheel carriages Wanhao uses…

It’s possible to create a 120mm wide base, IF you offset the mounting of the bearing blocks from the centre as can be seen above and below…

Continue reading “D9 Linear rails upgrade – Bed”

Wanhao D9-300 Linear rails upgrades…

220mm base too wide 3Just running through a few ideas in Tinkercad whilst I await some parts to arrive….it pays to mockup things before committing to a design, I’m liking how easy Tinkercad is to do something that, on the surface looks quite complex………

on My D9, looking from the front, the Y axis rails are spaced at 202mm edge to edge….so it makes sense that an approximatley 202mm deep by 202mm wide square would form the most stable base available, whilst still using the original dimensions of the frame………..

….Nope…..

 

 

The mockup above  shows a base plate of 202mm square bolted straight to the Hiwin clone rails……also shows the 325mm outline of the heated bed – it’s transparent to help visualise

Unfortunatley, having a 202mm square base for the linear rails bearing blocks has prevented the 325mm moving bed from obtaining its full travel – you can see below the the vertical line of the extruder output is not too far from the centre of the bed, even though if the bed moves forward, the bearing blocks will run off the end of the rails

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This image below shows how far the blocks need to move off the end of the rails to allow the extruder to almost reach the edge of the heated bed

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The extruder can easily reach the end of  the heated bed when the bed travels backwards – with the additional slight overhang provided by the 500mm long rails being used

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so, summary

I’m not going to be using a 200ish mm square base plate with my 4 linear rail blocks on!…

it’s looking like it’ll need to be a 200ish wide rectangle that’s hopefully not less than 100mm deep – as the linear rail blocks are 45mm!