Difference between revisions of "Nixal Mini Kossel"

Latest revision as of 07:41, 26 August 2017

This is the project page of my (nixal) build of mini Kossel 3D printer
bitbucket

REPRAP LINKS

reprap MOST LINKS BELOW FROM THIS REPRAP PAGE
think3dprint3d at UK
deltaprinter-parts
Misumi 15x15 Aluminium profile

 5mm bore at one end, while the other end is threaded to fit a M5 threaded rod

builda3dprinter.eu Seperate Parts
misumi-europe.com UK
$289 no shipping cost for Ireland kit

Linear Guides

Used by Johann: Acetal Sphere, Polished, Opaque White, Standard Tolerance, 3/16" Diameter (Pack of 100)

Kossel Mini MGN12 12mm miniature linear rail slide = 3pcs 12mm L-400mm rail+3pcs MGN12H carriage for X Y Z axis ordered this

Build Manuals

Build Videos

Kossel Mini 3D printer build and first print

Demo Videos

550 mm sec moves
170 perimeters
190 infill
4500 acceleration

Smoothieboard powered delta 3d printer extreme speed

550mm sec moves
5500 acceleration
160mm infill
90 perims
.30 layers.
1/16th microstepping with allegro 4982 drivers.
much less resonance and buzzing than drv8825 powered x5 and half the microsteps also!

nixal speed configuration

Azteeg X5 powered delta is controlled by smoothie-board, so the setting might be too fast for Arduino-Mega. TO BE TESTED^{Opinion: Nikos:07.03.2016}

Parameter	Video Value	nixal old value	nixal new value	Comments
Perimeters	170	120	170
Infill	190	160	190
non Print moves	550	200	550
Acceleration	4500	0	4500	nixal: Change all 5 to 4500,
Max Print speed		220	600

KIT

SINTRON at Aliexpress $370

BOM

PARTS

E3D Nozzle

E3D-online Nozzles

Nozzle Size	1.75mm	3.00mm	Application	                        ID Dots*
0.25mm	●	£7.50	£7.50	High Precision - Slower Prints	        0
0.30mm	●	£6.50	£6.50	 	                                1
0.35mm	●	£5.50	£5.50	 	                                2
0.40mm	●	£4.50	£4.50	Balanced Nozzle - Supplied by Default	3
0.50mm	●	£4.50	£4.50	 	                                6
0.60mm	●	£4.50	£4.50	 	                                4
0.80mm	●	£4.50	£4.50	Lower Precision - High Speed	        5

SILENTSTEPSTICK TMC2100

Hardware compatible with StepStick and Pololu A4988
Drive capability up to 1.2A (RMS) continuous coil current
Step/Dir interface with microstep interpolation (up to 256 microsteps)
otor voltage: 5...45V
stealthChop - for quiet operation and smooth motion
spreadCycle - highly dynamic motor control chopper

3D printer parts StepStick MKS TMC2100 stepper motor driver ultra-silent excellent stability and protection aliexpress € 7,30 / piece shipping 2-3eur/pc decreases with quantity

Free heatsink
Price for 4 pcs including shipping cost € 35,13 (7.2€ x 4 + 6.33€)

Ordered Parts

ALL KOSSEL PARTS^{Ordered: 28.12.2015}705.82€

Ordered in Sorted Table

Vendor	Shipp from	Date	Material(s)	Cost/pc	QTY	Q.Cost	Tax	S.Cost	Total	Delivered	Purchase notes	Reviews & Additional notes
E3D NOZZLES	UK	20160216	Nozzle E3D 0.4mm^{Ordered: 16.02.2016}17.5€	£4.50	2	£9	£2.22	£2.10	£13.32	20160219
Watterot	DE	20160217	Watterot SilentStepStick TMC2100^{Ordered: 17.02.2016}22.15€	9,95€+2,20€	1+1	9,95€+2,20€	3,54€	10,00€	22,15€	22.02.2016	heatisink@2.2€, shiping via DHL @ 10€ is expensive, Available also at Aliexpress	If this board is really silent then can upgrade noisy 3D printers and remove BLDC from LF-Pick-Place
E3D PTFE Bowden Tubing (100mm) (1.75mm Filament)	UK	20160216	PTFE tube for 1.75 fillament^{Ordered: 21.02.2016}6.5€	£0.33	6	£1.98	£0.82	£2.10	£4.90	pending
E3D Volcano Block and Fixings	UK	20160216	Volcano Block & Nozzle 0.4mm^{Ordered: 21.02.2016}34.70€	£15.00+£4.50	1+1	£19.50	£4.32	£2.10	£25.92	delivered		ordered for easier flow, compact bowden was too streched
E3D Volcano nozzles & 8mm Bushings	UK	20160305	Bushing 8mm, GT2 Spring, Volcano Nozzle 0.4mm, 1.2mm,7mm Nozzle Spanner ^{Ordered: 05.03.2016}23.51€	£15.00+£4.50				£2.10	£17.52	delivered		to test Volcano, and future design with 8mm Bushings
E3D Replace damaged Heater and Thermistor	UK	20160320	Fibreglass Sleeving for Insulating Thermistors (100mm) Heater Cartridge - 12v 40w 100k Ohm NTC Thermistor - Semitec^{Ordered: 20.03.2016}£12.42£	£0.25+£4.50+£3.50	1+1+1	£8.25	£2.07	£2.10	£12.42	pending		To replace the damaged Thermistor and Heater during volcano testing

To order

The heater is rated at 10 A, giving an output of 120W at 12V, 
and supplied complete with a MF58104F3950 thermistor which you should Kapton-tape to the centre of the aluminium plate.  
Wires are prepared for fitting to RAMPS board fitted at the base of the Kossel. 
... they heat up significantly faster than standard PCB heatbeds because of the higher power density (6kW/m2 vs 3kW/m2)

Kapton Bed Heater 160mm Round buildakossel €14.00 Ex. VAT

Kapton bed heater with a 160mm diameter. Used in the Kossel Mini. Lead wires are 1 meter in length.
Delivered with a 3950 100k thermistor. Select type 8 as your temp sensor type in Marlin Firmware

Aluminium heat-bed plate for Mini Kossel Diameter: 200mm Thickness: 3mm think3dprint3d price £6.00

STL

Item	Link	Source	Description	Deployed	Usage	[NIXAL] Reviews & Additional notes
01.02	Kossel Mini E3D Effector Redux by AndrewBCN, published Apr 1, 2015	OpenScad		YES	This used due to lower weight, E3D, customisable
03&04.21	Kossel carriage with implant screw support for belt tension and endstop trigger adjustable by dcchi007, published Jun 1, 2015			YES
12&13.13	Sturdy Leg With Adjustable Foot For Kossel by GunghoLabs, published Nov 18, 2015			YES
14.15	Mini Kossel Frame Brace by elmuchacho, published Jan 8, 2015			YES
15.17	Kossel Clear Arduino Mega 2560 Mounting Bracket by SteffenL, published Jan 16, 2014			YES
16.19	Auto bed leveling using piezo discs - Remixed by inornate, published Oct 24, 2015			YES		Not used with piezo yet
17.16	Kossel Filament guide for top mount spool by M4vrick, published Apr 12, 2015			YES
01	Compact Bowden Extruder, direct drive 1.75mm by schlotzz, published Mar 19, 2014				MK8 gear creates issues, replaced with MK7 design by Tech2C
03	Mini Kossel Retractable Auto Bed Leveling Probe (for use with larger hotends) by ianlee74, published Nov 22, 2013				abandoned
18.04	Cable Clip for aluminium extrusions, parametrizable by schlotzz, published Mar 15, 2015
05	RAMPS 1.4 Fan Mount, 40mm, parametrizable by schlotzz, published Sep 4, 2013
06	Kossel Mini SmartLCD-Case by schlotzz, published May 4, 2014			YES
07	MOAB - MOther of All fan Brackets Made by AndrewBCN, uploaded Nov 20, 2014				abandoned
08	Misumi extrusion 1515 wiring clip by MasterAnubis, published Nov 16, 2014
09	Kossel Mini Custom Z Probe Retractable - 3mm probe by kalazzerx, published May 1, 2014
10	RAMPS 1.4 / Mega Holder MOUNT on 2020/1515 Extrusion by yik_cheung, published Feb 26, 2014
11	Kossel mini RAMPS 1.4 mount by gtrick90, published Jan 28, 2015
12	Mini Kossel Frame Riser by oliasmage, published Mar 2, 2015
14	E3D v6 hotend complete mount (with groove) for Kossel mini 3D printer by gtrick90, published Feb 7, 2015
18	Mini Kossel 120mm Fan Mount by Scuttlebot, published Jun 10, 2014
20	Kossel Mini 120mm Fan Stand by ynchow01, published Jan 20, 2016
22	Compact Bowden Extruder, 1.75mm Filament for MK7 Drive Gear by Tech2C, published Apr 12, 2015, youtube		Edited the schlotzz openscad file dimensions for the larger MK7 drive gear			Very weak, at least if printed in PLA - not working!!!^{Opinion: Nikos:21.02.2016}
23	Compact Bowden extruder, direct drive, bearing bloc, auto load 1.75mm filament by scarou, published Feb 6, 2015			YES		This one worked fine, this design is much better than original^{Opinion: Nikos:21.02.2015}
24	Piggyback layercooling fanduct for e3d-v6 hotend by RoPa, published Jan 13, 2016
25	Power Switch by Winne, published Apr 19, 2015	scad				rs CWSB21AA2F
26	3D v6 Hotend - 40mm Fan Duct by loco, published Jun 5, 2014

Z probe

Firmware

Olimex AVR-ISP-MK2

used this for WIN10 driver: Recommended drivers for Windows 10

Johann C. Rocholl Marlin at github
Arduino Previous IDE Releases use version 1.0.5
... slightly modified copy of Rich Cattell’s version of Marlin, which I’ve named Marlin_RC_master
Arduino Monochrom Graphics Library for LCDs and OLEDs at github by olikraus
A lean, high speed I2C LCD Library for Arduino, which supports MCP23008 and MCP23017 at github by lincomatic
fixes & updates to the Arduino SD library - totally in progress. works but in beta at github by adafruit
printrun use it only for calibration, then go with repetier host. Can comunicate with both Marlin and Repetier-firmware
Repetier Firmware

Calibration

Adjust Endstop Trigger Points

Kossel Mini - feedback and tweaks

it is easier to use Repetier Host macros

G28 G1 X-76 Y-43 Z20 F7000 Home the printer and Move the extruder to just in front of the X pillar [macro 1]
G28 G1 X76  Y-43 Z20 F7000                                                                Y        [macro 2]
G28 G1 X0   Y85  Z20 F7000                                                                Z        [macro 3]
Lower the extruder  until 80g/m2 paper just drugs on the nozzle
M114 and note Z, (nothing more for X)                                                              [macro 5]
Adjust the  screw on top of the Y,Z, carriage to raise or lower the trigger point (FOR Y,Z)
Repeat steps until the Z height noted is the same as that recorded for the X axis (FOR Y,Z)
#define MANUAL_Z_HOME_POS INITIAL-Z_X //Marlin  ...and compile, reload firmware

The endstop trigger points are now all within 0.1mm of each other

Calibrate the firmware to print flat

Calibrating a Delta 3D Printer -> goto 3

The value in the firmware constant DELTA_RADIUS (both Repetier and Marlin) controls the “flatness” of the movement of the carriage at a given Z height.

If DELTA_RADIUS is too large/small, the extruder nozzle will track below/above the desired Z height inside the calibrated points X, Y, and Z Adjust Endstop Trigger Points.
for Marlin: DELTA_RADIUS = DELTA_SMOOTH_ROD_OFFSET - DELTA_EFFECTOR_OFFSET -DELTA_CARRIAGE_OFFSET
To correct the problem, the best course is to change one of the variables set earlier to force the value of DELTA_RADIUS to increase(to lower the extruder nozzle) or to decrease (to raise the nozzle).

G28 G1 X0 Y0 Z0 F7000     [macro 4] The extruder nozzle will be above the build surface, at just the right height (using the paper test), or will hit the build surface.
increase DELTA_RADIUS by increasing DELTA_SMOOTH_ROD_OFFSET(Marlin) To lower the extruder nozzle
decrease DELTA_RADIUS by decreasing  DELTA_SMOOTH_ROD_OFFSET(Marlin) To raise the extruder nozzle,

Next, repeat the Adjust Endstop Trigger Points calibration process .
Changing the DELTA_RADIUS changes the Adjust Endstop Trigger Points calibrations, so you must cycle through the process again.

And when the Adjust Endstop Trigger Points are set, test the center again.

You may have to repeat this a few times with smaller changes to DELTA_RADIUS, but eventually, the drag on a piece of paper should be the same at all four locations. Now the printer knows how to print flat at a given Z height.

RepetierHost configuration

Backing Up Repetier 3D Printer Settings Posted on August 11, 2013 by daveItalic text

Backing Up (Done on the old machine)

Launch regedit.exe and browse to HKEY_CURRENT_USER\Software\Repetier then right click on the Repetier Folder and select Export.  
      Save this file someplace safe.  Example RepetierRegistry.reg
Browse to C:\Users\dave.HUNTGANG\AppData\Local\RepetierHost and copy all of these files to someplace safe [nikos: F:\prj\REPETIER]
Browse to C:\Users\dave.HUNTGANG\AppData\Roaming\Slic3r and copy these files to someplace safe [nikos: F:\prj\REPETIER]
Note: The folder dave.HUNTGANG should be replaced with the name of your user account

Restoring (Done on new computer)

Double click on your Repetier Registry settings file.  Example RepetierRegistry.reg
Browse to C:\Users\newprofile\AppData\Local\ and restore the RepetierHost folder [nikos: this can be somewhere elese like: F:\prj\REPETIER]
Browse to C:\Users\newprofile\AppData\Roaming\ and restore the Slic3r folder     [nikos: this can be somewhere elese like: F:\prj\REPETIER]
Now simply Install Repetier Host from their website and you should be good to go!

MK8 Gear

PID auto calibration Marlin

Setup the thermal environment like Fans, room temperature:
Auto calibrate PID for (example) 200 Celsius in 5 iterations

M303 S200 C5

This powers the heater and cycles the heating. When finished prints the Kp,Ki,Kd

Set the P,I,D values that were produced from M303 in use:

M301 Pxx.XX Ixx.xx Dxx.xx

Store to EEPROM:

M500

Retraction

Small blobs since changing to E3D hot end

I suggest you reread the E3D page . . . 2mm is for standard extruders . . . for Bowden, they suggest starting at 5mm:
"Excessively long retractions will cause issues by dragging soft filament into cold areas, 
because of the PTFE liner however Lite6 can cope with quite aggressive retractions without sticking. 
For direct extrusion systems you should use anywhere from 0.5mm-2.0mm, 
for bowden systems you might want to go up to 6mm. 
Retraction beyond 8mm should never be necessary. A good starting point for direct systems is 1mm, and 5mm for bowden setups."

...I solved this problem by increasing retraction to 8mm.

Calculation of steps/mm for Marlin

PULLEY 20 ΤΕΕΤΗ

(FULL_STEPS_PER_REV/ACTIVE_PERIMETER) * MICROSTEPS
(200/40)                              * 32              1.8 DEG/STEP->200_STEPS/REV, 20 TEETH * 2mm PITCH -> 40mm ACTIVE PERIMETER, 32 MICROSTEPS
5                                     * 32              
160

MK8 GEAR

(FULL_STEPS_PER_REV/ACTIVE_PERIMETER) * MICROSTEPS
(200/22)                              * 32              1.8 DEG/STEP->200_STEPS/REV, 7mm DIA * π->22mm ACTIVE PERIMETER, 32 MICROSTEPS
9.09                                  * 32              
291