Upgrading to Duet/Diamond

[CRPerryJr]

And so it begins...

[img]http://www.perrydice.com/images/day1.jpg[/img]

A few more things to print, and then it's time to get buzy!

[img]http://www.perrydice.com/images/day1-midnite.jpg[/img]

Midnite is wondering what the holdup is?!?

[3D-Print]

Awesome! Will follow along. Like the belt tensioner's. I love them.

What are your plans for extruder steppers?

[CRPerryJr]

Tonight I followed the RepRapPro Duet instructions and successfully installed the latest RepRapFirmware. (Release 1.09x as of this writing.) Here's a screen shot of the web interface... (Love it!)

[img]http://www.perrydice.com/images/2016-03-19.png[/img]
Larger Screenshot

[CRPerryJr]

Awesome! Will follow along. Like the belt tensioner's. I love them.

What are your plans for extruder steppers?

I picked up these guys. (I don't have them together properly yet. I wanted to get a picture for you.)
[img]http://www.perrydice.com/images/day1-extruder.jpg[/img]

[CRPerryJr]

I have successfully updated the firmware for the PanelDue and calibrated the 7" touchscreen.

[img]http://www.perrydice.com/images/day2-panel.jpg[/img]

Now to create the extension cables like 3D-Print did here and here.

I just want to send a huge THANKS to all the people that have preceded me in upgrading your printers and posted your knowledge on these forums. I couldn't attempt this without your guidance!

EDIT: I also updated the firmware over the network on the Duet and updated the DWC files. Very slick process. Thanks for your guidance mhackney!

[CRPerryJr]

I managed to finish printing the PanelDue and Duet Base today created by 3D-Print. I had a lot of issues with the 7" panel portion, and tried several times to print it, but it never came out right. (Totally something I was doing wrong, I'm sure.) So I ended up making my own version of it that just slips on over the PanelDue controller and Duet Base. I forgot to add an access port for the SD card though. I also don't have the needed wires on hand to extend the connection from the PanelDue controller to the 7" panel, so I ordered a premade one, along with some other connectors I'll be needing. I still have some printing to do for the Spool holders by JFettig and the mount for the Duet by Great_Thark.

[img]http://www.perrydice.com/images/day3-enclosure.jpg[/img]
Mojo checking out the work so far...

[img]http://www.perrydice.com/images/day3-enclosure2.jpg[/img]
Slips right on...

[img]http://www.perrydice.com/images/day3-enclosure3.jpg[/img]
Back side...

Here is a copy of the Paneldue 7" cover I designed to slip over the base made by 3D-Print.

paneldue7_cover_slipon.stl

(147.45 KiB) Downloaded 237 times

[3D-Print]

Looks awesome...... I like the slip cover you made. Not sure why the other isnt printing, but I think I will print yours and use it!!!

Thanks,

[CRPerryJr]

It's been very busy lately, and I haven't been able to work on the printer upgrades, until TODAY! So here we go...

Printer Deconstruction
[img]http://www.perrydice.com/images/Rostock-deconstruct.jpg[/img]
[img]http://www.perrydice.com/images/rostock-demo1.jpg[/img]
[img]http://www.perrydice.com/images/rostock-demo2.jpg[/img]
[img]http://www.perrydice.com/images/rostock-demo3.jpg[/img]

[CRPerryJr]

And now we start putting in the new goodies....
[img]http://www.perrydice.com/images/rostock-recon1.jpg[/img]
[img]http://www.perrydice.com/images/rostock-recon2.jpg[/img]

[CRPerryJr]

Day 2 of the Reconstruction:
[img]http://www.perrydice.com/images/rostock-recon3.jpg[/img]
[img]http://www.perrydice.com/images/rostock-recon4.jpg[/img]
[img]http://www.perrydice.com/images/rostock-recon5.jpg[/img]

[CRPerryJr]

Day 3 & 4-I got the bottom pretty much buttoned up, and power tested.
[img]http://www.perrydice.com/images/rostock-recon6.jpg[/img]

[3D-Print]

Awesome. Love the pictures. Great job!!

I didn't install jfettig's "J" brackets to keep the bowden tubes controlled for each spool of filament...

[Lightpath]

Your duet mount is beautiful. Mine didn't turn out so good.

What material did you print it from? How much support/infill? Gorgeous, just gorgeous.

[CRPerryJr]

Sorry this has taken so long! Summer is here!
Here is my status as of today...
[img]http://www.perrydice.com/images/rostock-recon7.png[/img]
[img]http://www.perrydice.com/images/rostock-recon8.png[/img]
[img]http://www.perrydice.com/images/rostock-recon9.png[/img]
[img]http://www.perrydice.com/images/rostock-recon10.png[/img]

What's Changed?
Replaced effector with an air duct integrated layer fan effector inspired by jimmustangguitar.
Replaced cheapskates with newer injection molded.
Replaced stock hotend with Diamond Hotend
Replaced Rambo controller and display with Duet 0.85 controller/Duex4/7" touch screen/PanelDue
Added 2 more extruders and moved all 3 extruders to an easier place to access them.
Added 2 more filament holders and guides from JFettig
Added FSRs with mounts from mhackney
Replaced stock ATX Power supply with 750 Watt ATX power supply
Added 2 cooling fans to base of printer.

Here is a copy of my config.g for anyone who would like to use it as a starting point...

Code: Select all

; Configuration file for Rostock with Diamond/Duet from Perrydice
; ***Hardware Configuration for this build***
; Duet 0.85 controller/Duex4/PanelDue/7"Touchscreen
; Diamond Hotend
; 3 non-geared extruder motors
; FSR Z-Probes under heated bed
; Stock SeemeCNC arms (old 269 mm type)
; Stock Seemecnc cheapskates (new injection molded)
; Stock SeemeCNC heated bed with Boroglass
; ~260-270 mm printable area (280 is too big with old stock SeemeCNC arms on new cheapskates)

; Communication and general
M111 S0 ; Debug off
M550 PPerrydice_Delta ; Machine name and Netbios name (can be anything you like)
M551 Ppassword ; Machine password (used for FTP and web interface access)
M540 P0xBE:0xEF:0xDE:0xAD:0xFE:0xED ; MAC Address

;*** Adjust the IP address and gateway in the following 2 lines to suit your network
M552 P0.0.0.0 ; IP address (0 = use DHCP)
M554 P192.168.1.1 ; Gateway
M553 P255.255.255.0 ; Netmask
M555 P2 ; Set output to look like Marlin
M575 P1 B57600 S1 ; Comms parameters for PanelDue

;Default starting parameters
G21 ; Work in millimetres
G90 ; Send absolute coordinates...
M83 ; ...but relative extruder moves

;Fans (PEEK fan conected to ConstantON-Layer fan connected to Fan 0)
;M106 I1 ; Invert fans
M106 P0 S0 ; Turn off Fan 0
M106 P1 S0 ; Turn off Fan 1

; Axis and motor configuration
M569 P0 S0 ; Drive 0 goes backwards
M569 P1 S1 ; Drive 1 goes forwards
M569 P2 S0 ; Drive 2 goes backwards
M569 P3 S0 ; EDrive 0 goes backwards
M569 P4 S0 ; EDrive 1 goes forwards
M569 P5 S0 ; EDrive 2 goes forwards
M574 X2 Y2 Z2 S1 ; set endstop configuration (all endstops at high end, active high)
M665 R140.95 L269 B130 H396 ; set delta radius, diagonal rod length, printable radius and homed height
M666 X-0.02 Y-0.02 Z0.04 ; put your endstop adjustments here, or let auto calibration find them
M92 X80 Y80 Z80 ; Set axis steps/mm
M906 X1000 Y1000 Z1000 E1000 ; Set motor currents (mA) 
M906 I80 : Set motor Idle current
M201 X1000 Y1000 Z1000 E1000 ; Accelerations (mm/s^2)
M203 X20000 Y20000 Z20000 E3600 ; Maximum speeds (mm/min)
M566 X1300 Y1300 Z1300 E1300 ; Maximum instant speed changes mm/minute
M207 S5.0 F2400 : 5mm retraction at 2400mm.min (40mm/sec) for the all three extruders to prevent the Diamond Head ooze! 

;PID Settings
;For manual adjustments: if it overshoots a lot and oscillates, either the integral gain needs to be increased or all gains should be reduced. Too much overshoot? Increase D, decrease P. 
;Response too damped? Increase P. Ramps up quickly to a value below target temperature (0-160 fast) and then slows down as it approaches target (160-170 slow, 170-180 really slow, etc) 
;temperature? Try increasing the I constant. 
M301 H0 P24 I0.80 D105 T0.50 S1.0 ; PID settings for Print Bed (-P means bang bang setting and not PID)
M301 H1 P08 I0.20 D109 T0.50 S1.0 ; PID settings for Heater 1 (Diamond Hot)

; Thermistors
;*** If you have a Duet board stickered "4.7K", change R1000 to R4700 to the following M305 commands
M305 P0 T100000 B4286 R4700 H30 L0 ; Put your own H and/or L values here to set the bed thermistor ADC correction
M305 P1 T100000 B4375 R4700 H30 L0 ; Put your own H and/or L values here to set the 1st nozzle thermistor ADC correction
M570 S280 ; Hot end may be a little slow to heat up so allow it 280 seconds

; Tool definitions
M92 E146.27:146.27:146.27 ; Set steps/mm for extruders (not geared)

M563 P0 D0:1:2 H1 ; Define tool 0
G10 P0 S0 R0 ; Set tool 0 operating and standby temperatures 
M567 P0 E1.0:0.0:0.0 ; Set mixing to extruder 1 at 100%
M568 P0 S1 ; Turn on mixing S= (1 = on, 0=off)

M563 P1 D0:1:2 H1 ; Define tool 1
G10 P1 S0 R0 ; Set tool 1 operating and standby temperatures
M567 P1 E0.0:1.0:0.0 ; Set mixing to extruder 2 at 100%
M568 P1 S1 ; Turn on mixingS= (1 = on, 0=off)

M563 P2 D0:1:2 H1 ; Define tool 2
G10 P2 S0 R0 ; Set tool 2 operating and standby temperatures
M567 P2 E0.0:0.0:1.0 ; Set mixing to extruder 3 at 100%
M568 P2 S1 ; Turn on mixing S= (1 = on, 0=off)

; Z probe and compensation definition
M558 P4 X0 Y0 Z0 H3 ; Z probe is a switch and is not used for homing any axes
G31 X0 Y0 Z-.05 P500 ; Set the zprobe height and threshold (put your own values here)

;*** If you are using axis compensation, put the figures in the following command
M556 S78 X0 Y0 Z0 ; Axis compensation here
M208 S1 Z-0.2 ; set minimum Z

;Select tool and begin
T0 ; select first hot end

Huge thanks to mhackney, 3DPrint, jimmustangguitar, jfettig, DC42, Xenocrates and anyone else who contributed knowledge to this awesome forum for all your helpful posts and guidance. I still have a bit to go, but it's working!

PS. Updated config.g code to reflect changes noted below for dimensional accuracy. (YMMV)

[CRPerryJr]

Still having a little issue with Dimensional Accuracy....Everything is a bit small by about .975. I'm working through 626pilot's post now to correct the issue. I'm sure its related to the M665 L parameter (diagonal rod length) being not quite right, and the auto calibration is not correcting the issue in bed.g. (G30 S7)

[dc42]

It's usually best to use 6-factor auto calibration instead of 7-factor and set the diagonal rod length in the M665 command to the value you measured. Scaling inaccuracies are often caused by the bearing spacings being slightly different at the top and bottom ends of a pair of diagonal rods. You can correct small scaling errors using the M579 command in config.g, see http://reprap.org/wiki/Gcodes#M579:_Sca ... esian_axes.

[CRPerryJr]

Thanks dc42. Reading more into Configuring and calibrating a delta printer using the dc42 fork of RepRapFirmware, I see where G30 S7 can be a problem. I readjusted M665 L269 in the config.g, changed my bed.g to G30 S6, and focused on getting my endstops physically (rather than through software) as close to 0 as I can after auto calibration. Now after running bed.g, my M665 R is much more consistent on each run (140.95), and my endstops are less than .04 from 0. I'm printing a new calibration cube to see what affect this has made on my dimensional accuracy. My next step is to use M579 to ferret out the last of the dimensional problems.

[CRPerryJr]

Sorry it's been a while since the last update.
[img]http://www.perrydice.com/images/rostock_enclosure.png[/img]
As you can see from the picture, I've had to make some modifications since last time I posted.

Mods include:
1. Changed the way the filament feeds from the top sides to a more direct path straight down.
2. Reinstalled the enclosure

Mods planned but not yet completed:
1. Webcam
2. Enclosure heat

What I'm wrestling with now, is how to implement Grid Compensation. Posted in another thread...http://forum.seemecnc.com/viewtopic.php?f=111&t=11282
Thanks!

[rurwin]

That's a beautiful machine.