Y Axis Carriage Assembly

 

2 Y Carriages are assembled as in the diagram below.  M5x40mm hex bolts are fed through the carriage and a washer spacer is used on either side of the POM Guide roller.  The bolt is secured with an M5 Lock Nut.  Once assembled check that the assembly runs free and smoothly along the 2040Alu V Slot Profile.  If the assembly is loose or wont fit, loosen the bolts and even reove them and assemble the V slot guide while on the 2040 profile.

 

A spacer is required between the bearing and the nut and 3D printed part to allow the bearing to run freely.  The spacer should only cover the inner race of the bearing otherwise the bearing will be locked and unable to spin freely.

 

The assembly is completed by adding the bearings to the top of the Y Axis Carriages.

 

Y axis Bearing Assembly

A top M8x30 large washer is there to guide the GT2 Belt. 2 spacers are used around the bearing to allow is to turn freely.  A lower large M8x30 washer completes the guide for the GT2 belt.

The whole assembly is fixed with an M8 bolt which screws through the 3D printed part (there is a recess on the bottom of the part for the bolt head) and is secured on the top with an M8 safety nut.

Ensure that the correct spacer is used on the Y axis carraige.  The spacer with the flat side is for the Left Hand carraige to allow the belt to pass.  Ensure that the top bearing and lower bearing are placed in the right positions.

 

 

 

 

 

Please ensure that the flat edge of the spacer block is on the Left hand Y axis carriage and is aligned to allow the GT2 belt space to pass by.  (see overview picture below)

X Carriage Assembly

The X carriage is assembled in the same way as the Y carriage using M5x50 bolts, spacers and lock nuts.  The 2020 Alu profile is then passed through the space between the guide rollers.  If it is a problem to pass the profile in the gap, try loosening the bolts or even removing the lower guide roller and assembling it with the 2020 Alu profile already inserted.  

 

 

Assembly Overview X and Y Axis Carriages

The 2020 profile is attached to the Y carriages using M5 bolts and Nut 5 Alu T slots..These T slots should only be loosely fitted until the rest of the frame is assembled.  With the 2020 Alu Profile attached and the 2040 Alu profiles inserted the assembly should look like this:

(This rendering shows the old version of the RH Y Axis Carriage.  The new version has the small bump and the M3 hole for the micro-switch.)

 

 

 

All of the aluminium profiles should run smoothly between the guide rails.  

 

Corner Bearing Assembly

The corner bearing assembly is a double stack of 608ZZ bearings with guide washers and spacers to allow free movement of the bearings.  The whole stack is fixed to the the 3D printed corner assembly with an M8x40 Bolt and sfety nut.  The 3D printed corner block is attached to the 2040 Alu profile using M5 bolts and T slots.

 

 

 

 

Y&X Axis Stepper Mounts. 

The X and Y stepper mounts are fixed to the Alu frame using 5mm bolts and T nuts in the Alu profile.  The higher mount is placed on the right hand side of the printer so that the top belt is aligned properly.  The GT2 gears are the assembeld to the stepper motor shafts.  The gear height may need to be adjusted later to be aligned with the belt.

 

Z Axis Guide Rail Assembly.

It is better to complete the assembly of (one side at a time) of the whole Z axis guide assembly before inserting it into the Alu frame (upper bracket, lower bracket, hot bed bracket, stepper motor attached and 8mm guide rails.)

 

1. The NEMA 17 stepper motor is fixed to the lower bracket.  To do this remove 2 (diagonally opposite) screws in the motor casing (from the bottom) and replace with longer M3 bolts which pass through the bracket and into the stepper casing.

2. The M8 guide rods are slid through the middle hot bed bracket using the guide bearings and located in the lower bracket.

 

3. The M8 lead screw should be cut to length to fit between the NEMA17 motor and sit loosely into the top Z axis bracket. (Measure carefully and if required loose fit into the Alu frame to ensure the right dimension)

4. The cut M8 lead screw is passed through the middle hot bed bracket and fixed to the middle hot bed bracket with the lead screw nut. The middle hot bred bracket is the only part which cant be printed on a standard 200x200mm 3D printer and can be purchsed in my store here.

5. The screw is connected to the NEMA 17 motor with a 5x8 flexible coupler.  The M8 lead screw is only guided by the top bracket and should not rub against the top 2040 Alu profile.

6. The top guide bracket is attached to the assembly.

7. The whole assembly is put into the Alu frame and fixed with M5 bolts and T nuts.  Ensure that the assembly is positioned that the Hot End can reach the front and back side of where the heat bed will be assembled.

 

 

 

Complete Assembled Z Axis in Frame:

Ensure correct position for the Hot End to reach all areas of the heat bed!!

GT2 Belt Assembly

The GT2 belt is wrapped around the Stepper motor gears and bearings as such.  The yellow line represents the lower belt and the red line the top belt.  The belt is wrapped around the X Axis carriage and fixed together with zip ties.  The belt should be tensioned lightly before securing with zip ties.  Be careful to ensure the belt is aligned with the GT2 gears on the X/Y stepper motors.

 

 

 

 

  

When no electrical power is on, the carriages should move freely on the roller guides and the belt should remain aligned with the bearings and GT2 stepper gears at all times.

 

 

MK8 Filament Extruder Posiion.

Print the mounting bracket for the NEMA17 stepper and the MK8 extruder.  The PTFE pipe is then swung over the printer to the E3DV6 head.  Ensure the PTFE tube has enough travel and wont lash onto anything while printing. (why do I write that....hmmmm )

(This can of course be located on the left or right hand side.)