Ormerod FreeCAD Rework & My Ormerod Itteration

Ormerod FreeCAD Rework & My Ormerod Itteration Morning all, Updates on my project are scattered over a few threads so I thought I'd condense and summerise here. I kicked off this goal mainly as an exercise in FreeCAD and in order to adapt a few of the parts in order to reduce the failure rate of the PLA components. I appreciate some people have already done many of these mods and I am re-inventing the wheel in many places but what the heck! Progress: [list] [*] CAD reverse engineered from STL into FreeCAD with many parts built and tested (minus extruder ands electronics enclosure parts) [*] Modifications made to site a TR8 lead screw on the electronics side (ormerod2) of the z-axois extrusion using a modified bearing clamp to hold the anti-backlash nut. [*] Many parts adjusted to avoid size-for-size interference fits which exacerbated PLA part failures. [*] x-axis idler modified to include a guard to prevent my sons curious fingers from getting too close! [*] y-axis idler tweaked from thingverse (will credit original design soon!) with an adjusting nut and pulley finger guard / cover. [*] y-axis motor mount modified to remove rear bolt, add thirds bolt to front, and diagonal bracing above and below the motor back to the extrusion end plate surface. [*] Above necessitated the dropping of the y-axis belt by ~5mm which meant modifications to z-lower, y-axis-end-plates, y-idler, y-motor-mount, and y-axis bearing clamps. [*] E3D V6 (/lite) mount onto standard x-carriage. [/list] Currently Outstanding: [list] [*] Redesigning the z-lower mount to remove the need for the corner bracket and to only locate on one side of the z-axis extrusion. [*] Update FreeCAD assembly file. [*] Sort out GitHub repository to make a bit more sense. This will be sorted into copies of RepRapPro parts, my version of the Ormerod, and extra parts which are relevant to other machines such as my PanelDue support. [*] Create a RepRapPro style build manual. [*] Remove remaining countersunk bolts. [*] Move the bolts that secure ont o the face of teh y-axis extrusion to bolt on to the base of the extrusion on the y-dler and motor mount parts. For ease of assembly and repair. [*] Part cooling fan mount & duct design. [/list] mk3? [list] [*] Reduce fastener bill of materials? [*] V-slot version? - Not much work. [*] V-slot x-arm? - Pretty much complete rework of z, and x-axis. [*] Change bed support to use more off-the-shelf parts rather than the three cut profiles. [/list] Here's a teaser from the most recent mock up before it was stripped to replace bits that interfered with the build support and use bits to get my work horse Ormerod back running again after more bits broke! The last one may be Ormegog. Running with a Ramps board that I've recently acquired with an Ebay salvage lot! Not that I expect to get the RAMPs to out perform the Duet 0.6, but I would like to be able to see the difference between the two in the flesh. [attachment 108193 _20181121_095950.JPG] https://reprap.org/forum/read.php?340,839175,839175#msg-839175 Mon, 07 Sep 2026 13:45:36 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?340,839175,883069#msg-883069 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,883069#msg-883069 Sardi Ormerod Sat, 03 Apr 2021 14:22:01 -0400 https://reprap.org/forum/read.php?340,839175,874724#msg-874724 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,874724#msg-874724 oliof Ormerod Wed, 08 Jul 2020 04:54:21 -0400 https://reprap.org/forum/read.php?340,839175,874025#msg-874025 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,874025#msg-874025 oliof Ormerod Sat, 20 Jun 2020 16:41:53 -0400 https://reprap.org/forum/read.php?340,839175,874015#msg-874015 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,874015#msg-874015 WesBrooks Ormerod Sat, 20 Jun 2020 10:35:54 -0400 https://reprap.org/forum/read.php?340,839175,874013#msg-874013 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,874013#msg-874013 did you publish your work anywhere for curious minds?]]> oliof Ormerod Sat, 20 Jun 2020 10:31:29 -0400 https://reprap.org/forum/read.php?340,839175,862739#msg-862739 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,862739#msg-862739
What business are you operating if I may ask?]]> Karoo Klong Ormerod Tue, 19 Nov 2019 05:34:20 -0500 https://reprap.org/forum/read.php?340,839175,862727#msg-862727 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,862727#msg-862727
That said one of the reasons I moves o0nto the P3s was because I was disheartened by some strong vertical artefacts on this machine. As it happens I ended up chasing the same on those too. Long story short it appears to be a mix of both the 16 step drivers and counter intuitively (at least at first) a more rigid frame exacerbating ringing issues. I'll take another look at this project this week or next. Need to reduce the height of the bed (from the surface the machine rests on) and get a worm drive on the z. I'll be nearly done at that point.]]> WesBrooks Ormerod Tue, 19 Nov 2019 03:18:02 -0500 https://reprap.org/forum/read.php?340,839175,862726#msg-862726 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,862726#msg-862726 Karoo Klong Ormerod Tue, 19 Nov 2019 03:08:32 -0500 https://reprap.org/forum/read.php?340,839175,859595#msg-859595 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,859595#msg-859595
Lessons learnt in time or on the other machines mean the following will be tackled:

* Needs a far less restrictive fan duct.
* Motors may be over specced contributing to ripples.
* Y axis rsils to be dropped and mount sizes reduced.
* x carriage redesign for more travel.
* Worm drive to replace belt as the latter always drops with no power and worm is simpler than stepper brske.]]> WesBrooks Ormerod Fri, 20 Sep 2019 01:52:29 -0400 https://reprap.org/forum/read.php?340,839175,856005#msg-856005 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,856005#msg-856005
Will you keep it a single supported X-Axis printer?

I like te V-Slot idea. Does it not have too much play and show up in the prints as artifacting or ghosting?]]> Karoo Klong Ormerod Fri, 05 Jul 2019 03:29:53 -0400 https://reprap.org/forum/read.php?340,839175,849118#msg-849118 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,849118#msg-849118
[attachment 110511 190313_Cantilever_Mod2.png]

Here are some other pics following the assembly of the main y-axis/z-axis joint.

[attachment 110512 DSC_3225_red.JPG]

[attachment 110513 DSC_3224_red.JPG]

[attachment 110514 DSC_3223_red.JPG]

Edit: On my next mod I'll make sure there is a hole to tighten the grub screws on the drive pulley on the reduction shaft!

Edit 2: The obvious howler being I've nowhere to put my extruder so I will need to rework the back of the x-axis shoulder to mount the extrusion there. Happy accident really as that bodges my previous effort on extruder mounting!]]> WesBrooks Ormerod Wed, 13 Mar 2019 17:32:11 -0400 https://reprap.org/forum/read.php?340,839175,849104#msg-849104 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,849104#msg-849104
Edit: I can confirm cheap GT2 pulleys are off centre and naff!]]> WesBrooks Ormerod Wed, 13 Mar 2019 16:03:57 -0400 https://reprap.org/forum/read.php?340,839175,849074#msg-849074 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,849074#msg-849074 Sardi Ormerod Wed, 13 Mar 2019 11:35:42 -0400 https://reprap.org/forum/read.php?340,839175,847905#msg-847905 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847905#msg-847905
There is still a slight twist so I am currently planning to add a third bolt at the front edge of both sides to add a rotation of the side pieces by bolting down onto the extrusion.

This is the next issue to tackle after I've got rid of the ringing.]]> WesBrooks Ormerod Mon, 25 Feb 2019 04:55:24 -0500 https://reprap.org/forum/read.php?340,839175,847904#msg-847904 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847904#msg-847904 veryevil Ormerod Mon, 25 Feb 2019 04:51:15 -0500 https://reprap.org/forum/read.php?340,839175,847903#msg-847903 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847903#msg-847903
I give very little consideration to the aesthetics of colour to be honest! I had used black but got nervous about heat absorption near the hot end (both during print and in use on the machine) so I went full opposite to white, but I am now wondering if this is exacerbating part cooling issues as white cools slowest. After being recently asked about environmental issues, and as I have still not enclosed these machines I think I will move to natural colour next time.]]> WesBrooks Ormerod Mon, 25 Feb 2019 04:44:02 -0500 https://reprap.org/forum/read.php?340,839175,847901#msg-847901 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847901#msg-847901
I never considered white for printer printed parts, but they do look nice :) (but like a white car, probably wouldn't after a while of operation) :D]]> cheeseandham Ormerod Mon, 25 Feb 2019 04:37:47 -0500 https://reprap.org/forum/read.php?340,839175,847897#msg-847897 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847897#msg-847897
So far no z-wobble! :-)

I will compile a bill of materials soon but so far the major extras (over Ormerod 2) are:

3 x 20x20 vslot extrusion.
1 x 20x40 vslot extrusion.
3 x vslot wheels with nuts, bolts, spacers, and excentric spacers.
GT2 belt.
3 x 20t drive pulleys (may revise to smaller tooth count later)
3 x 20t 5mm bore idle pulleys
1 x 60t drive pulley
1 x microswitch (x axis)
1 x dc42 IR sensor
1 x mk3 alloy bed.
1 x mosfet heated bed driver & fuse/mount.
1 x radial fan.
1 x E3D V6 complete (bowden)

All printed parts aside from extruder.
Various fasteners (only 1 countersunk screw now other than what is in extruder.)

Will look at using polymer smooth rod bearings another time.

Will build in PETG when design is more settled.]]> WesBrooks Ormerod Mon, 25 Feb 2019 04:13:50 -0500 https://reprap.org/forum/read.php?340,839175,847896#msg-847896 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847896#msg-847896
[attachment 110242 190225_yaxis_belt.JPG]

Y axis rod supports mounted direct on-top of 20x20 extrusion. M3 bolts screw axially onto the rods so that the belt tension doesn't pull the ends in, and allows larger error in cutting the length of rods. The other side is simply a mirror. Microswitch mounted in a similar location to normal Ormerod 2.

[attachment 110243 190225_yrodsupport.JPG]

Rear view of x carriage, z axis motor, and z axis smooth rods.

[attachment 110244 190225_zaxis_rearxcarriage.JPG]

Pulley reduced z-axis drive. Same physical step size per mm as a TR8 four start screw. No screw related over constraint or wobble. Axle not cut yet as I don't need the extra yet and I may still tweak the design a bit.

[attachment 110245 190225_zbase.JPG]]]> WesBrooks Ormerod Mon, 25 Feb 2019 04:11:53 -0500 https://reprap.org/forum/read.php?340,839175,847894#msg-847894 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847894#msg-847894
[attachment 110238 190225_ormerod_extruder.JPG]

X carriage running on large vslot wheels. Since found some smaller ones but not worth rebuilding just for a few mm of extra travel until I have evaluated the whole machine better. There are other tweaks I would like to do too since finding the smaller wheels in my stash!

[attachment 110239 190225_xcarriage.JPG]

Not sure who had the idea for this originally but like it. I saw it first on P3Steel parts. Toothed idler running in a shell that is pulled back by one bolt on the centre line of the x-axis belt.

[attachment 110240 190225_xidler.JPG]

X axis stepper. Half the belt path is within the extrusion. The hole on the side allows access to the pulley grub screws.

[attachment 110241 190225_xstepper.JPG]]]> WesBrooks Ormerod Mon, 25 Feb 2019 04:04:37 -0500 https://reprap.org/forum/read.php?340,839175,847162#msg-847162 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847162#msg-847162
I've got some resolution test cases that I discussed on the duet forums an age ago that suggested the major steps of the stepper was a significant factor over microstepping. If that is still the case on these machines then reduction drives and 24V on the other axis will be a priority for me over a higher controlled (rather than interpolated) microstepping.

At the end of the day I'm providing a service and unless I can demonstrate a clear time or cost saving I can't justify swapping the board out just because I want to and it will run quieter. Dahm metwork switch makes more noise than my printers anyhow! :-D

More pictures soon.]]> WesBrooks Ormerod Sat, 16 Feb 2019 03:27:26 -0500 https://reprap.org/forum/read.php?340,839175,847158#msg-847158 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847158#msg-847158

Quote
WesBrooks
[*] Duet 0.8.5 (because I didn't have a 0.6 spare!)

The Duet Maestro works well in the Ormerod too, despite the Ormerod using only 12V. I used my Ormerod as the test bed for the original prototype of the Maestro.]]> dc42 Ormerod Sat, 16 Feb 2019 02:50:34 -0500 https://reprap.org/forum/read.php?340,839175,847150#msg-847150 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,847150#msg-847150
Very nice work, I like it.
Few more pics please :)]]> cheeseandham Ormerod Fri, 15 Feb 2019 19:35:59 -0500 https://reprap.org/forum/read.php?340,839175,846965#msg-846965 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,846965#msg-846965

Ditched acrylic end plates in favour of printed parts mounted onto 2020 extrusion that mounts onto original y axis extrusion.
Screws in y axis rod supports, screwing axially onto rods to ensure belt tension doesn't pull sides in.
Microswitch x-axis limit.
Rotated x axis belt 90 degrees about x axis and run half of it in extrusion.
Used x axis smooth rod on z axis.
Dropped y axis belt slightly in z axis from bed support and redesigned bearing caps to suit. (hang over from interim design of a braced y axis motor mount using all four face bolts and not the rear bolt)

]]> WesBrooks Ormerod Thu, 14 Feb 2019 05:51:40 -0500 https://reprap.org/forum/read.php?340,839175,846911#msg-846911 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,846911#msg-846911
This is the first major itteration but it is definately draft, and bits to mount extruder is a bodge.

Only design things that remain from the Ormerod 2 is the plates that make the bed support, and the extruder.

It reuses the smooth rods, extrusion, bed support, extruder, and bearings.

Major changes are:

GT2 Belts
Belt driven z
4:1 Reduction belt drive on z.
Belt tension done on idlers, with one bolt similar to some P3Steel systems.
40x20 extrusion for x-axis.
dc42 IR probe.
Mk3 alloy bed.
E3D V6.
Duet 0.8.5 (because I didn't have a 0.6 spare!)
Blower fan with cooling duct on z.
... probably other bits but I'm late to pick up my son!

All designed in FreeCAD, printed using slic3r on other ormerods. Designs will be on github when I'm happy with them. This is the first print.

[attachment 110033 DSC_3028red.JPG]]]> WesBrooks Ormerod Wed, 13 Feb 2019 11:58:22 -0500 https://reprap.org/forum/read.php?340,839175,840094#msg-840094 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,840094#msg-840094
This unit may interfere with the standard acrylic x-arm as there is a protrusion around one of the nuts for the z-axis guide that may get very close.

Another thing on my to-do list is to swap to a switch for the x-axis limit other than not having to tipex my trigger it would also allow getting the sensor a little closer to the nozzle.]]> WesBrooks Ormerod Sat, 01 Dec 2018 03:05:56 -0500 https://reprap.org/forum/read.php?340,839175,840043#msg-840043 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,840043#msg-840043
Offset in the x axis direction relative to the probe is the same.]]> WesBrooks Ormerod Fri, 30 Nov 2018 04:06:50 -0500 https://reprap.org/forum/read.php?340,839175,840041#msg-840041 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,840041#msg-840041

Quote
WesBrooks
Just noticed my new fans are 0.25A rather than 0.15. Should shit some more air! :-)

Your design looks very nice! - yes a centrifugal blower is the way to go, I nicked a 0.24A (Delta Electronics BUB0512Hb) from a Makita charger and that's plenty of air

Quote

Edit 2: You do loose some y axis travel.

How much did you offset the nozzle?]]> ormerod168 Ormerod Fri, 30 Nov 2018 03:32:41 -0500 https://reprap.org/forum/read.php?340,839175,840031#msg-840031 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,840031#msg-840031
Just noticed my new fans are 0.25A rather than 0.15. Should shit some more air! :-)

Edit:

[attachment 108362 DSC_2613_reduced.JPG]

*smugmode* :-)

That whole assembly should fit on a standard Ormerod 2. Not bolted on the machine yet and thinking about some heat reflective tape close to the heater block.

Edit 2: You do loose some y axis travel.]]> WesBrooks Ormerod Fri, 30 Nov 2018 01:54:29 -0500 https://reprap.org/forum/read.php?340,839175,840029#msg-840029 Re: Ormerod FreeCAD Rework & My Ormerod Itteration https://reprap.org/forum/read.php?340,839175,840029#msg-840029
The machine is alive and all heaters tuned. Delays from over extrusion on my work horse Ormerod and trying to get decent parts off a Mendel with a big heavy diamond 3-1 hot end on it.

Not much progress on my to-dos list but have sorted the z-lower mount and am currently printing first attempt of a radial fan mount (more fit check than expecting right first time) that has two long slots either side of the E3D V6 hot end.

I've Print Bite on order (they're experiencing delays too) and I'm using my V6 rather than second hand Lite as after stripping and unblocking the latter I found it had a knackered temp sensor.

This printer will Run PETG and once tuned will re-print the parts for my first Ormerod.

Fan mount is a chunky beast but I wanted it to deflect most of the hot air from the hot end fan up as well as hold the fan and direct the air down two long prongs. Do wonder if the radial on my current machine is drawing much air from the hot end fan. Will add pictures shortly.]]> WesBrooks Ormerod Fri, 30 Nov 2018 01:44:12 -0500