Mendel X-axis

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Revision as of 13:20, 16 October 2009 by Skinnyed (talk | contribs) (Assembly)
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You may find the assembly data sheet useful during assembly.

X-axis-assembly.PNG


Carriage

BOM

Total # of assemblies: 1

Name Qty/assembly Total Qty Type
x-carriage-belt-clamp_2off 2 2 RP
x-carriage-lower_1off 1 1 RP
x-carriage-upper_1off 1 1 RP
m4-nut 12 12 Fastener
m4-nylock 10 10 Fastener
m4-washer 58 58 Fastener
m4x16-cap 6 6 Fastener
m4x40-cap 14 14 Fastener
x-flag 1 1 Thin sheet

Reprapped parts

Carriage-printed-parts.PNG


Assembly

Before this assembly it's important to understand the key mechanical concepts of how the axes work. If you haven't already, check this video out:

<videoflash type="vimeo">6982104|640|480</videoflash>

Assemble the lower carriage first (1). Note trapped nuts.

Carriage-lower-assembly.PNG

Then assemble the upper carriage (2).

Carriage-upper-assembly.PNG

Assemble the two halves together (3) using 6 M4x40 caps (don't forget the optoflag!). Tighten the middle two caps, keep the outer two pairs loose. When fully assembled use a piece of ø8 mm bar to set the distances between the bearings. Slide the bar between the bearings and tighten/slacken the outer two pairs of M4x40 caps to achieve a smooth, low resistance, running fit.

Carriage-without-extruder-assembly.PNG

Finally assemble the extruder (4).

Carriage-with-extruder.PNG

Idler bracket

BOM

Total # of assemblies: 1

Name Qty/assembly Total Qty Type
x-180-z-bearing-plate_2off.par 2 2 RP
x-bar-clamp-m3_6off.par 2 2 RP
x-end-bracket_2off.par 1 1 RP
m3-capx20.par 4 4 Fastener
m3-nylock.par 4 4 Fastener
m3-washer.par 8 8 Fastener
m4-nylock.par 11 11 Fastener
m4-washer.par 36 36 Fastener
m4x16-cap.par 2 2 Fastener
m4x40-cap.par 9 9 Fastener
m5-mudguard-washer.par 2 2 Fastener
624-bearing.par 6 6 Bearing

Reprapped parts

X-idler-bracket-printed-parts.PNG


Assembly

Do not tighten the two adjuster bolts marked with a * in this diagram. These will be used to set the contact between the bearings and the Z shaft. If you attempt to tighten them now you may damage the bracket.

X-idler-bracket-assembly.PNG


Vert bearing 180

BOM

Total # of assemblies: 1

Name Qty/assembly Total Qty Type
z-flag.par 1 1 Thin sheet
x-axis-side-plate-nut-jig_2off.par 1 1 RP
x-bar-clamp-m4_4off.par 2 2 RP
x-vert-drive-nut-trap_4off.par 2 2 RP
x-vert-drive-side-plate-180-end_2off.par 2 2 RP
m4-nut.par 4 4 Fastener
m4-nylock.par 4 4 Fastener
m4-washer.par 16 16 Fastener
m4x40-cap.par 8 8 Fastener
m8-nut.par 1 1 Fastener

Reprapped parts

X-vert-bearing-180-printed-parts.PNG


Assembly

Use the ‘side plate nut jig’ to trap the nuts for the bar clamp bolts. There is room between the jig and the side plate for washers on both sides.

X-vert-bearing-180-assembly.PNG


Vert bearing 360

BOM

Total # of assemblies: 1

Name Qty/assembly Total Qty Type
x-360-z-bearing-plate-mirror_2off.par 2 2 RP
x-360-z-bearing-plate_2off.par 2 2 RP
x-axis-side-plate-nut-jig_2off.par 1 1 RP
x-bar-clamp-m4_4off.par 2 2 RP
x-vert-drive-nut-trap_4off.par 2 2 RP
x-vert-drive-side-plate-360-end_2off.par 2 2 RP
opto-endstop-v2-1-pcb.par 1 1 PCB
m3-capx20.par 1 1 Fastener
m3-nylock.par 1 1 Fastener
m3-washer.par 2 2 Fastener
624-bearing.par 6 6 Bearing
m4-nut.par 4 4 Fastener
m4-nylock.par 14 14 Fastener
m4-washer.par 44 44 Fastener
m4x16-cap.par 4 4 Fastener
m4x40-cap.par 14 14 Fastener
m8-nut.par 1 1 Fastener


Reprapped parts

X-vert-bearing-360-printed-parts.PNG

Assembly

As with the Vert Bearing 180, there is room between the nut jig and the side plate for washers on both sides.

X-vert-bearing-360-assembly.PNG


Motor bracket

BOM

Total # of assemblies: 1

Name Qty/assembly Total Qty Type
x-bar.par 2 2 Bar
drive-pulley_3off.par 1 1 RP
x-bar-clamp-m3_6off.par 4 4 RP
x-end-bracket_2off.par 1 1 RP
m3-capx20.par 8 8 Fastener
m3-nylock.par 4 4 Fastener
m3-washer.par 12 12 Fastener
624-bearing.par 4 4 Bearing
m4-nylock.par 4 4 Fastener
m4-washer.par 12 12 Fastener
m4x16-cap.par 4 4 Fastener
m5-mudguard-washer.par 4 4 Fastener
stepper-motor-nema17-fl42sth47-1684A-01.par 1 1 Motor

Reprapped parts

X-motor-bracket-printed-parts.PNG

Assembly

Assembly is also compatible for NEMA 14 motors.

For all axis motors you'll need to file your own flats onto the drive shafts. There's a few essential tips for doing this:

  • Put blue-tak/tape around the base of the drive shaft to prevent alloy filings getting dragged into the bearings (the motor's magnets will try to suck them in!)
  • The flat should extend down the shaft to ~ 3mm from the face of the motor.
  • The depth of the flat depends on your drive pulley hole profile, so have a good look before you do this.
  • Ensure flat depths are even or you'll get a wobbly drive pulley.
  • The fit should be tight so that it won't come off on its own, but not too tight or you'll split the drive pulley.
  • When pushing the drive pulley onto the motor shaft make sure the rear of the shaft is supported so that you can lightly tap the pulley with a hammer. Failure to support the back of the motor shaft will result in a broken motor.
  • While you're tooled up you may as well do all the motors in one shot.

X-motor-bracket-assembly.PNG

Fit bars. Make sure the bars do not touch the bearings.

X-motor-bracket-assembly-with-bars.PNG

Final x-axis assembly

BOM

Total # of assemblies: 1

Name Qty/assembly Total Qty Type
x-motor-bracket 1 1 Assembly
x-motor-bracket-spacer_2off 2 2 RP
x-vert-bearing-360 1 1 Assembly
x-vert-bearing-180 1 1 Assembly
x-idler-bracket 1 1 Assembly
x-belt 1 1 Belt
x-carriage 1 1 Assembly

Reprapped parts

X-axis-printed-parts.PNG

Assembly

Don’t tighten belt until the x-axis is mounted on the main assembly.

X-axis-final-assembly.PNG



Back to Mendel mechanical construction root.