X5SA Tronxy - Direct drive Extruder mount (Stock parts) - 1 for 2 fan Hotend / Heatbed cooling

thingiverse

2023-07-28 Update: At the moment I am happy with it. Print quality is improved, higher speed due to direct extruder is possible and 1 for 2 Fan design works great. I make a break and maybe later I design a suitable filament sensor for it. <big> <big> Scope: This Project shall provide: * Hotend carrier & mounting base for a direct mount extruder V1-1 (ok) (with mount for: orig. BLS & Cap. BLS) * Holder for direct extruder from stock (original Titan extruder) (ok) * Holder for filament and bowdan pipe (ok) * Holder for capacitiv level sensor (d=18mm) (orig/new carrier) (ok) * Hotend cooler with exhaust to heat bed to avoid filament cooler (for orig./new carrier v2-5 (wires left); for new carrier V22 (wire right); ok) (this is an ongoing <big> experiment <small> with good results, at the moment) (you can also use the orig. cover and attachments instead) * Parallel fan control via diodes in distribution box (ok) * 40x40mm Fan inlet duct (ok; can be improved) Reqirements: -- Independent mount of: BLS; Hotend cooler; Extruder; Hotend -- Flexible carrier base for direct drive extruder & (stock parts) attachments -- Insulation of heat-block from airflow -- Improve heat-block regulation loop -- Improve Hotend cooler new design/version (wiring & mounting) -- Improve 1-fan control with two drivers (simple SW adaption, with 2-diodes). -- Use as much stock parts as possible. -- If possible: mount of filament sensor near the extruder Updage: 5.6.2023 * regulation loop optimized (config file added) * Thermal measurements of airflow (diagram added) * Parallel operation of fan control implemented (in RTN lines of the distribution box) Update: 27.05.2023/ 02.06.2023 two parts updated, due to minor mountig issues: * Body Stepper Holder V20 (stepper mount wholes miss match fixed) * Body Extruder Base V20 (wholes for rear carrier fix increased fixed) * Cooler Case V22 (for new carrier plate, optimized) some minor issues fixed (too small wholes, fixation leash, reduced size, ...) * pictures added / explanation update Additional modifications: - Y-stop needs to be adjusted to thicker Carrier Baseplate (~2-5mm) - Cable-chain-holder need to be mounted from outside the printer frame. (stepper motor can touch the cable-chain). - "Extention-cable for Stepper motor needed :-)" - Mount filament run out sensor ToDo -> filament holder designed (may use a fixation at the main frame) I use this version instead: https://www.thingiverse.com/thing:4946690 - For Fan control 2 diodes (1A 30V schottky/Si) needed to combine both supply lines. (!! connection in RTN line! !). - Cable chain extension needed: https://www.thingiverse.com/thing:4916875 <big> My printer is a Tronxy X5SA-400 pro from 12/2020 with Titan extruder. My relevant Modifications: - Wirechain to the right to stay inside the cabinet (with stock parts) - BLS: Capacitive level sensor (explanation, settings and config file below (gcode)) https://www.thingiverse.com/thing:4817851 <big> <big> Explanation: - As an experiment and due to different Ideas, I designed a hot-end cover with only one fan. (it works and fits to my original/new carrier; I need more experience) - I decided to use the original carrier (in first step) with airflow exhaust direction to the heat-bed with ~15% of the airflow for direct cooling at the heat bed. The original cover mixes the air over all elements (incl. heat-block). The reuse of the exhaust is possible to the low heat transfer power from a solid surface to air. You need at big surface for relevant heat transfer (example car cooler). Further I want to protect the heat block from excessive cooling by the airflow. I also added a metal cover over the open silicon cover for the heat block. All modifications together it insulates the heat-block from nearly the complete airflow and only over the heat-break a thermal power transfer to the cooler is possible. -> better cooling & better heating - With the new carrier I implemented a carrier base for a direct drive extruder. It is usable with the stock parts. It is a carrier base, where different extruder can easily mounted with a adapted holder. - With the measurements below the air heats up only +7K. -> 37°C exhaust temperature. This is cold enough to cool the filament down to 50°C@PLA and 70-80°C@PETG. With the low thermal conductance of the plastic it is not needed to have an excessive airspeed. Further it is necessary for a long cooling time realized by a big area of airflow around the nozzle and also the right nozzle temperature. - Never the less I want to reduce the normal Airspeed down to ~50% (for the first layers) and increase when needed. Therefore I want to couple Hotend-fan controller (const. at 50%) with Nozzle-fan cooler (min. to 100%) with two diodes in parallel (in RTN line). Results in diagram picture. I decided to use 58% minimum and increase to 80% after 4th layer. - My optimization of the Heat-block regulation loop used parameter: M301 P5.0 I1.04 D150.00 Detail results below. - Ongoing: Optimization of metallic heat shield (front airflow). And thermal measurements around the nozzle. (58% & 80% fan speed) <big> Materials: - Some M3 Screws and nuts are needed M3x6 to M3x20mm - A metallic plate out of a can for thermal shield. - The heat block is covered with the metal as a thermal reflection (size tbd.) and airflow shield (Cooler case: ~32mm * (30mm+25mm)folded and cut to the right size). - Wire extension: connectors 4pin (1xmale / 1xfemale), wires - Fan control: conector 2pin (2xfemale, 1xmale) & 2x Diode 1N4148/1N6642..., wires - Drills: 2,5mm; 3mm; ... 5mm : Some wholes need to be adjusted to the screws: -- M3: core: 2.5mm; out: 3.0-3.5mm -- M4: core: 3.5mm; out: 4.0-4.5mm -- M5: out: 5.0-5.5mm <big> Results: <small> (with update) * <big> Temperature:<small> 220°C/75° Hotend/Heat bed; 30°C in the cabinet; 32-33°C in the cover (+2-3K); 37°C flow to heat bed Diagram: -- Thermal measurements done at 196°C hotend only. Power is the AC power heat consumption (-Stdby). --> Result: +5-8K exhaust heatup referred to inlet temperture --> internal heatup at hotend is less ~+3-6K * No delamination as a result of too much cooling with the old fan. I mainly had delamination on the left side due to the cooling from right to left. https://www.thingiverse.com/thing:4892309 Even at a low speed of ~20%. * Airflow: cooling is arround the heatblock with +3-6K (temperature shown in the diagram) * Power parameter of the hotend is optimized (Regulation loop). Hotend needs significant less power. New parameter: <big> M301 P5.0 I1.04 D150.0000 <small> -> Heatup +10K; later -3/+1K ; Stabilization 1min. after overheat First there is a heatup with 100%duty (64Wac). -> ~+10k overheat. Second: switch to 0% duty ~11.2Wac stdby. ->~-5-10K under heat. Then loop starts for regulation when <Tsoll. -> ~1min until stabilized (~20-26Wac). I found no way to avoid the ovrheat. -> When setting is changed there is a minimum overregulation of dT change and/or the same behaviour like startup. * Power consumption after heatup: (all measured at AC Grid) -- PLA 200°C/50°C 115Wac (incl. heatbed & motors) -- PETG 220°C/78°C 195Wac (incl. heatbed & motors) -- standy: 11,1-11,4W included. * <big> Weight: Actual 3D Parts: <small> - Hotend-cooler (PLA/PETG & high resolution & supports) (17g) (original wire connection from left side) (print with fan side bottom) (fits to original carrier) - Hotend-carrier (13.3g) with mounting base for direct extruder. (PETG; 3 walls; >25% infill) - Direct extruder mount base (13g base, fixation & 1xscrew) (PLA) - Holder Direct extruder mount (14,5g); (PLA) - Holder PTFE-Filament-tube (13,2g with bowdan screw) (PLA) - Holder Capacitiv level sensor (7,1g with screws) (fits to original carrier) (PLA) - Fan-inlet-duct 40x40mm (needs improvement, less space to front main frame) (PLA, PETG) <big> -> together: ~67g (incl. screws..); plus stock parts: ~370g (extruder...) - orig. Hotend carrier: 70,2g to new 26.4g - orig. Hotend coolder-case: 51,3g to new 17g - BLS: capacitiv: ~25g ; orig: 13g If you want to honor my work and the effort and you want to make a donation to me https://paypal.me/MakeDE If you have some comments or you have a make don't hesitate to post it. https://www.thingiverse.com/search?q=makede&type=things&sort=relevant If you want the FreeCAD files, please ask.