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CozmicRay Wally Build

PostPosted: Tue Dec 17, 2013 1:33 am
by Cozmicray
I'm well into my Wally built
without instructions or assembly drawing.
Here are some comments and hints on the design / my build.

1. Check the polymer threaded parts, it is important that the internal threads in the X-Y forearm are formed correctly, and the other threaded parts engage properly, -- it must be printed correctly to hold the the arms together firmly at the hotend.

2. I am using 13 mm 5 ply birch plywood, this seems to be too thick for the 16mm M3 bolts and I had to countersink them into the back of the board. Check your build boards, you may want to obtain longer bolts. M3x20 vs M3x16 in BOM

3. I started using M3 stop nuts with nylon inserts, these seem to bind and tend to rotate in the hex hole in the plastic parts, rounding out the hex hole. I have replaced those with regular nuts and it seems to work fine.

4. I'm using washers between the bearings in the arms, if the arms are just slightly bent they bind, so the washers space them up a bit to allow them to rotate freely. This tends to lock the inner races of the bearings together and provide free rotation.

5. It also appears that the bolts (M8x70) holding the table arms to the back board, are too short, probably because of the thicker plywood, I will replace those with longer bolts, The M8 captive nuts with the nylon inserts may interfere with the table.

6. The table is as wide as the opening between the arms, so there is no room on the sides of the table for any type of parts or clamps for attaching heater or build material. I plan on using glass for my build surface, so I will have to put the parts to hold the glass, on the front and the back of the table.
Are table levelers required?

7. I am planning to use an "AirTripper" extruder. I have the mechanical parts and am printing the plastic parts. Nick's extruder using UHMW block, where the UHMW will have to be milled.

8. The wiring hole was nicely covered by the X-Y motors, new holes farther down were drilled. It seems that the wire channels the on the back are really not necessary, and one might just want to use cable ties or clamps. (I am using 4 wire shielded cable on the stepper motors)

9. There are no set screw holes in the Z axis pulley, I drilled and installed M4 set screws

That's it for now, hope this is helpful, the BUILD continues

Re: CozmicRay Wally Build

PostPosted: Tue Dec 17, 2013 5:22 pm
by Nicholas Seward

Are table levelers required?

I use software leveling. I prefer this to trying to do any physical adjustments.

Re: CozmicRay Wally Build

PostPosted: Sun Dec 22, 2013 2:15 am
by Cozmicray
Here's Wally Maybe Wally Chrome (Chrome spray paint on boards)

Wally Chrome front
Wally_front_s.jpg (82.11 KiB) Viewed 76709 times

Wally chrome back
Wally_Back_s.jpg (82.63 KiB) Viewed 76709 times

Black forearm reprint to get beter internal threads

Freaduino Mega 2560, RAMPS (all to be replaced --- real pain)
Arduino Mega 2560, New RAMPS
30A 12V power supply
Square hard PC Bed Heater
Airtripper extruder (1.75mm)
Hotend not in yet

Have been using Macbook, Repetire-Host, Marlin

Real hassel with electronics


Re: CozmicRay Wally Build

PostPosted: Sun Dec 22, 2013 2:29 am
by Nicholas Seward
Great progress.

Re: CozmicRay Wally Build

PostPosted: Thu Jan 02, 2014 1:27 am
by Cozmicray
Everything is hooked up
and wally is moving
J-Head hotend not mounted
need 30mm extender to make it same length as Ubis

I could use some help
Marlin settings / parameters
Repitier-Host parameters / settings

How to adjust z-max/min to make up for not having 10mm basalt slab.


Re: CozmicRay Wally Build

PostPosted: Thu Jan 02, 2014 3:01 am
by Nicholas Seward
You could put some risers on the bed, lower the arm mounts, raise the bed arm mounts.

Now that I think about it I would probably raise the bed arms and cut some of the height off the bottom of the backboard.

Congrats on getting it moving.

Re: CozmicRay Wally Build

PostPosted: Fri Jan 03, 2014 4:17 am
by Cozmicray
Anyone out there building a Wally with a RAMPS 1.4 electronics?

running on PC with Win XP-64
Replaced Freaduino
with genuine Arduino Mega 2560
and different RAMPS board and Polulu drivers

all functions work X,Y,Z, extruder motors, bed heater, Bed temp, Extruder heater, extruder temp

Need some help setting Marlin and Repetier-Host.

my (set in Marlin config.h)
X 8 steps/mm
Y 8 steps/mm
Z 166 steps/mm
E 100 steps/mm

Wally on "Home Z" pulls bed up 110mm
after about 30 sec Z-motor disables and bed drops

If I home Z and then move bed up/down
then Home again home position is forgotten and Z pulls table up 110mm
(breaking the string)
Motor stop doesn't work on Z-Axis? (must use emergency stop)

X and Y move but can't correlate to R-H commands
best I can see is R-H commands are like deg of rotation of big pulley?

Scratchin all my hair off trying to figure out!
changing marlin code/config and R-H parameters.


Re: CozmicRay Wally Build

PostPosted: Mon Jan 06, 2014 11:21 pm
by Cozmicray
Still looking for Marlin code/settings for Wally

Also nee Repetier-Host or other software settings for Wally

Please Help


Re: CozmicRay Wally Build

PostPosted: Tue Jan 07, 2014 3:14 am
by Nicholas Seward
What do you mean R-H?

I don't use marlin so no dice there.

It sounds like you have movement and have set the steps/mm. What are you trying to do that you can't do? I am just not following.

Re: CozmicRay Wally Build

PostPosted: Tue Jan 07, 2014 3:16 am
by Nicholas Seward
BTW, home (0,0,0) is when the bed is at the bottom and the arms are out. When you press home nothing should happen if you have disabled all the endstops. To fix this situation you can call a g92 x0 y0 z0 e0 command to zero everything and then you can run code that has gone through segmentize. Or at least that is the plan. :-)