Merge pull request #8 from eamars/v1.1

Add v1.1 files
eamars · Oct 5, 2023 · 07c231f · 07c231f
2 parents d936849 + 8fae988
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diff --git a/CAD/GT2_40T_Pulley.step b/CAD/GT2_40T_Pulley.step
diff --git a/CAD/bearing_helpers.step b/CAD/bearing_helpers.step
diff --git a/CAD/open_trickler.step → CAD/open_trickler_v1.1.step b/CAD/open_trickler.step → CAD/open_trickler_v1.1.step
diff --git a/CAD/powder_hopper_beta2.step b/CAD/powder_hopper_beta2.step
diff --git a/Manual/Resources/belt_tensioning.png b/Manual/Resources/belt_tensioning.png
diff --git a/Manual/Resources/fx_shield_final_view.png b/Manual/Resources/fx_shield_final_view.png
diff --git a/Manual/Resources/open_trickler_body_install_belt.png b/Manual/Resources/open_trickler_body_install_belt.png
diff --git a/Manual/Resources/open_trickler_body_install_rotary_tubes.png b/Manual/Resources/open_trickler_body_install_rotary_tubes.png
diff --git a/Manual/Resources/open_trickler_body_overview.png b/Manual/Resources/open_trickler_body_overview.png
diff --git a/Manual/Resources/open_trickler_connect_front_body.png b/Manual/Resources/open_trickler_connect_front_body.png
diff --git a/Manual/Resources/open_trickler_front_body_install_bearing_cover.png b/Manual/Resources/open_trickler_front_body_install_bearing_cover.png
diff --git a/Manual/Resources/open_trickler_front_body_install_bearings.png b/Manual/Resources/open_trickler_front_body_install_bearings.png
diff --git a/Manual/Resources/open_trickler_front_body_install_front_body_cover.png b/Manual/Resources/open_trickler_front_body_install_front_body_cover.png
diff --git a/Manual/Resources/open_trickler_front_body_install_front_door.png b/Manual/Resources/open_trickler_front_body_install_front_door.png
diff --git a/Manual/Resources/open_trickler_front_body_install_heatset_inserts.png b/Manual/Resources/open_trickler_front_body_install_heatset_inserts.png
diff --git a/Manual/Resources/open_trickler_front_body_overview.png b/Manual/Resources/open_trickler_front_body_overview.png
diff --git a/Manual/Resources/open_trickler_rear_body_install_bearing_cover.png b/Manual/Resources/open_trickler_rear_body_install_bearing_cover.png
diff --git a/Manual/Resources/open_trickler_rear_body_install_bearings.png b/Manual/Resources/open_trickler_rear_body_install_bearings.png
diff --git a/Manual/Resources/open_trickler_rear_body_install_heatset_inserts.png b/Manual/Resources/open_trickler_rear_body_install_heatset_inserts.png
diff --git a/Manual/Resources/open_trickler_rear_body_install_motors.png b/Manual/Resources/open_trickler_rear_body_install_motors.png
diff --git a/Manual/Resources/open_trickler_rear_body_install_pulley.png b/Manual/Resources/open_trickler_rear_body_install_pulley.png
diff --git a/Manual/Resources/open_trickler_rear_body_install_rear_door.png b/Manual/Resources/open_trickler_rear_body_install_rear_door.png
diff --git a/Manual/Resources/open_trickler_rear_body_overview.png b/Manual/Resources/open_trickler_rear_body_overview.png
diff --git a/Manual/Resources/powder_hopper_install_screw.png b/Manual/Resources/powder_hopper_install_screw.png
diff --git a/Manual/Resources/powder_hopper_install_to_rear_body.png b/Manual/Resources/powder_hopper_install_to_rear_body.png
diff --git a/Manual/Resources/powder_hopper_overview.png b/Manual/Resources/powder_hopper_overview.png
diff --git a/Manual/Resources/powder_hopper_travel_limiter.png b/Manual/Resources/powder_hopper_travel_limiter.png
diff --git a/Manual/Resources/pulley_alignment.png b/Manual/Resources/pulley_alignment.png
diff --git a/Manual/assembly.md b/Manual/assembly.md
@@ -1,155 +1,257 @@
 # Open Trickler Assembly Manual
 
 ## BOM
-|          **Name**          | **Quantity** | **Remarks** |
-|:--------------------------:|:------------:|:-----------:|
-|   Heatset Inserts M3x5x4   |      22      |             |
-|          M3x6 BHCS         |       5      |             |
-|          M3x8 BHCS         |       8      |             |
-|         M3x12 SHCS         |       4      |             |
-|         M3x10 SHCS         |       8      |             |
-|          M3x8 SHCS         |       7      |             |
-|      6804-2RS  Bearing     |       2      |             |
-|       608-2RS Bearing      |       2      |             |
-| Nema 17 34mm Stepper Motor |       2      |             |
+
+| **Name**                                  | **Quantity** | **Remarks** |
+|:-----------------------------------------:|:------------:|:-----------:|
+| Heatset Inserts M3x5x4                    | 22           |             |
+| M3x6 BHCS                                 | 5            |             |
+| M3x8 BHCS                                 | 9            |             |
+| M3x12 SHCS                                | 4            |             |
+| M3x10 SHCS                                | 8            |             |
+| M3x8 SHCS                                 | 7            |             |
+| 6804-2RS  Bearing                         | 2            |             |
+| 608-2RS Bearing                           | 2            |             |
+| Nema 17 34mm Stepper Motor                | 2            |             |
+| Shim Washer (OD=6mm, ID=3mm, Thick=0.5mm) | 10           |             |
 
 ## Tools
+
 Subject to the self supplied components, following tools may be required. 
+
 * 2.0mm, 2.5mm ball-end hex drivers are recommended.
 
 ## Assemble Open Trickler Rear Body
+
 ### Overview
+
 ![open_trickler_rear_body_overview.png](Resources/open_trickler_rear_body_overview.png)
 
 ### Component Prep
+
 This design relies heavily on heatset inserts. Make sure you have the proper inserts (check the hardware
 reference for a close up picture and the BOM for dimensions).
 
 Melt 4x heatset inserts to the bottom part of the rear body with your soldering iron. Make sure 
 heatset inserts are flush with the bottom surface. 
+
 ![open_trickler_rear_body_install_heatset_inserts.png](Resources/open_trickler_rear_body_install_heatset_inserts.png)
 
 ### Assembly
-Press 6804-2RS bearing top the top cut out and 608-2RS to the bottom cut out. You may experience some 
-resistance but that is normal. 
+
+Press 6804-2RS bearing to the top cut out and 608-2RS to the bottom cut out. [Printable bearing insert helpers](../STL/OpenTrickler/Tools) are supplied if you want to use bench top vise in this application. 
+
 ![open_trickler_rear_body_install_bearings.png](Resources/open_trickler_rear_body_install_bearings.png)
 
-Use 8x M3x8 BHCS screws to fix two stepper motors onto the frame, but don't tighten them yet.
-Make sure the motor can slide left to right. 
+Slide the bearing cover to the rear cut out. The cover should sit flush with the top of the rear body, while two bearings are still free to rotate without resistance.
+
+If you can feel the abnormal resistance after installing the bearing cover, press the bearings inwards for additional 0.1mm to clear the interference. 
+
+![open_trickler_rear_body_install_bearing_cover](Resources/open_trickler_rear_body_install_bearing_cover.png)
+
+Use 8x M3x8 BHCS screws with the optional equal number of M3 shim washers to fix two stepper motors onto the rear body, but don't tighten them yet. Make sure the motor can slide left to right. 
+
 ![open_trickler_rear_body_install_motors.png](Resources/open_trickler_rear_body_install_motors.png)
 
-Install 2x 40T pulley to the motor shaft. The pulley height will be adjusted in later steps. 
+Slide 2x 40T pulley to the motor shaft but don't tighten the set screws yet. The pulley height will be adjusted in the later step.
+
 ![open_trickler_rear_body_install_pulley.png](Resources/open_trickler_rear_body_install_pulley.png)
 
+Slide the rear door to the cut out and the rear body assembly is complete. 
+
+![open_trickler_rear_body_install_rear_door](Resources/open_trickler_rear_body_install_rear_door.png)
+
 ## Assemble Open Trickler Front Body
+
 ### Overview
+
 ![open_trickler_front_body_overview.png](Resources/open_trickler_front_body_overview.png)
 
 ### Component Prep
+
 Flop the printed part over and melt 4x heatset inserts to the bottom part of the front body with your soldering iron. 
 Make sure heatset inserts are flush with the bottom surface
 
 ![open_trickler_front_body_install_heatset_inserts.png](Resources/open_trickler_front_body_install_heatset_inserts.png)
 
 ### Assembly
-Press 6804-2RS bearing top the top cut out and 608-2RS to the bottom cut out. You may experience some 
-resistance but that is normal. 
+
+Press 6804-2RS bearing to the top cut out and 608-2RS to the bottom cut out. [Printable bearing insert helpers](../STL/OpenTrickler/Tools) are supplied if you want to use bench top vise in this application.
 
 ![open_trickler_front_body_install_bearings.png](Resources/open_trickler_front_body_install_bearings.png)
 
+Slide the bearing cover to the rear cut out. The cover should sit flush with the top of the rear body, while two bearings are still free to rotate without resistance.
+
+If you can feel the abnormal resistance after installing the bearing cover, press the bearings inwards for additional 0.1mm to clear the interference.
+
+![open_trickler_front_body_install_bearing_cover](Resources/open_trickler_front_body_install_bearing_cover.png)
+
+Slide the front door to the cut out, the front door should sit flush with the top of the front body
+
+![open_trickler_front_body_install_front_door](Resources/open_trickler_front_body_install_front_door.png)
+
+Slide the front body cover to the groove top of the front body then the front body assembly is complete.
+
+![open_trickler_front_body_install_front_body_cover](Resources/open_trickler_front_body_install_front_body_cover.png)
+
 ## Assemble Open Trickler Body
+
 ### Overview
+
 ![open_trickler_body_overview.png](Resources/open_trickler_body_overview.png)
 
 ### Assembly
+
 Insert both large and small rotary tube through the rear bearing. You may experience some resistance subject to the 
 tolerance of the printed part. 
 
-Adjust the motor position towards rotary tubes. Once done, slide the belt onto rotary tubes and pulleys. Make
-sure the longer belt is connected to the motor on the right side. 
+![open_trickler_body_install_rotary_tubes.png](Resources/open_trickler_body_install_rotary_tubes.png)
+
+Slide the motor towards rotary tubes to the nearest position. Once done, slide the belt onto rotary tubes and pulleys. Make
+sure the longer belt is connected to the motor on the right side. **Do not tension the belt, nor adjust the depth of the pulley for now.**
+
 ![open_trickler_body_install_belt.png](Resources/open_trickler_body_install_belt.png)
 
 Side rotary tubes to the front body though bearings. 
-![open_trickler_connect_front_body.png](Resources/open_trickler_connect_front_body.png)
 
-The last step is to slide the front, rear doors to the groove, then side front and rear cover to the top of front and 
-rear groove. 
-![open_trickler_install_covers.png](Resources/open_trickler_install_covers.png)
+![open_trickler_connect_front_body.png](Resources/open_trickler_connect_front_body.png)
 
+The OpenTrickler is now partially assembled. In the later steps the OpenTrickler will be mounted to one of the scale adapter for final assembly.
 
 ## Assemble A&D FX-120i/300i Weight Pan Adapter
+
 ### Overview
+
 ![weight_pan_adapter_overview.png](Resources/weight_pan_adapter_overview.png)
 
 ### Component Prep
+
 ![weight_pan_adapter_top_install_heatset_insert.png](Resources/weight_pan_adapter_top_install_heatset_insert.png)
 
 ### Assembly
+
 Use 1x M3x6 BHCS to install the top part to the weight pan adapter. The screw should sit flush or 
 below, more importantly, not extruding beyond the surface.
+
 ![wieght_pan_adapter_assembly.png](Resources/wieght_pan_adapter_assembly.png)
 
 ## Assemble A&D FX Shield
+
 ### Overview
+
 The FX Shield provides the interface between the A&D FX-120i/300i.The Open Trickler is also designed to
 be mounted directly on top. 
+
 ![fx_shield_overview.png](Resources/fx_shield_overview.png)
 
 ### Component Prep
+
 8x heatset inserts are to be melted into the plastic on both sides of the scale shield printed part. 
+
 ![fx_shield_install_heatset_inserts.png](Resources/fx_shield_install_heatset_inserts.png)
 
 ### Lower Assembly
+
 Use 4x M3x12 SHCS to join scale base adapter ring, scale pan cover and scale shield together. 
+
 ![fx_shield_lower_assembly.png](Resources/fx_shield_lower_assembly.png)
 
 ### Upper Assembly
+
 Use 8x M3x10 SHCS to join the trickler adapter plate, with front and rear discharger. Screws are to be
 threaded to the bottom the Open Trickler front and rear body. 
+
 ![fx_shield_upper_assembly.png](Resources/fx_shield_upper_assembly.png)
 
 ### Put upper and lower together
+
 Use 4x M3x8 SHCS to join the upper and lower together. (The Open Trickler body is hidden to for demonstration purpose)
+
 ![fx_shield_general_assembly.png](Resources/fx_shield_general_assembly.png)
 
 ## Assemble Pan Cover
+
 The pan cover is used to protect the pan from dust or accidental drops. The pan cover can be seamly
 put onto the shield body when not used. 
 
 ### Overview
+
 ![pan_cover_overview.png](Resources/pan_cover_overview.png)
 
 ### Component Prep
+
 Melt 3x heatset inserts into the plastic body from the top.
+
 ![pan_cover_install_heatset_inserts.png](Resources/pan_cover_install_heatset_inserts.png)
 
 Install 2x M3x6 BHCS to the bottom of the lower body. Please do not over tighten those screws
 as they are designed to directly screw into the plastic. 
+
 ![pan_cover_install_locator.png](Resources/pan_cover_install_locator.png)
 
 ### Assembly
+
 Use 3x M3x8 SHCS to join the pan cover lid to the body. 
+
 ![pan_cover_assembly.png](Resources/pan_cover_assembly.png)
 
 ## Assemble Rear Discharge Cup
+
 The discharge cup is used to help cleaning powder from the reservoir by catching remaining powder
 from the drainage hole. 
 
 ### Overview
+
 ![rear_discharge_cup_overview.png](Resources/rear_discharge_cup_overview.png)
 
 ### Component Prep
+
 Melt 2x heatset inserts into the ring. 
+
 ![rear_discharge_cup_install_heatset_inserts.png](Resources/rear_discharge_cup_install_heatset_inserts.png)
 
 ### Assembly
+
 Use 2x M3x6 BHCS to join the ring to the discharge cup. 
+
 ![rear_discharge_cup_assembly.png](Resources/rear_discharge_cup_assembly.png)
 
+## Powder Hopper Assembly
+
+### Overview
+
+![powder_hopper_overview.png](Resources/powder_hopper_overview.png)
+
+### Assembly
+
+Stack the hopper base to the rear body interface. Note the travel limiter should sit in the groove and the valve is in the "open" position. 
+
+![powder_hopper_travel_limiter.png](Resources/powder_hopper_travel_limiter.png)
+
+Stack 2x M3 washer to the rear body adapter pocket, then thread the M3x8 BHCS directly to the hopper base. Don't over tighten the screw and make sure the hopper base can rotate (with some resistance) between ON and OFF position. 
+
+![powder_hopper_install_screw.png](Resources/powder_hopper_install_screw.png)
+
+Lastly, slide the powder hopper to the top of the rear body. Make sure to push the powder hopper all the way in. The rear body adapter should sit flush with the rear body assembly.
+
+![powder_hopper_install_to_rear_body.png](Resources/powder_hopper_install_to_rear_body.png)
+
 ## Post Installation Adjustments
+
+### Adjust Pulley Depth
+
+Look through the unit from the left and right side, push or pull the pulley on the shaft to align the flange with the rotary tubes.
+
+![pulley_alignment.png](Resources/pulley_alignment.png)
+
+### Tension The Belt
+
 You need to adjust the tension of the belt. First loosen 8x M3x8 BHCS used to secure stepper motors. 
 Then pull motors slightly to tension the belts. Once done, tighten all 8 screws. 
 
+![belt_tensioning.png](Resources/belt_tensioning.png)
+
 # Congratulations
-Your Open Trickler is assembled!
+
+Your Open Trickler v1.1 is now assembled!
 ![fx_shield_final_view.png](Resources/fx_shield_final_view.png)
diff --git a/Resources/assembly.PNG b/Resources/assembly.PNG
diff --git a/Resources/assembly.jpg b/Resources/assembly.jpg
diff --git a/Resources/render.PNG b/Resources/render.PNG
diff --git a/STL/Legacy/README.md b/STL/Legacy/README.md
@@ -0,0 +1 @@
+# No, you don't need to print any files from the Legacy folder. 
diff --git a/STL/OpenTrickler/lee_bottle_adapter.stl → STL/Legacy/lee_bottle_adapter.stl b/STL/OpenTrickler/lee_bottle_adapter.stl → STL/Legacy/lee_bottle_adapter.stl
diff --git a/...Trickler/rear_reservior_adapter_plate.stl → STL/Legacy/rear_reservior_adapter_plate.stl b/...Trickler/rear_reservior_adapter_plate.stl → STL/Legacy/rear_reservior_adapter_plate.stl
diff --git a/STL/OpenTrickler/40_teeth_gt2_pulley.STL b/STL/OpenTrickler/40_teeth_gt2_pulley.STL
diff --git a/STL/OpenTrickler/40_teeth_gt2_pulley_x2.stl b/STL/OpenTrickler/40_teeth_gt2_pulley_x2.stl
diff --git a/STL/OpenTrickler/Tools/608_bearing_eject_helper.stl b/STL/OpenTrickler/Tools/608_bearing_eject_helper.stl
diff --git a/STL/OpenTrickler/Tools/608_press_helper.stl b/STL/OpenTrickler/Tools/608_press_helper.stl
diff --git a/STL/OpenTrickler/Tools/6804_bearing_eject_helper.stl b/STL/OpenTrickler/Tools/6804_bearing_eject_helper.stl
diff --git a/STL/OpenTrickler/Tools/6804_bearing_press_helper.stl b/STL/OpenTrickler/Tools/6804_bearing_press_helper.stl
diff --git a/STL/OpenTrickler/Tools/README.md b/STL/OpenTrickler/Tools/README.md
@@ -0,0 +1,7 @@
+# Bearing pocket calibration? What is it?
+
+The bearing pocket calibration is the file derived as a part of the front body. You can print this part and test fit with both 6804 and 608 bearings. 
+
+* If you cannot insert the bearing to the pocket even with the help with bench top vise, you may need to re-calibrate your print for flow extrusion. Your flow is too high. 
+
+* If the bearing is sitting loose in the pocket and can fall off, it means the printed part is under extruded. Still, you may need to re-calibrate your print for flow extrusion as your flow is too low. 
diff --git a/STL/OpenTrickler/Tools/bearing_pocket_calibration.stl b/STL/OpenTrickler/Tools/bearing_pocket_calibration.stl
diff --git a/STL/OpenTrickler/bearing_cover_x2.stl b/STL/OpenTrickler/bearing_cover_x2.stl
diff --git a/STL/OpenTrickler/front_body.stl b/STL/OpenTrickler/front_body.stl
diff --git a/STL/OpenTrickler/front_door.stl b/STL/OpenTrickler/front_door.stl
diff --git a/STL/OpenTrickler/front_rear_door_x2.stl b/STL/OpenTrickler/front_rear_door_x2.stl
diff --git a/STL/OpenTrickler/large_rotary_tube.stl b/STL/OpenTrickler/large_rotary_tube.stl
diff --git a/STL/OpenTrickler/rear_body.stl b/STL/OpenTrickler/rear_body.stl
diff --git a/STL/OpenTrickler/rear_door.stl b/STL/OpenTrickler/rear_door.stl
diff --git a/STL/OpenTrickler/small_rotary_tube.stl b/STL/OpenTrickler/small_rotary_tube.stl
diff --git a/STL/Powder Hopper/README.md b/STL/Powder Hopper/README.md
@@ -19,12 +19,11 @@ Material
 * hopper_body: Translucent material like natural PETG or translucent PLA. 
 * hopper_cap: TPU95a is recommended. But you can print it in any material you like. 
 * rear_body_interface: Any hard material you like. 
+
+
 
-
-
-## Special about hopper_body
+## How to Print opper_body
 
 The hopper_body is parameterized. You can scale the length of the body along Z axis to make it bigger. 
 
-The hopper_body is recommended to print in VASE mode with 0.8mm single wall thickness to give you best translucent look and no Z seam. 
-
+The hopper_body is recommended to print in **VASE mode with 0.8mm single wall thickness** to give you best translucent look and no Z seam. 
diff --git a/STL/Powder Hopper/hopper_body.stl → STL/Powder Hopper/hopper_body_100mm.stl b/STL/Powder Hopper/hopper_body.stl → STL/Powder Hopper/hopper_body_100mm.stl
diff --git a/STL/Powder Hopper/hopper_body_150mm.stl b/STL/Powder Hopper/hopper_body_150mm.stl
diff --git a/STL/Powder Hopper/hopper_body_200mm.stl b/STL/Powder Hopper/hopper_body_200mm.stl
diff --git a/readme.md b/readme.md
@@ -1,36 +1,40 @@
-# Open Trickler Mechanical Design
+# Open Trickler
+
 ![render](Resources/render.PNG)
 
 Inspired by the [AutoTrickler v4](https://autotrickler.com/pages/autotrickler-v4) and [Super Trickler](https://supertrickler.com.au/), the OpenTrickler is designed be printed and assembled using common tools to build Voron printers.
 
 Join our [discord server](https://discord.gg/ZhdThA2vrW) for help and development information. 
 
-
 # BOM
+
 BOM is now a part of the assembly [Manual](Manual/assembly.md#bom)
 
 # Sourcing Guide
+
 [Sourcing Guide](Manual/sourcing_guide.md)
 
 # Print Guide
+
 The printer need to be tuned at least for extruder e-stepts and flow as it has plastic to metal contact which requires certain tolerances. The Open Trickler can be printed in various materials.
 
- * Body Material: ABS/PETG/PLA you name it.
- * Belt: TPU 95A.
- * 4 walls, 5 tops and bottoms.
- * 0.2mm layer height, force 0.4mm line width and 0.2mm for the first layer.
- * 40% infill is recommended.
+* Body Material: ABS/PETG/PLA you name it.
+* Belt: TPU 95A.
+* 4 walls, 5 tops and bottoms.
+* 0.2mm layer height, force 0.4mm line width and 0.2mm for the first layer.
+* 40% infill is recommended.
+
+# Print Orientation
 
-# Print Orientation 
 You should print provided STL with default orientation
 
+# Assembly
 
-# Assembly 
 [Assembly Manual](Manual/assembly.md) 
 
-
 # Controller
+
 The Open Trickler Controller is split into following projects: 
 
- * Custom PCB with Raspberry Pi Pico [Raspberry Pi Pico Motor Expansion Board](https://github.com/eamars/RaspberryPi-Pico-Motor-Expansion-Board)
- * Firmware that utilises the Raspberry Pi RP2040 micro controller [OpenTrickler RP2040 Controller](https://github.com/eamars/OpenTrickler-RP2040-Controller)
+* Custom PCB with Raspberry Pi Pico [Raspberry Pi Pico Motor Expansion Board](https://github.com/eamars/RaspberryPi-Pico-Motor-Expansion-Board)
+* Firmware that utilises the Raspberry Pi RP2040 micro controller [OpenTrickler RP2040 Controller](https://github.com/eamars/OpenTrickler-RP2040-Controller)