Smart Orbiter v3.0 summary
Smart Orbiter v3.0, a brand new innovative all in one dual drive extruder.
The main mission of this design is the integration o the well proven Orbiter v2 concept into a lightweight all in one smart extruder.
Why smart? This is the first extruder with integrated electronics. Together with Klipper, it is an awesome combination I guarantee!
1. Features and performance
This brand new all in one
extruder design with many cool features we call Smart Orbiter v3.0
is one of my latest and finest extruder design
made in collaboration with LDO Motors. The extrusion system concept and mechanical
performances are similar to the Orbiter v2.0 but completely redesigned from ground
up.
Summary of the coolest features
ü
Pure plated copper heat-block with 60W ceramic
heater and Bontech CHT nozzle for highest possible weight VS flow ratio;
ü
Heat-break performance optimized with finite elements
analysis for extreme temperature gradient to ensure clogless free printing
experience;
ü Unique
tensioning mechanism with elastic predefined tension levels
ü Frameless
recessed fan to reduce the extruder weight and outside dimension
ü Large
RNC coated dual drive gears with planetary gear reduction, similar to orbiter
v2.0
ü New
precision main shaft design to reduce gear eccentricity
ü Full
aluminum housing with Delrin plastic gears for low noise and long lifetime
ü The
smart feature – integrated electronics
ü Easy
remove system of the secondary drive gear for easy cleaning and maintenance
ü Double
filament exit guide system for best TPU printing performance
ü Overall
weight is 175g
Heat-block
New 60W ceramic heater with Bondtech CHT nozzle for highest flow/weight ratio.
Very short distance between drive gears and heat-block (17.7mm)
Screw mounted thermistor for best thermal contact (104NT-4-R025H42G - Optional PT1000)
Easy and fast nozzle + heat-block swap – single screw
release
Bimetallic heat-break
Heat-break made out of stainless steel tube with 0.25 mm wall thickness for lowest heat transfer.
M7 heat-block mounting screw - compatible with V6 heat-block styles
Bi-metallic heat-break together with the heatsink optimized for highest temperature gradient using finite element analysis.
Wire strain release
Stainless steel wire strain release feature to avoid wire brake issues of the heater and thermistor wires.
Shape optimized for bad thermal transfer to reduce thermal losses.
Quick nozzle change
Quick nozzle change
optimized for best thermal performance implies a simple swapping of the
heat-block retained by one single screw.
Heater and thermistor
wires connected via microfit connectors for easy electrical disconnection.
High Flow
Best optimized weight vs flow ratio thanks to Bondtech CHT nozzle.
Note: Actual flow depends on the filament type, nozzle
temperature and size. The picture exemplifies a typical behavior measured using
SUNLU PLA @ 210°C. The figure shows performance results using standard V6 plated
copper nozzle, Bondtech CHT 0.4mm and 0.6mm.
Double filament guide
For good TPU printing experience its important that there is no gap left between the drive gears and exit guide where the filament could escape.
The two guarding features, center and side leads to no physical space where even the most flexible filament can escape.
The center guide stops filament to be chewed in between the drive gear tooths.
The side guides stops the filament to be chewed into the gap between the drive gears.
Filament Tensioning
Filament tensioning lever with three predefined positions: open, L1 (soft) and L2 (hard).
No need to guess anymore the correct tensioning, the
predefined positions ensure repeatable and always correct tensioning.
The elastic tensioning arm makes sure the tensioning is independent from filament diameter and avoids filament deformation due to over-tensioning.
Secondary drive gear
Secondary drive gear easy remove feature for easy cleaning and maintenance.
The secondary drive gear together with the tensioning arm can be removed simply by removing one M3 screw.
Precision mainshaft
Redesigned octagonal shaped precision aluminum main shaft.
The outer diameter of the shaft is slightly bigger than the inner diameter of the bearing and the main drive gear. The octagonal shape allows slight deformation of the aluminum shaft to match the exact inner diameter of the bearings and the drive gear, therefore reducing any eccentricity to a minimum.
Integrated electronics
Integrated electronics, the smart features:
ü Filament sensing and auto load
ü Filament
auto unload
ü RGB
LED lit filament input
ü White
LED hotend lit
ü Extruder
temperature sensor
ü ESD
and short circuit protection
ü Optimized
for Klipper
Outside Dimensions
Total weight of 175g.
3. SO3 Firmware configuration
3.1 Basic configuration
* The extruder itself without filament can handle acceleration up to 25000mm/s2. Adding weight of the filament it drags along its recommended to set max acceleration below 8000mm/s2. To reduce clicking noise of the extruder (due to fast direction change) you may limit acceleration to 3000mm/s2
3.2 Klipper extruder configuration
[extruder]
step_pin: Pxx #define correct port number
dir_pin: !Pxx #define correct pin number
enable_pin: !Pxx #define correct pin number
microsteps: 16
full_steps_per_rotation:
200
rotation_distance: 4.69 #includes gearing ratio
nozzle_diameter: 0.4 #define nozzle
diameter
filament_diameter: 1.750
max_extrude_only_distance:
500
max_extrude_only_velocity: 120
sensor_type: ATC Semitec 104NT-4-R025H42G
sensor_pin: Pxx #define correct port number
pullup_resistor: 4700
min_temp: 0
max_temp: 350
pressure_advance: 0.015
pressure_advance_smooth_time: 0.03
min_extrude_temp: 170
smooth_time: 0.5
max_extrude_cross_section:10
control = pid
pid_Kp=21.558
pid_Ki=1.482
pid_Kd=78.418
[tmc2209 extruder]
uart_pin: Pxx #define correct pin number
interpolate: true
run_current: 0.85 #**
sense_resistor: 0.11 #**
stealthchop_threshold: 0
driver_TBL: 0
driver_HEND: 6
driver_HSTRT: 7
driver_TOFF: 4
**Very important note!!! Please make sure the sense resistor is set according to what you have on board. TMC2130, TMC2208 and TMS2209 usually have 0.11Ω, TMC2660 have 0.051Ω and TMC5160 have usually 0.075Ω.
As an example, if you set by mistake the sense resistor to 0.11Ω instead of 0.051Ω the real current of the motor will be more than double, and the power injected in the motor more than four time higher, yes you read it correctly FOUR - AKA 4 times higher. 0.85A shall give a power loss of about 3.5W doubling the current will lead to >14W - this will melt all the plastic gearset before you even notice something is wrong!
How you can identify the sense resistor? It’s pretty easy, look for two identical resistors which are bigger than all the others onboard or around the stepper driver. See the examples in the next pictures.
Resistor marking examples: R110 means 0.11, R075 means 0.075Ω, R051 means 0.051Ω;
Sometimes I also doubt myself if the setting I'm playing with really sets the current and not something else does. Here is what I do to make sure I’m doing it right:
Set the current to a very low level 0.1-0.2A. Command extrusion, you should see the extruder turns but it skips steps very easy. This means you are tingling the right configuration, then set it to what it should be and check motor temperature, should not exceed 75°C running at room temperature. If yes you might have misconfigured something (shunt / sense resistor) causing higher motor current than you believe.
3.3 Integrated Smart Features
Internal electronics smart features are:
ü Filament sensing & auto load
ü Filament auto unload
ü RGB LED lit filament input
ü White LED hot-end lit
ü Extruder temperature sensor
Pinout of the internal electronics connector is the following:
1 -> Hot-end lit
2 -> Extruder temperature - 100K NTC
Generic 3950
3 -> Filament Unload
4 -> Filament Sensing
5 -> RGB Filament input lit - WS2812B
6 -> +5V
7 -> GND
The correct pins to which the Smart Orbiter signals are corrected must be defined first. It can be done very simple by defining the correct port names in the [board_pins SMARTORBITER3] section from the beginning of the configuration file. Please do not change the pins alias name!
Include the configuration file into the beginning of your printer.cfg.
3.4 Motor current vs extruder performance and temperature
First let me repeat that stepper motors are running hot
by design. Is not uncommon to run stepper motors at temperatures over 100°C. Actually,
designs in which the stepper motor does not run hot are the bad ones /
heavily overengineered. And do not worry, nothing will happen to your stepper
running hot. You will not extend its lifetime by running it at lower
current and cooler.
The stepper used in the Smart Orbiter design is rated to 180°C. Of course, you should not run it that hot. The limit of the Orbiter max temperature is limited by the plastic DuPont Delrin gears with temperature
deflection rating up to 120°C.
Concluding all these limits the
orbiter stepper temperature shall not exceed 100°C at any conditions.
See the attached graphs
defining the Smart Orbiter v3.0 (for LDO36STH20-1004AHG) performance based on motor
current.
4. SO3 Tool-board
Should a tool-board magic smoke come out because of
user error? Why?
Should a tool-board be destroyed by a fault in your 3D printer?
Why?
My answer is NO! And this is what this tool-board is all
about!
We are hobbits, professionals and let’s face it, we do
mistakes, and when the magic smoke shows up everybody is disappointed, even if
we know it’s a user fault. In this board, I promise you the magic smoke
is kept inside extremely tight!
4.1 Features
Smokeless Features
·
Optimized
for Smart Orbiter v3 shape and features
·
STM32F042
microcontroller running on 48MHz
·
Automotive
USB communication to Raspberry PI
·
Onboard
LIS2DW12 accelerometer
·
TMC2209
extruder stepper driver
·
Direct
connection to SO3 integrated board
·
1x PWM
controlled part fan outputs
·
DC-DC
converter based Hot-end fan driver, compatible with 12/24V fan types with RPM
speed input signal
·
Hot-end
temperature sensor input compatible with standard NTC or PT1000 temperature
sensor types
·
I/O
for bed level sensor
·
X-Stop
sensor input
·
Onboard
temperature sensor
· Advanced thermal management
Protection Features
·
Active
short circuit protected Hot-end output
·
Active
short circuit protected fan driver outputs
·
Active
Protection circuit against reverse power supply connection
·
Protection
against loss of GND supply
·
Analog
and digital inputs protected against short to +24V supply voltage
·
USB
data lines protected against short circuits to GND and +24V
·
EMI
interference and ESD protection for all inputs and outputs
4.2 Block diagram
Block diagram for Orbitool SO3 v1.4
4.3 Pinout definition
Part cooling uses two 12cm side blowers and a deflector fixed to the SO3 which redirects air downward towards the printed part.
6. Adapters Mounts
Collection of mounts, adapters for Orbiter v3.0 extruder designed by our 3D community members. A big thanks to all of them, we all appreciate your work!
The list will grow as new adapters are designed, in case I missed some please contact me via our Facebook support group.
To link you project I have a few minimum requirements:
· The solution shall be proven and verified.
· Provide a nice rendered picture or a nice picture of the setup you are proud of.
· Link to where the design is stored.
Orbitron Cube
This is the cooling and mounting solution of the Orbitron 3D printer.
Uses an L shaped aluminum mounting part which holds the SO3 and the belts.
Part cooling uses two 12cm side blowers and a deflector fixed to the SO3 which redirects air downward towards the printed part.
For more details check out the Orbitron cube webpage!
Railcore II ZL X LDO Smart Orbiter V3 & Euclid probe mount
A great adapter design for Railcore II, designed by Yves from Fractalengineering.
Beltender adapter for Ender 3 V2 with MGN12 X gantry
Complete toolhead designed using SO3 for the Beltender. The toolhead should be compatible with most of the ender v2 MGN12 upgrades.
*Note: This design is not fully tested, its still under beta testing, but its a good start and idea sharing project of how the SO3 could be mounted on a bedslinger printers.
