Titan AERO :D

Post improvements made for UP, and share ideas.
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arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Titan AERO :D

Post by arhi » Sun Apr 15, 2018 11:00 pm

I'm in the process of mounting Titan Aero from E3D on the UP Plus2 ... Why? Well I have bunch of 3mm filament I want to print with so I purchased Titan Aero for 3mm filament and ... well so far mounted properly, need to make new extruder board (designed, need to make it tonight/tomorrow) as heater I put on Aero is 50W and original heater is 18W (on UP's hotend) so I don't know if the fet's on the original board are able to handle higher current nor if the PSU is at the limit or not, so I'm using the 12V going normally in to the heater to trigger a fet that will use external 12V source to drive the heater..
Attachments
Capture1.JPG
schematic for the new extruder board
Capture1.JPG (180.14 KiB) Viewed 3217 times
Capture.JPG
pcb for the new extruder board
Capture.JPG (414.5 KiB) Viewed 3217 times
IMG_0886_1000.JPG
Titan Aero on UP Plus2
IMG_0886_1000.JPG (189.19 KiB) Viewed 3217 times

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Sun Apr 15, 2018 11:05 pm

ah and if all goes well this mounting option includes the piezo bed sensor :D .. after I'm done and it all works I'll share all the files :D and more pics

hoek67
Posts: 28
Joined: Tue Oct 13, 2015 11:09 pm

Re: Titan AERO :D

Post by hoek67 » Tue Apr 17, 2018 10:19 pm

Very nice!

I assume you reverse engineered the PCB near the extruder?

Really wish the Up was more open as I'd love to make an OLED display for it and have remote shutdown functionality.

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Wed Apr 18, 2018 4:28 am

hoek67 wrote:
Tue Apr 17, 2018 10:19 pm
I assume you reverse engineered the PCB near the extruder?
not much there, just few connectors, you see the pinout of the connectors on my schematic
but since the original heater is low power (18W) I had to add this mosfet driver to power the heater from external source.. I'll be doing same with bed heater too since the bed take forever to heat up so I want to put more powerful heater for bed too
hoek67 wrote:
Tue Apr 17, 2018 10:19 pm
Really wish the Up was more open as I'd love to make an OLED display for it and have remote shutdown functionality.
I gave up on their system while back and upgraded to smoothieware board so bed mesh leveling, full control of the printer... all chabang .. now trying to get this aero to work so I can print 3mm too

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Wed Apr 18, 2018 11:24 pm

first test - WORKS :D
- motor works
- heater works (pulling 4A from external PSU, switched with mosfet)
- extruder fan works (turns on/off with global up plus enable pin)
- part cooling fan works
- pt100 sensor works

now need to mount this pcb to extruder somehow and start printing with 3mm filament :D
0-02-05-857a2a0c9b667d4ba2d99888d4b7ac4ded561deba20e0e7cf2c875ae0369ec4e_740174f5.jpg
0-02-05-857a2a0c9b667d4ba2d99888d4b7ac4ded561deba20e0e7cf2c875ae0369ec4e_740174f5.jpg (133.58 KiB) Viewed 3095 times
0-02-05-e0fafc2dd75a6889eb9ea9007aba8614b5366f8a5809aad0c910ad16f7098f31_c8a77d7a.jpg
0-02-05-e0fafc2dd75a6889eb9ea9007aba8614b5366f8a5809aad0c910ad16f7098f31_c8a77d7a.jpg (69.98 KiB) Viewed 3095 times

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Wed Apr 18, 2018 11:45 pm

hoek67 wrote:
Tue Apr 17, 2018 10:19 pm
I assume you reverse engineered the PCB near the extruder?
here's the image if you want to make your own changes..
12 on the P4 - 12V when enable is running (printer on, motors on), floating when print is not enabled
G in the P4 and P5- GND

P1.30 on the P2 connector - this is the pin smoothieboard sees, it's the pin original electronics sees as bed leveling pin, it's pulled up high so you need to draw it to ground to "trigger" it
G on the P2 connector - ground

G on the P5 connector - ground
12 on the P3 and P5 = 12V always (irrelevant to enable)
P1.8 on P3 - this is tied to ground when part cooling fan is enabled (if you set part cooling fan on P1.8), originally this is supposed to control some light, probbly on mini as plus has no lights

HH - heater
PP - PT100

R - red cable to motor
BLU - blue cable to motor
BLA - black cable to motor
G - green cable to motor
UP_PCB_decoded_arhi.jpg
UP_PCB_decoded_arhi.jpg (416.21 KiB) Viewed 3092 times
part cooling fan.JPG
part cooling fan.JPG (198.62 KiB) Viewed 3093 times
hoek67 wrote:
Tue Apr 17, 2018 10:19 pm
Really wish the Up was more open as I'd love to make an OLED display for it and have remote shutdown functionality.
with existing electronics .. you can read temp from the extruder, that's about what info I can get on the top of the printer so not really very informative... if you switch to smoothieware then you can add a lcd if you like, I personally use octoprint+smoothieware and I have lcd on the octoprint not on the printer itself (also the filament runout sensor I attached to octoprint, camera..) .. that gives you remote control..

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Wed Apr 18, 2018 11:50 pm

one additional info, in the schematic I put a general mosfet driver and general mosfet, what I'm using on the board are

TLP250 driver (I wanted to use HCPL-J312-000E that's ~3x more expensive and can push double the current into the mosfet but it shown not to be required)

IRL8743 mosfet

the pinout is more/less identical between drives and between mosfets so you just find what satisfy your current requirements and your speed

ricks01
Posts: 165
Joined: Wed Dec 30, 2015 6:07 pm

Re: Titan AERO :D

Post by ricks01 » Thu Apr 19, 2018 2:25 am

seems to me like its too much trouble and work just so you can use 3mm filament.

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Thu Apr 19, 2018 8:41 am

well, not really :D ... took about 2 hours to design, etch and solder the board .. few minutes to draw the part that clamp and hold the AERO to UP and another hour to crimp all the cables on AERO (I'd have to do that anyhow on aero so that should not count :D ) .. AERO is actually purchased for another printer, but I want to test it on UP 'cause I want to see if it is possible to have plastic base plate held at single point with single screw .. and what kind of print quality I can expect :D .. aero will move from UP soon (working good or bad, irrelevant) and will be replaced with flex3drive (much lighter then aero, also with 3mm system)...

now as for "why move to 3mm" - 3mm filament is waaaaaaaaaaay more precise then 1.75mm filament for the same price. the filament manufacturer explained me the ropes .. thing is when you are making it the absolute precision is what changes the cost so for e.g. you can make filament at x$ per kilo that's 0.05mm precise .. now if you look at 3mm filament 0.05mm is 1.6% error but for 1.75mm that's almost 3% so error doubles ... same issue is with roundness of the filament etc.. so 3mm is really more precise, but to extrude 3mm you need stronger motor, more heat etc etc..

the other reason to switch from UP's extruder are nozzles. I do love my UP's extruder, it's so simple and after I tweaked it a bit and put microswiss hardplated nozzle (so I can print metal filled and glow in dark filaments) it works really great, but the availability of nozzles is really really limited .. 2 nozzles from TT and 3-4 nozzles from microswiss and that's about it .. on the other hand when I switch to E3D heater block I have more nozzles then I can count :D (including the ruby one for extra hard materials)

so, no, I don't agree it's too much work for the testing I'm doing... certainly not something I'd recommend to "everyone", especially not before it's tested for a while :D ... we'll see how this goes and how flex3drive will work later on .. for now the only really super important upgrade I do suggest for every UP Plus2 user is the https://www.thingiverse.com/thing:2509563 as with that one you can print Nylon, PETG, PC etc.. without issues.... the PLA printing kit is also great https://www.thingiverse.com/thing:2529826 but it requires control over the part cooling fan that I'm not sure you can have without changing the cpu board on UP so that one might be useless for regular UP users (you could link the fan to 12V "always" and maybe add some pwm circuit to manually change speed but.. it does not sound too good)

hoek67
Posts: 28
Joined: Tue Oct 13, 2015 11:09 pm

Re: Titan AERO :D

Post by hoek67 » Thu Apr 26, 2018 1:16 am

Hi, thanks a lot for the detailed explanation of the small PCB.

My mod was fairly simple, complete redesign of the extruder housing and hacked into the small pcb to power a small LED above the extruder. I found with the original one on any job > 2+ hours the stepper motor would get so hot it would sear skin on contact! I redesigned so the stepper sits on small "ribs" that allowed air from the fan to flow around the stepper but without interfering with the extruder.

The aim was to make the stepper operate as cool as possible, be as small and light weight as possible and still offer a few other small "tweaks" (ie. filament feeding).

I "invested" in some extruder insulation that also stopped a lot of heat transfer.

The end result after a 10 hour print was a successful print and ability to touch and hold the stepper motor! :shock:

My mod on thingiverse that I've been using for years now without any problems. https://www.thingiverse.com/thing:365935

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Thu Apr 26, 2018 11:33 pm

hoek67 wrote:
Thu Apr 26, 2018 1:16 am
the stepper motor would get so hot it would sear skin on contact!
well the stepper is used here as a part of a heatsink that's why it's getting that hot. they can operate safely at 80C and that's not something you want to touch, the problem is when the whole thing is hot printing PLA is almost impossible (not that I care too much about PLA but anyhow)

look at this piece (my design): https://www.thingiverse.com/thing:2509563
you replace the original fan with a blower, it cools extruder so good that motor temp drops significantly

now, additionally I use also https://www.thingiverse.com/thing:2529826 (also my design) that does two things
1. makes the air flow around the stepper motor cooling it
2. uses that air to cool your printed part

you can attach the blower to the 12V you have on the board there and have it blow non stop (not bad for PLA, maybe add a switch so you can turn it off for first layer manually) ... or if there's finally a way to control part cooling fan from the UP software (hw allows it, it's just question if sw does it) you can hook it as explained for the small board (P3)

before I did all this I glued few memory/stepperdriver/chipset heatsinks on the stepper itself, that helps too and those are cheap

anyhow this combo of 2509563+2529826 I'm printing
PLA
ABS
PETG
Nylon
CF FILLED ABS
PC
PP

so from 185C to 320C without issues (and finally today I upgraded the bed heater to more powerful one, will write a post in a sec about it so now my bed can go to 120C in my lifetime :D )

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Thu Apr 26, 2018 11:51 pm

btw those parts I use, all have sources exposed (onshape) so you can easily mod them to whatever you like :D

I see you use in-line resistor hack - don't "studio" allow for setting arbitrary temp now? afaik that resistor is no longer needed (I used to use the 100R multiturn pot instead of fixed res to setup different temp offsets for different materials)

arhi
Posts: 229
Joined: Sun Mar 08, 2015 10:51 pm

Re: Titan AERO :D

Post by arhi » Wed May 02, 2018 1:16 am

doing some tests with aero I have to say that tiertime original extruder with few of my upgrades is lighter and works better for 1.75mm filament then titan aero for 1.75mm filament.. of course original one can't be used for 3mm filament but for 1.75 petg, pc, nylon.. it all works flawlesly with original TT extruder!!!

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