Hacdc log

I thought it would be good to keep a log of what's going on. Contributions encouraged. Note that many entries extend into the morning of the following day. Aug. 14, 2018 The box2 print on the Taz had finished but was about a mm short, presumably due to a likely z axis skipping problem. I later stopped someone else's print because filament had stopped extruding, then noticed that the new filament guide tube was missing & the reel, which had been changed (light green), was on backwards. I fixed the reel and the print worked (but looked sloppy). I found the missing tube on the previous reel (white), reinstalled it, and, after adjusting the printhead height, started another box2. I also redesigned the probe mount for the Taz (probemount2A.escad & probemount2B.escad (both at renderadmin/ImplicitCAD/radioshack_box)). Neither regular printer was working. Aug. 16 The box2 print failed due to the same intermittent connection failure that's been plaguing the printer. Had delayed monthly meeting. Julia worked extensively to fix the z axis skipping but the z axis now keeps getting badly out of level between the 2 sides so the Taz is unusable. On the other hand, after turning on the controller (it was off but I think it was on on Aug. 14), both regular printers are now working. Aug. 20 Julia located a good design for a replacement extruder for the Ultimaker. Julia worked on the Taz. It it now working but the z axis still seems to be skipping & the intermittent disconnect problem is probably still there. There is now a box for RODS. Caution: It is dangerously topheavy. Aug. 23 A box again printed successfully but was a mm short. Julia rebuilt the Taz. Started another box but the filament stopped feeding; shut printer off. I added documentation to the Wiki on the laser cutter but unfortunately broke the front panel (flimsy plastic); I was able to sort of fix it by adding washers. Sept. 1 Rewired laser cutter (details in Cheap Chinese Laser entry). The laser should now be ready for testing by an expert. Several people from Nova Labs visited. They said Nova Labs would probably help HacDC fix broken equipment (if we can get it there). Sept. 3 Tom showed up to test the laser cutter. Manual firing worked but safeties did not. Got computer control of mirrors working but computer did not fire laser. See Cheap Chinese Laser entry for details. Due to the Wiki being uneditable the log was not updated. To summarize some of what happened: Julia replaced the power supply for the 3D printer computer monitor which may have been causing the random printer disconnections. She found that one roll of filament was causing problems because it needed to be extruded at 230 C (no simple way to test this). She also added heat sinks on the Taz z axis controller & stepper motors which solved the skipping problem. The Wiki was cleaned up (causing the above-mentioned uneditability). A test piece (the "sphinx") for the new Ultimaker extruder was printed. Oct. 4 The basement was found open & the lock for the outer grate is missing; it was temporarily replaced with a combination lock (contact Julia if you need the combination). Oct. 5 There was considerable chaos with Nick & people looking for him showing up at different times (finally resolved). The phone doesn't work. New parts for the Taz z axis are here. The science event list was finally updated (about time). Started printing a box4. Oct. 8 Phone is working. box4 & an Arduino cover printed well; started a box3. Finished design (still need to set values) for z-x rod joint for improved Taz z axis drive & the sphinx. Oct. 9 box3 printed well, started another. Only 4 people (including a new member) at the monthly meeting; little to report. Finished design for general pulley mount. Oct. 11 box3 failed due to filament stripping. Successfully printed stenograph machine stand. Started printing test body for new Ultimaker extruder. Fixed Cura so it will work for Rostock; tabletop computers D8PGDD1, 1M0QJH1, 5VVYKH1, & DJ7VKC1 now work. Determined that problem with some faulty tabletop computers was the USB drive and rewrote one drive. Created new HacDC hacks entry on Blabber to document fixes like how to change the cordless phone ring & fix Cura. Oct. 15 Extruder body print failed due to filament stripping but several other prints worked. The Algix filament was found to print well at an unusually low 180 C. Julia worked on the Rostock. Oct. 18 The Taz jammed & Julia cleared a clog from the printhead. The Algix filament did not print satisfactorily. A print with leftover filament worked but a new roll of filament had problems with stripping. A member swapped a nonworking (regular) Kodak printer for a working (after a little work) Epson one. A visitor tried to use the CNC mill (note that the parallel cable connects to the upper connector on the computer) but the y axis would not move. Oct. 19 The filament on the Taz may require a higher temperature; testcube printed fine at 225 C. The boxes have been recompiled for the Rostock (box1t32Rf.gcode etc. in /ImplicitCAD/Radioshack_box on renderadmin) and the zero-thickness problem eliminated. Tried to print a box3 at 225 but the filament started feeding erratically and the printhead now seems completely jammed like before. Oct. 22 Julia worked on both the Taz & Rostock. Additional cleaning of the feed gear and shifting the printhead down seems to have fixed the Taz problem (which may be the result of a tiny fan starting to fail); also the current filament should be printed at 229 C. The Rostock works but the fan may need to be turned off (set fan speed to 0) or down and there seems to be a loose connection (causing the temperatures to read def). Started printing (Taz) test body for new Ultimaker extruder. Oct. 23 HacDC has 2 new voltmeters (labeled HacDC 1 & 2). Extruder body test print successful. Attempt to print a box4 on Taz failed, possibly since it started at 215 C. Cleaned feed gear & successfully started a box3 at 229 C. After a false start printed a box1 on Rostock. Rostock printhead will not go above ~210 C and will drop when fan comes on, possibly crashing the print (def problem mentioned above). Immediately set fan speed to 0 when it comes on (typically when the first layer is completed). Started a box2 on Rostock. Oct. 25 Both boxes printed successfully. The Rostock temperature will plummet & crash the print if the fan is at 30%; at 25% the temperature doesn't seem to go over around 218. After a false start part of a kayak holder started printing OK on the Taz. Another object was successfully printed on the Rostock but an attempt to print another box resulted in everything going wrong - the printer behaved erratically, the printhead scraped the tape but then was in the air after being adjusted, the outer tube came off the extruder, & the short outer tube piece with a burnt end in the printhead clogged at the unburnt end. Oct. 29 Kayak holder part printed successfully. Nick dropped off 2 computers. Julia fixed the Rostock and found that the CNC mill was clogged & needed cleaning. Found that ImplicitCAD seems to get stuck on a certain rotate. The Taz printed another (small) object and started printing another copy of the sphinx (first copy is missing) while the Rostock started printing a box1. Oct. 30 Sphinx & box1 both successful. Started a box3 on both printers - the Rostock is printing wobbly. Put big metal case under table by SEM with computers inside (but wiring should be adjusted). Killed 2 flying bugs over the last 2 days (hopefully that's all of them). Nov. 1 Both boxes printed. The distortion (about warp factor 3) with the Rostock was from a loose printhead - fixed. A couple first-timers visited. Julia reflowed the graphics chip from an iMac G5 after a replacement for the badly burned-out halogen bulb for the soldering system was found in the basement but didn't have time to complete the repair. Some small items were printed on the Taz. Started printing another box3 on the Rostock & a test of the redesigned sphinx for the new Ultimaker extruder on the Taz. Nov. 5 The sphinx printed but the box3 stopped partway thru; both printers seem to have disconnected (the Taz after finishing), possibly due to a power fluctuation. The iMac repair worked (amazing) after a couple damaged connectors were fixed. Another small Taz print worked along with a test piece for the improved Taz z axis and a box4 was started on the Taz & a box2 on the Rostock. Tom got a new laser printer working (HP_Laserjet_Professional_P1606dn, can print double sided). An inkjet printer was successfully disassembled without ruining the controller. The inner door to the basement was open & the light was on but the outer door was still padlocked (opened from inside?). Nov. 7 Both boxes printed but there was still some distortion from the Rostock. Started printing another Taz z axis test piece & a box4. Nov. 8 Both prints worked. Small prints were done on both printers. A modified z axis test piece was printed on the Taz and the next version started. The Rostock again had a problem with not moving, not as bad as last time but it still seems to have caused the printhead to clog. Nov. 11 Test piece printed. Air conditioner was on - why? Printed an improved test piece - very close to final form. Started a box3 Nov. 12 Box3 printed. Printed a revised test piece. Julia unclogged the Rostock & found that the printhead heaters had weakened greatly (replacements ordered). The partially disassembled printer from Nov. 5 was apparently ruined. The problem with the intermittent failure of the Rostock to move may have been due to loose belts which have been tightened. The Rostock fan power supply was left unplugged to avoid having to turn the fan off (why didn't we think of this foolproof solution before?). The Rostock clogged repeatedly but finally worked (the third time's the charm). Another version of the Taz test piece was printed and seems perfect. The Rostock print crashed again - apparently the power supply is for another fan connection that isn't being used (so much for foolproof). (That power supply is actually for a fan on the extruder & was later plugged back in.) The belt tightening & unclogging procedures for the Rostock have been documented. Started box3s on both printers. The missing bathroom key turned up on the floor by the Taz. Nov. 13 Both boxes printed. Monthly meeting canceled - too few showed up. One visitor who was interested in repairing an old radio. Taz y-axis motor mount designed (but most parameters need to be added). Started a box2 on Rostock & box4 on Taz. Nov. 15 Both boxes printed but the box2 was a bit short because the Rostock ran out of filament. Two new people visited. Assigned values so a trial version of the Taz motor mount is ready to print. Printed a production version of the Taz z axis joint (but a minor change should be made and the position of the rod hole may also need to be changed). Printed half of a coupler for the new Taz z axis rod & started the other half. Nov. 19 Coupling printed. Small items printed. Installed coupling on testbed Taz; satisfactory. Measured rod position & adjusted z axis joint design accordingly. Designed improved generic coupling, printed test piece, adjusted design, & printed production version. Started printing new version of joint. Nov. 23 Z axis joint printed & it was installed on the testbed Taz & measured; some adjustments were made to the design and, after printing another coupling half, the revised joint was printed. It was just right so started printing another. Nov. 26 Joint printed (the filament broke leaving less than a foot left when the print finished, a clear violation of Murphy's Law). Julia dropped off filament for the Taz & Rostock, and parts. Printed 2 coupling halves (Taz, leaving about a foot of unused filament on one reel) & test motor mount for 2nd Taz (Rostock). Started another joint (Taz) & endpiece for 2nd Taz (Rostock). Nov. 29 Joint & endpiece printed. One hole in redesigned coupling turned out to be too big & at least one motor rod is notched; redesigned coupling accordingly and printed notched version. Found that ImplicitCAD would not compile some rotates because it ran out of RAM. Belt was installed on one side of the optical table. Started redesigning printer endpiece & motor mount as single stronger piece. The Rostock jammed extremely badly. A couple small items printed on the Taz. Started printing unnotched half of coupler. Dec. 1 Coupler printed. Installed revised coupler on 2nd side of testbed Taz. Coupler seems fine but rod was off by about .5 mm so joint does not seem to be exactly same on both sides. Printed another coupler half & started a 2nd. Dec. 3 Coupler printed. Julia worked her magic & got both the Rostock & CNC mill working including replacing the failing heaters in the Rostock printhead (so the fan should no longer be turned off). Printed 3 more coupler halves. Started a box 2 on Rostock & box4 on Taz. Dec. 6 Boxes printed. Was able to move new z axis on testbed Taz. Julia brought in 4 laptop video cameras but was unable to get any of them to work yet. Test print of body for new Ultimaker extruder brought in. Installed new z axis parts on Taz; rods were off by ~1.7 mm vs. ~.5 on the testbed Taz. New z axis works but printer needs to be adjusted - DO NOT USE the Taz. Started a box4 on Rostock. Dec. 10 Box printed. Started a box1 but it failed because one of the arms came loose at the top - fixed. One of the upgraded rods on the Taz wobbled badly which turned out to be due to an old part that was known to be warped. Shimming it with washers mostly eliminated the wobble. Taz has been recalibrated and is ready for use (so the z axis upgrade project has been successfully completed!). The "supercomputer" originally built to compile a huge fluidics chip was brought back in operation. Preliminary design of the motor mount endpiece for the Taz is complete. One of the laptop cameras was found to be incompatible with the current version of Linux altho a driver existed for it. Started printing box1s on both the Rostock & Taz but the Rostock stopped dead & the 3D printer computer will not respond (screen stays black) altho the Taz is still printing away normally. Dec. 11 Box1 printed but had a small shift part way up. 3D computer worked after restarting & reconnecting USB cable. Started a box4 on Rostock and a test piece for the new Taz motor mount end on the Taz. Found that Cura works for the Rostock on computers 1LDNKH1 & 7KDNKH1. Dec. 13 Test endpiece & box4 both printed. Corrected flaws in endpiece and, after a series of infuriating false starts, and discovering that excess belt on the Taz bed was snagging the main part of the belt and folding it so it snagged itself instead, started printing the revised endpiece & the other (pulley) endpiece. Dec. 17 Both parts printed. Designed & printed test piece for pulley mount for 2nd Taz. Modified endpieces & started to reprint both. Dec. 18 Both parts printed. Some parameters were corrected but there are unresolved problems: The pulley sticks out of the side of the pulley mount which will prevent it from fitting into the endpiece, the new belt is only about 12 mm below the top of the endpiece but the bottom of the pulley mount side is about 12 mm below the top of the endpiece, & the notch for the belt at the motor mount is too narrow and cannot be made much wider without reaching the bolt slots. Monthly meeting was fairly well attended. HacDC's rent will be going up significantly posing a serious problem. There was also a significant cost resolving the legal issue with Nancy. Small item printed on Taz. Started printing latest test version of pulley end & mount for Taz. Dec. 20 Objects printed. Pulley endpiece redesigned which should solve all the problems. A visitor wanted help developing a sleep aid light. Started printing latest test endpiece. Dec. 24 Endpiece printed. Broke testbed Taz endpiece pulley mount trying to remove pulley for examination but was able to remove pulley, make necessary measurements, and complete design of the pulley mount. Printed test pieces for 2 different versions & started a box3. Dec. 27 box3 printed (with hardly any leftover filament, another violation of Murphy's Law). Julia brought more filament (1 reel for Taz (seems to work at 215 C) & 2 for Rostock) & a high-resolution still camera (entrusted to Bobby). She installed the test pieces in the testbed Taz with satisfactory results; adjustments were made to endpiece designs. Piece holding belt to bed needs to be replaced. Small drone camera mount printed. Printed production version of pulley mount for testbed Taz and started motor endpiece and (to use up remaining filament) a box1 on Rostock. Dec. 30 Objects printed, but motor endpiece had lifted off bed; Julia had started another that printed with a shift and some possible separation. Small item printed. Started the production version of the pulley endpiece and a hopeful replacement for the belt-bed joint. Dec. 31 Endpiece printed but it & joint were backwards (WARNING: Bobby is terrible at thinking in 3 dimensions) altho basic idea of new joint was found to work. Another test joint was printed and design further adjusted. Heater installed in testbed Taz. Rather chaotic time with Julia's going-away party simultaneous with trying to get major work done. Adjusted level of Rostock bed with significant improvement (but need to document procedure). Started printing corrected pulley endpiece & box2. Jan. 2, 2019 Objects printed but endpiece lifted off bed; will hopefully still be usable. Added Rostock bed leveling to instructions. Printed another test joint. Replaced right bed leveling bolts on Taz with slightly longer ones to make adjusting easier. Started printing another version of the joint & a box4. Jan. 3 Objects printed. Test joint seems fine; belt attachment method seems to work very well. Several items printed but multiple object print failed because Taz ran out of filament - always check & it is best to print one object at a time; it should be faster & if something goes wrong you won't end up with multiple failed prints. Tom replaced the keyboard on a visitor's laptop. Jan. 5 Installed motor endpiece, pulley endpiece, pulley mount, & belt-bed joint in testbed Taz. Appears satisfactory; made a few minor adjustments to designs. Jan. 6 Julia took the Taz. Jan. 7 Tom did an amazing job to get the testbed (now only) Taz working under manual control (but it needs to be calibrated as well as set up for computer control). Some Ultimaker extruder parts printed but another print stopped dead - the dreaded disconnect problem. Jan. 8 At the monthly meeting the entire contents of the basement were declared outgoing so a major clearing out can be done, possibly at the end of March. If you want anything in the basement mark it or otherwise make it known. (The miter saw, one fire extinguisher, & a clip-on light socket are on loan from Bobby.) Jan. 10 Several visitors. One wanted to print rubber with the Mini but it wouldn't connect. A print on the Rostock failed because the design was too thin. Kevin got the Mini to connect but didn't get it unclogged & was unable to get the replacement Taz to respond. Installed setscrew in Taz endstop. Some sorting done. Jan. 17 A visitor tried to do a test print on the Rostock but it didn't work, probably due to a software problem since the old testcube printed fine. Kevin got the replacement Taz to move and discovered that it is version 1 rather than version 2 & a bunch of documentation for it. Jan. 18 After some problems getting the TV screen to work (documentation needed), movie night (The Martian) was successful altho turnout was rather low. Hot melt glued USB drives to several tabletop computers & some sorting was done. Jan. 21 It is now possible to routinely connect to the replacement Taz & give it commands. Attempts to read the current values of the parameters (which should be done before the firmware is updated) have been unsuccessful. Documented inductive sensor for Taz autoleveling in 3Ddoc.txt. Jan. 28 Two people successfully printed a bunch of small objects on the Rostock. Feb. 4 Several objects were successfully printed on the Rostock & Mini. Design for Taz belt-bed joint was adjusted to recover 10 mm of y capacity. Feb. 7 A bunch of rubber objects were printed on the Mini. Feb. 11 There was a moderate leak in the basement. The source is unknown; the leak had probably stopped when it was found. Object printed successfully. Feb. 14 Kevin was able to read & modify the firmware for the Taz. End cap for new reel holder for the Mini was printed & the holder started. Feb. 15 Print failed; the intermittent printer disconnect problem recurred (the print separated from the bed as well). Trying long prints is not recommended until this problem can be corrected. Movie night OK. The space behind the basement wall is not unexcavated dirt but a concrete tunnel. HacDC may be able to use this for storage. Feb. 18 Object printed. Kevin was able to change the calibration of the Taz z-axis but the results were inconsistent. Started printing (after unclogging Rostock extruder; 160 seems to be too cool when removing the old filament, try 180) improved version of the new reel holder for the Mini. Feb. 19 Reel holder printed, was installed on Mini, & is almost perfect!