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Insert 6x `m5-hex-nut` into the following region ![](img/y-gantry-hex-nut.png) ## Create Front-Left-Leg Subassembly + +### Prepare front-left-leg +- Remove any stringing from the print with a heat gun +- Insert 3x `m5-hex-nut` into the following regions + - 2x in bottom of the leg for customer-side `front-leg-extension` mounting + ![](img/front-leg-extension-mounting-nut1.png) + ![](img/front-leg-extension-mounting-nut2.png) + - 1x near extrusion pocket for customer-side attachment of front-drag-chain-mount + ![](img/front-drag-chain-mount-nut.png) + +- Insert 1x `m5-nylock-hex-nut` into in the underside of `belt-tensioner-arm` mounting post + ![](img/belt-tension-arm-nut.png) + ### Prepare belt-tensioner-arm -- Press an `M3-hex-nut` into the `belt-tension-arm` with the `arbor-press-jig` +- Press an `M3-hex-nut` into the `belt-tension-arm` with a `arbor-press-jig` ![](img/tensioner-arm-m3-hex-nut-insertion.png) -- Thread an `M3x16-bolt` all the way through the `belt-tension-arm` +- Thread a `M3x16-bolt` through the `belt-tension-arm` ![](img/m3x16-tensioner-bolt-install.png) -- Thread an `M3-acorn-nut` onto the end of the bolt +- Thread a `M3-acorn-nut` onto the end of the bolt - The `M3-acorn-nut` and `M3-hex-nut` should be on the same side of the `belt-tensioner-arm` - - Tighten the `M3-acorn-nut` onto the `M3x16-bolt` with pliers and an allen wrench + - Tighten the `M3-acorn-nut` onto the `M3x16-bolt` with a 5.5mm socket and an allen wrench ![](img/M3-acorn-nut-install.png) + ![](img/tighten-acorn-nut1.png) + ![](img/tighten-acorn-nut2.png) + - Rotate the `M3x16-bolt` until the `M3-acorn-nut` is loosely resting against the `M3-hex-nut` !!!info "This ensures the `belt-tensioner-arm` is installed with it's adjustment range fully available for when it's time to tension `GT2-belt`" + ![](img/tensioner-bolt-ok-ng.png) + - Insert a `M5-nylock-hex-nut` into `belt-tension-arm`'s hex-nut pocket ![](img/gt2-pivot-hex-nut-insert.png) @@ -36,26 +54,14 @@ The purpose of this work instruction is to explain the assembly process for the ![](img/gt2-idler-pivot-bolt.png) -### Prepare front-left-leg -- Remove any stringing from the 3D print with a heat gun -- Insert 3x `m5-hex-nut` into the following regions - - 2x in bottom of the leg for customer-side `front-leg-extension` mounting - ![](img/front-leg-extension-mounting-nut1.png) - ![](img/front-leg-extension-mounting-nut2.png) - - 1x near extrusion pocket for customer-side attachment of front-drag-chain-mount - ![](img/front-drag-chain-mount-nut.png) - -- Insert 1x `m5-nylock-hex-nut` into in the underside of `belt-tensioner-arm` mounting post - ![](img/belt-tension-arm-nut.png) - - -### Install belt-tensioner-arm onto the front-left-leg +### Install belt-tensioner-arm onto front-left-leg - -- Install the `belt-tensioner-arm` onto the `front-left-leg` +- Add a drop of `ptfe-silicone-lubricant` to both sides of `belt-tensioner-arm`'s pivot point + +- Install `belt-tensioner-arm` onto `front-left-leg` ![](img/belt-tensioner-arm-asm-install.png) -- Secure the `belt-tensioner-arm` onto the `front-left-leg` with a `M5x40-bolt` +- Secure the `belt-tensioner-arm` onto `front-left-leg` with a `M5x40-bolt` - Avoid over tightening this bolt as the `belt-tensioner-arm` should be able to pivot freely without *much *resistance ![](img/belt-tensioner-pivot-bolt.png) @@ -116,7 +122,9 @@ The purpose of this work instruction is to explain the assembly process for the ![](img/zip-tie-y1-cable3.png) -## Install front-left-leg and back-leg onto 600mm-alu-extrusion +## Assemble y-gantry-left + +### Install front-left-leg and back-leg onto 600mm-alu-extrusion - Begin by inserting a `525mm-m3-t-nut-bar` into a piece of `600mm-alu-extrusion` - There should be about 51.5mm between the end of the `525mm-m3-t-nut-bar` and the right-side end of the `600mm-alu-extrusion` after installation @@ -162,7 +170,7 @@ The purpose of this work instruction is to explain the assembly process for the ![](img/y-gantry-left-process-check1.png) -## Install linear-rail-550mm +### Install linear-rail-550mm - Roughtly position `linear-rail-550mm` onto top-side of uppermost `600mm-alu-extrusion` @@ -186,7 +194,19 @@ The purpose of this work instruction is to explain the assembly process for the ![](img/y-linear-rail-bolt-sequence.png) -## Install GT2-belt +- Remove the `linear-rail-2020-alignment-jig` from both ends of `linear-rail-550mm` +- Slide the linear-rail-carriage back and forth a few times, checking to see that it travels smoothly and consistently + +### Halfway Checkpoint + +- Verify that `y-gantry-left` matches the following photo + + ![](img/y-gantry-checkpoint.png) + +!!!success "If `y-gantry-left` matches the photo, proceed to the next section" +!!!failure "If `y-gantry-left` does not match the photo, correct discrepancies before proceeding to the next section" + +### Install GT2-belt - Route a 1.3m-long piece of `GT2-belt` through `y-gantry-left` !!!info "Belt routing step-by-step" @@ -202,6 +222,13 @@ The purpose of this work instruction is to explain the assembly process for the - Slide the `y-gantry` subassembly onto the `linear-rail-carriage` while pulling slack out of the `GT2-belt` ![](img/route-belt-through-step2.png) + ![](img/belt-pulled-through-irl.png) + +- Bolt `y-gantry` to the `linear-rail-carriage with` 4x `M3x8-bolt` + - Tighten each bolt to 0.5 N/M + - Push `y-gantry` inward towards the `linear-rail-carriage while tightening the mounting bolts to align it + + ![](img/bolt-y-gantry-to-carriage.png) - Use `belt-clamp` with 2x `M5x10-bolt` to clamp the left-side of the `GT2-belt` to the `y-gantry` - Tighten each `M5x10-bolt` to 0.5 N.M @@ -209,7 +236,7 @@ The purpose of this work instruction is to explain the assembly process for the ![](img/route-belt-through-step3.png) ![](img/route-belt-through-step4.png) -## Tension the Y-Gantry +### Tension the Y-Gantry - Pull the right-side `GT2-belt` tightly towards `front-left-leg` @@ -220,32 +247,42 @@ The purpose of this work instruction is to explain the assembly process for the ![](img/route-belt-through-step6.png) - -- Bolt `y-gantry` to the `linear-rail-carriage with` 4x `M3x8-bolt` - - Tighten each bolt to 0.5 N/M - - Push `y-gantry` inward towards the `linear-rail-carriage while tightening the mounting bolts to align it - - ![](img/bolt-y-gantry-to-carriage.png) - - - Rotate the `M3x16-bolt` clockwise on the `belt-tensioner-arm` to tension the `GT2-belt` installed on `y-gantry-left` - This will cause the `belt-tensioner-arm` to pull the `idler-pulley` away from the `front-left-leg` which adds desired tension to the `GT2-belt` ![](img/tension-belt-arm.png) -## Final details - - Trim the loose `GT2-belt` on either side of the `y-gantry` - For the `front-left-leg` side of the `y-gantry` print, trim the loose `GT2-belt` until it's flush against the belt-clamp - For the `back-leg` side of the `y-gantry` print, trim the loose `GT2-belt` until it's flush against the belt-clamp ![](img/belt-cut-to-length.png) - -- Use 3x `extrusion-cable-clip` to secure the `Y1-stepper-motor-cable` to the underside of the lowermost `600mm-alu-extrusion` -## Outro -After completing the previous steps, a finished `y-gantry-left` will be ready for Gundam QC testing. A `y-gantry-left` that was built while following the above steps will match the following image +### Add cable management + +- Use 3x `extrusion-cable-clip` to secure the `Y1-stepper-motor-cable` to the inner side of the lower `600mm-alu-extrusion` + + ![](img/y-gantry-extrusion-cable-clip.png) + +## Quality Checks +A `y-gantry-left` that was built while following the above steps will match the following image -![](img/finished-y-gantry-left.png) +![](img/complete-y-gantry-left.png) + +- Inspect the completed `y-gantry-left` assembly with the following QC checklist + 1. M5 bolts installed where required + 2. `M5-hex-nut` installed where required: + 1. 2x M5 hex nuts pressed into `front-left-leg` bottom + 2. 1x M5 hex nuts pressed into `back-leg` bottom + 2. 2x M5 hex nuts pressed into `y-gantry` for use with customer-side `x-gantry` mounting + 1. `GT2-belt` have been trimmed appropriately + 1. `GT2-belt` is laying flat in the `600mm-alu-extrusion` channels + 1. 3x `extrusion-cable-clip` have been installed onto the `y-gantry-left`'s lower `600mm-alu-extrusion` + 1. `Timing-pulley` is tightened down and at proper height + 1. `Y1` cable was used on `y-gantry-left` + + !!!warning "Stay vigilant for new failure modes not listed above and report them to a production lead when found" + +!!!success "If everything looks good" + Set the finished `y-gantry-left` aside for functional QC testing at the Gundam test station -!!!info "`Extrusion-cable-clips`, `Y1-stepper-motor-cable`, and `zip-tie` not shown" \ No newline at end of file