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extruder harness able to get caught in large print
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We have a large print going on the WE on @bigmansas's desk and had to pull the extruder harness up out of the way once it got a little past the middle of Z travel so that it doesn't get caught; it was dragging on the print. We were afraid of it getting caught by one of the currently hook-shaped features of the print.


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i will look into a small printed part that will hold the cables straight out the back of the carriage that will be zip tied or clamped to the cable such that there is no modification to existing parts.

logan added a comment.Jul 12 2019, 1:31 PM

@tutley What about another leash that would attach near the connector at the rear of the carriage and the other end on the harness so it just holds it in a U shape with the slack going upwards?

logan added a comment.Jul 12 2019, 1:38 PM

I have utilized a rubber band to demonstrate:

logan added a comment.Jul 12 2019, 1:39 PM

Probably needs to be a bit tighter loop than that to reach bottom right of travel.

lol nice. yea something like that could work.
i am printing a flexy cable collar thing that zip ties around the harness flush with the back of the x carraige that will hold the cables straight out.

adam added a comment.Jul 12 2019, 2:07 PM

Just be sure it clears the frame when it homes Z

logan added a comment.Jul 12 2019, 2:19 PM

@adam I moved it to be zip-tied at the lower slot on that side:
X-Max/Z-Min


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(this is just to show the concept)

i installed the thing i printed and it seems to work initially, but i can tell over time the cables could still droop down.

i have slightly modified the xcarriage_cover model and created a rigid cable brace that mounts to it. I wont have time to print it today though.

I think the leash/rubber band thing seems like a last minute mod/hack so i personally feel we should avoid that. but it is an option

@logan heh, at least use the LB green ninjaflex!!!

Looking forward to the changed part @tutley let us know if you need more distributed for testing.

logan added a comment.Jul 12 2019, 2:33 PM

The final part would of course have to be in the classic LB green ninjaflex. Just putting the idea out there, I wouldn't ever dream of putting an actual rubber band in production lol

for sure! and it is a very simple solution

here is what i came up with. There is room for improvement, but this seems to work really well

logan added a comment.Jul 12 2019, 3:22 PM

I like that too. Do you think moving the top center cable clip towards the right more would be beneficial as well? In conjunction with something similar to what you've shown of course.

with this design, having the clip in the middle leaves just enough slack to hit all parts of the bed for the first layer.
i think the clip should be as far right as we can go while still hitting the full build volume and not guitar stringing the cable

logan added a comment.Jul 12 2019, 3:29 PM

Exact middle on the top frame rail? I will make a jig so we get consistent placement, once we nail that location down.

tutley added a comment.EditedJul 15 2019, 9:13 AM

@logan will something like this interfere with packaging?

logan added a comment.Jul 15 2019, 9:21 AM

If what you pictured doesn't protrude past the rear of the rear frame rail I cant see any reason it would.

sounds good!

tutley added a comment.EditedJul 15 2019, 10:04 AM

@logan it does protrude past the rail but not past the harness or cable clips that are on the top rail. Any concern here? i can get a pic if youd like

If you can snap a quick pick that would be great, doesn't sound like it will be an issue though

Yeah that should be fine

So this would be an additional printed part plus 2x- HD-MS0058 zip ties to AS-PR0167 Final Assembly
@adam could you create a printed part number for those? I think call it Extruder Harness Cable Guide

it would also add 1x m3 brass insert, 1x m3x8 bhcs, and 1x m3 washer

@tutley Does the insert go in the X-Carriage Cover?

yep! i will post the stls here if you want to print one out and test it

BOM change summary
PP-IS0117 X-Carriage Cover with Inserts:
Add 1x- HD-MS0030

AS-PR0166 X-Carriage Assembly:
Add
1x- HD-BT0137
1x- HD-WA0038
1x- PP-GPxxxx

AS-PR0167 Final Assembly:
Add 2x- HD-MS0058

Will need updated insert drawing for the X-Carriage cover to update OHAI here: https://ohai.lulzbot.com/project/thermal-insert-instructions-workhorse/taz-workhorse-edition/
Will need to retake X-Carriage Assembly here: https://ohai.lulzbot.com/project/x-carriage-assembly-workhorse/taz-workhorse-edition/
And retake photos here: https://ohai.lulzbot.com/project/final-assembly-taz-workhorse/taz-workhorse-edition/

@tutley could you push those model files to this branch and tie them to a slice request?

@logan yea that looks good

Oh we also moved the top cable clip, do you want it exact center on the top rear frame rail?

that seems to be the ideal position

@logan @cmerot I know we are already running production. I assume this is something we need to get all the printers updated with? I want to make sure when I update OCA that we don't mess up the inventory system.
@Heather @tomc we are going to need routes for [PP-GP0465] Extruder Harness Cable Guide, Black set up.

@adam @cmerot To me it seems like a safety concern to have the harness able to get caught under the nozzle. Should we go as far as reworking all Workhorse in existence? or flush part inventory for PP-IS0117/related and implement this for the start of production?
I'd like to see more testing on this before production begins, which would mean reworking existing Workhorse printers and having users run a fast full volume print like a box or something to ensure that we've properly addressed the issue.

adam added a comment.Jul 15 2019, 11:05 AM

@logan to my knowledge production has already begun. This is a question of whether or not we ship out printers without the printed part change. I think moving the cable clip can be done in cal for all the ones not already moved and that is easy to address. Reworking the x carriage with the new part is a heavier lift and, as you mentioned, we have little testing.

Being that we're still in the midst of addressing beta feedback, the product isn't ready for production to begin.
Let me know what you want to do

"adam added subscribers: Heather, tomc.Mon, Jul 15, 10:46 AM
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@logan @cmerot I know we are already running production. I assume this is something we need to get all the printers updated with? I want to make sure when I update OCA that we don't mess up the inventory system.
@Heather @tomc we are going to need routes for [PP-GP0465] Extruder Harness Cable Guide, Black set up."

This product has no 'Used In tab' on it's product card so it doesn't appear to be on a BOM as of yet. Will need to see that to build out routes and reordering rules.

tomc added a comment.Jul 15 2019, 2:18 PM

@adam when you have this sorted on the BoM lets us know and we can deal with the route needs. In the future...tagging inventory into this isn't the best way to handle routing since we do not deal with manufacturing issues....just the parts and there resting places
.

tomc removed a subscriber: tomc.Jul 15 2019, 2:18 PM
adam added a comment.Jul 15 2019, 2:23 PM

BOMs are updated and archived and are ready to set to active as soon as we have printed parts.

adam added a comment.Jul 16 2019, 8:51 AM

I'm having 10x of the new X covers inserted now. the other pieces should be printed in the next hour or so. I will be distributing the new covers for replacing and testing.

adam added a comment.Jul 16 2019, 9:06 AM

Rather than test by running 60+ hour prints, I have mocked up a really quick thin wall that I'm placing at the back of the build plate with a z wobble test tower at the front center. At high speed it's estimating 9 hours.

adam added a comment.Jul 16 2019, 9:33 AM

@logan FYI it took me less than 5 minutes to swap the x cover

logan added a comment.Jul 16 2019, 3:18 PM

This works well on my unit in MER. Haven't got a chance to run the other one yet.
I have it running burnin right now and cant see any spots where it will droop below the carriage.
I think this is a good solution.

adam added a comment.Jul 16 2019, 3:28 PM

I'm almost finished with a full height print using a HS+ to speed it up. so far I'm higher than @bigmansas was and no issues yet.

adam added a comment.Jul 17 2019, 7:36 AM

I ran a quick test print yesterday and the new mount and routing piece keep the cable completely out of the way. Please excuse the blurriness of the one photo and the print quality issues.

adam added a comment.Jul 17 2019, 7:38 AM

@tutley @west @logan - I would like to get this merged today. Do any of you have any reservations or further tests you want to see?

west added a comment.Jul 17 2019, 7:39 AM

nope, its a good design and solution

adam added a comment.Jul 17 2019, 8:01 AM

@tutley @west is this going to change in light of T8793 where they are looking at increasing the diameter of the braided loom?

logan added a comment.Jul 17 2019, 8:08 AM

I am quite pleased with this solution from what I've seen. I'd like to push forward on this as quickly as possible.

@adam yea it might need to be adjusted. without having some of the sleeving it is kind of hard to say.

it looks like we are not going to change the diameter of the sleeving now. so this wont be a problem

adam moved this task from Report Issues Here to Needs Review on the Redgum board.Jul 17 2019, 3:32 PM
adam assigned this task to Steven.

since we aren't changing the size of the braided loom, this is ready to be merged to master.

logan added a comment.Jul 17 2019, 3:59 PM

@adam @west @tutley before we merge we need updated insert drawing for the PP-IS0117 X Carriage Cover

adam added a comment.Jul 17 2019, 4:00 PM

@logan this must be why we review, because I thought that was already in there.

logan added a comment.Jul 17 2019, 4:07 PM

let me look, I didn't see commits tied to the ticket. one moment

logan added a comment.Jul 17 2019, 4:08 PM

Yah thats a negative, the PP-IS0117 drawing on T8707 branch is a couple versions ago and short the new insert

adam added a comment.Jul 17 2019, 4:08 PM

the BOM needs to be pushed with the corrected BOMs as well. I made the changes in OCA and archived them so the BOM is still not showing the new parts. I will push that in a moment.

I'm providing @david.hall with one of the completed ones so his crew has an example to reference so we can keep this going tomorrow.

adam added a comment.Jul 17 2019, 4:18 PM

pushed updated BOM to branch

west added a comment.Jul 17 2019, 4:33 PM

Insert drawing updated

Steven closed this task as Resolved.Jul 18 2019, 8:49 AM

I removed 'test' from one of the gcode file names. This is now merged into master.

Include hardware updates:
Step 1
Remove HD-BT0206
Increase HD-BT0204 QTY to 2

adam added a comment.Jul 24 2019, 10:55 AM

@logan can you confirm the BOMs correct and we just need OHAI update?

@adam Thinking about this and now looking at the BOM in OCA for AS-PR0166, I think the PP-GP0465 may be better to install at final because then the X-Carriage will stack better in bins and there's less chance of the guide breaking.
This would mean moving 1x HD-BT0137/HD-WA0038/PP-GP0465 to AS-PR0167
Thoughts?

adam added a comment.Jul 24 2019, 11:15 AM

if that would be better, now would be the time to do it - we would have to review again and merge again. The essence of this ticket has been solved so it might be better to do that change on a new ticket.

Let me gather some feedback from assemblers real quick

Looks like we're short of experienced final assemblers to gather feedback from today. Lets go ahead and leave it as is, if breakage or anything becomes an issue we can change it later.

adam added a comment.Aug 6 2019, 8:04 AM

@logan is this good to close now?

logan added a comment.Aug 6 2019, 8:11 AM

@adam This is not updated in the OHAI yet

zachah added a subscriber: zachah.Sep 12 2019, 9:58 AM

OHAIs have been updated with the new additions.

Updated the X carriage assembly to include the new parts in all of the pictures. Added the 1x- [PP-GP0465] Extruder Harness Cable Guide, as well as an additional 1x- [HD-WA0038] M3 Washer, Black-Oxide, and an additional 1x- [HD-BT0204] M3x22 FHCS, Black-Oxide
https://ohai.lulzbot.com/project/x-carriage-assembly-workhorse/taz-workhorse/

Updated the final assembly OHAI to include the new parts as well. All steps showing the old part were removed and replaced with the new ones. Also added two additional zip ties 2x- [HD-MS0058] Wire Tie, 8" Black, for securing the cable harness to the new harness cable guide.

@zachah I'm seeing step 5 here: https://ohai.lulzbot.com/project/x-carriage-assembly-workhorse/taz-workhorse/ still contains the HD-BT0206 in the text, that will need removed and HD-BT0204 QTY of 2.

Could you also update Final step 13 to include the correct spacing with the jig? (T9048)

After that this should be good to close as resolved, everything else looks good. Nice job @zachah!

Updated step 5 of the X carriage assembly to remove the HD-BT0206 and replaced it with another HD-BT0204. Also updated the final OHAI on step 13 to include the new spacing jig.

logan closed this task as Resolved.Sep 12 2019, 10:40 AM

Looks good @zachah, thanks!