Yet another E3Dv6 fan duct for dc42 IR height sensor

hairy_kiwi · 14 Apr 2017, 13:17

Not being quite satisfied (for various reason) with the current IR sensor mounts for E3Dv6 fan ducts - and wanting to get my teeth into Onshape for some time, I'm happy to present the hairy_kiwi 'E3Dv6 fan duct for dc42 IR height sensor V1'

Fitted, in use:
photo to follow

Design intent:

Moderately-strong clip strength to attach to E3Dv6 Heatsink - both radially, at top and bottom of the Heatsink, and also vertically, to ensure minimal influence on probe z-position,
Improved airflow rate + fan-noise reduction - by increasing duct internal volume between 30mm fan and Heatsink,
30mm fan mounts with E3D supplied screws.

Printing guide:

Orient with the inlet face to the printer bed,
NO support material required,
0.3mm layer height,
1 perimeter,
infill 35%,
3 solid top and bottom layers.

Files:
Onshape Part/Assembly
E3Dv6 fan duct for dc42 IR height sensor - V1 - via MoI3D.STL
E3Dv6 fan duct for dc42 IR height sensor - V1 - via MoI3D.STP

dc42 · 14 Apr 2017, 16:09

Looks good! Would you care to upload it to Thingiverse? If you do then I'll add a link from the IR sensor fitting instructions.

Roland · 14 Apr 2017, 17:02

Nice one. Do you have any provision to stop the duct rotating on the heatsink to prevent the back of the IR probe PCB shorting against the heater block - assuming no/defective silicone sock?

TYPPA Albert Einstein · 14 Apr 2017, 19:27

Good evening everyone, this is my post in this forum having recently purchased the Wi-Fi Duet and its corresponding sensor IR dc42. I take this opportunity to ask a question relating to the offset in X-Y of the sensor with respect to the nozzle of the V6 E3D. If this information must be declared in firmaware? I use Rhino to draw. I want to understand how to calculate the center of the sensor between the two sensor LED. Sorry for my bad English.
Good Easter holiday

dc42 · 14 Apr 2017, 20:16

Yes, you declare the offset of the sensor with respect to the head reference point (which is the nozzle position in a single-nozzle printer) in the G31 command in config.g.

TYPPA Albert Einstein · 15 Apr 2017, 07:52

@dc42:

Yes, you declare the offset of the sensor with respect to the head reference point (which is the nozzle position in a single-nozzle printer) in the G31 command in config.g.

Hi dc42, thanks for the reply. But the center is calculated based on the width of the PCB or the distance of the LEDs? You can make a drawing with the measures, I do not see any reference about it on the pcb or wiki. Thanks so much

DjDemonD · 15 Apr 2017, 17:22

I'm not sure a millimeter or two difference will matter to subsequent calculations for grid levelling, and since delta calibration doesn't use the offset (it just measures the surface at the point below the sensor) it's only an approximate measurement. If you did want more accuracy you could measure the trigger point by moving the sensor over the top of a small object like a 3x3mm tower so see exactly where it triggers.

TYPPA Albert Einstein · 15 Apr 2017, 19:50

DjDemon , thank you for the tip .

dc42 · 15 Apr 2017, 20:36

The sensitive area of the sensor is below the round black capacitor.

hairy_kiwi · 18 Apr 2017, 18:36

Apologies for my stony-silence since opening this thread - I've been out and about without a spare moment.

@dc42:

Looks good! Would you care to upload it to Thingiverse? If you do then I'll add a link from the IR sensor fitting instructions.

@Roland:

Nice one. Do you have any provision to stop the duct rotating on the heatsink to prevent the back of the IR probe PCB shorting against the heater block - assuming no/defective silicone sock?

Thank you both.

Now published on Thingiverse as: E3Dv6 fan duct for dc42 IR height sensor V1 | http://www.thingiverse.com/thing:2250394

Although I don't currently have an absolute solution to the issue of the duct rotating on the heatsink, there are a few factors that give me peace of mind that the risk of the PCB shorting is minimal:

With the PCB fixed to the side of the mounting tabs furthest from the heater block, it would be possible to rotate the PCB greater than ±45° with (IMHO) no significant risk of either the PCB or supplied screws touching the heater block. The same is not true if the sensor PCB is fixed to the inside of the mounting tabs - though for the PCB to be able to rotate through the 45° position would likely require the almost complete breakdown of the E3D silicon sock along a vertical edge,
Along with dc42's own fitting instructions, I'm advocating the use of Kapton tape on the back of the PCB,
On my own printer, the location of the duct between the X-carriage linear shaft bearings physically prevents significant rotation,
Other thoughts:
Addition of an anti-torque grub-screw or extra clamp to the design ought to be possibile,
Five of the six ducts I've printed have all gripped the E3D Heatsink much more firmly than the original E3Dv6 duct ever did. For a more detailed explanation, visit the Thingiverse page and read the Note under Print Settings regarding higher print speed resulting in firmer grip characteristics.

Any thoughts appreciated - especially if you think I'm being over optimistic in my assumptions.