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Reduce 3D print failures with this clever 3D printer error detection & correction system – 3ders.org (blog)

by • April 14, 2016 • No Comments

Apr 15, 2016 | By Benedict
Chris Barr, an engineering and 3D printing blogger of Adelaide, Australia, has utilized magnetic encoders to turn it into a 3D printing device error detection system. According to Barr, the modification may be utilized to decrease errors cautilized by overheating stepper drivers, belt slips, and accidental filament buildup.

One of the many common problems synonymous with 3D printing, especially on affordable machines, is the phenomenon of layer shifting. Layer shifting occurs when the stepper motors of a print head “skip” a step, which can be cautilized by a number of facts such as excess stress, poor lubrication, or running the 3D printing device at too high a speed. Whatever the cause, layer shifting is a big problem, and generally ruins the 3D print in question—once the nozzle becomes misaligned with the printed object, there’s usually no saving it.
When encountering failed prints, it usually makes sense to donate the guilty 3D printing device a swift tuneup and maybe alter the print settings to a thing less demanding. Some 3D printing devices come equipped with dedicated webcams and alert systems for letting users understand if a thing has gone wrong with a print. Chris Barr, yet, wanted to donate himself an engineering challenge by tackling the problem of 3D printing device errors in a additional direct way. After a few experimentation, the tech tremendous invented a rudimentary 3D printing device error detection and correction system, one which uses magnetic encoders to track axis motion.
Barr’s error detection system consists of an AMS AS5311 linear magnetic encoder IC, a custom PCB, and an ATmega328 microcontroller for tracking axis motion and implementing I2C communication. The tinkerer created alters to his 3D printing device Marlin firmware to get all things working together. As the designer’s video evidence demonstrates, the system appears to do a excellent job of getting the print head back on track when it is forced out of place. In the video, Barr can be seen forcing the X axis out of position, to which the head of the 3D printing device responds by returning to its prior position and resuming the print.

On the other hand there are noticeable errors in the print where the 3D printing device had to correct itself, Barr’s test prints are yet a excellent deal advantageous than a 3D print which has succumbed fully to layer shifting. So while the error detection system can not be worth employing for prints requiring ideally
ideal surface more detail, it may pretty be utilized for prototype parts, non-aesthetic pieces, non-critical components and such like.
Barr’s demonstration maybe demonstrates an unrealistic source of layer shifting—grabbing moving parts of the printing device—but the engineer suggests which the system may be utilized to prevent errors cautilized by the next occurrences: stepper drivers overheating, the print nozzle getting snagged on a print, other cases of insufficient torque, and stretching or slipping of the belt. Depending on the severity of every of these problems, additional maintenance can well be needed on the 3D printing device in question, but Barr’s system pretty provides a handy on-the-spot solution to minor errors.

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