Mendel X-Axis Belt Modification

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Published on September 24, 2011

Description

After having backlash problems on my RepRap Mendel X-axis and getting sick of the awkward round-4-corners belt path, I decided to give it a re-design, in the hope of shortening the belt to take up some slack while simplifying the construction.

These brackets make the belt-path compatible with carriages intended for Prusa Mendel. I have included an adapter bracket that allows it to still be used with the original Mendel X-Carriage when necessary, however the idler bearing and pulley need to be spaced quite far out from the plastic parts in order to keep the belt parallel to the X-axis, with a full nut and a washer or two in the case of the bearing.
I hope someone will design something like the OpenX Carriage (http://www.thingiverse.com/thing:6278) but compatible with this, so that a 624-bearing-based carriage can be used with the Prusa-style belt-path, that is if I don't design one first.

I have also included an optional second idler bearing bracket to go directly next to the motor bracket, so that the belt turns slightly less of a sharp angle as it goes round the pulley, hopefully reducing belt wear, though I really don't think it's necessary.
The big circular holes in the motor & idler2 brackets are there to allow ventilation around the X-motor, so that PLA parts don't heat up too much. (I wanted test parts to be biodegradeable in case I messed up)

N.B. I have updated the files for the main brackets at either end as I found a couple of weaknesses in my first prototypes where I cut away excess corner material too liberally and found that the slots for m3 captive nuts shrank more than I thought they would, making it difficult to fit them. They should also be easier to print now.

Instructions

The idler is designed such that you should be able to fit the belt in whatever clamps you want easily, then adjust the tension by pulling the bearing back before tightening the nut(s) securing it.

By using this as opposed to reprap.org/wiki/Mendel_Alternate_X_Motor_Bracket you will save:
4x 624 Bearings
4x M4x15/20 Bolts
4x M4 Nylock Nuts
12x M3x20/25 Bolts
12x M3 Nylock Nuts
and associated washers

While using an additional:
1x 608 Bearing
M8x40mm Studding
3x M8 Washers
2-3x M8 Full Nuts
2x M8 Mudguard/Penny Washers (or a printed pulley)
7x M3x10 Bolt
8x M3 Full Nut (All 8 bolts & captive nuts are not strictly necessary)

and if you use the adapter for the original x-carriage:
Replace 4x M4x40 bolts each with 1 washer and full nut with -
2-4x M4x35 bolts + washers & full nuts (all 4 not necessary)
4x M4x25/30 bolts
4x M4 Nylock Nuts
8x M4 Washers
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AH HA!!! I have connected the dots! you are "engineeringourfreedom" I've been digging for ages to find out how that "blog guy" got his sells to use the prusa belt config. BTW Did you lose/gain any Z height from this mod by any chance?

Time to print this out and try out the hot swappable x carriages

Thanks so much for sharing this design =)

Cheers, I'm just trying to design up an all-in one version that re-uses some parts, since I think my Z-axis trapped nuts are finally wearing out after many months of use, and the assembly of the remaining bits of Sells' x-axis are quite awkward to dis-assemble and re-assemble.
I do like how he used parallel 624's on one side of each axis to prevent binding from imperfectly fitting smooth rods, but if I build another CNC machine I think I'll keep that part and use linear bearings or bushings on the 3-bearing side.

Hi 4ndi.. how did it influence the printing quality? did you get better prints after your modification? Happy with the system so far?

Yeah it's working pretty well; combined with http://www.thingiverse.com/thi... it's very easy to keep the belt tight enough and the movement is very smooth now, so I don't have backlash problems. The prints seem marginally better, everything else being equal.

I could even fit a 1cm-wide belt into this system when the current one eventually gives due to fatigue, which I have got one ready for. :)

The weakest link in my print quality now is probably the old mendel-parts 'v5' 0.5mm extruder nozzle I'm using; a design that I can't get replacement parts for at the moment. :(