OHAI: Open Hardware Assembly Instructions

1 Preparing the material palette

Assemble the materials needed for the [AS-PR0144] Filament Sensor Assembly

3X [HD-BT0116] Black Alloy Steel Flat-Head Socket Cap Screw, Class 10.9, M3 Size, 10mm Length, .50mm Pitch
4X [HD-BT0118] M3 x 14 Bolt FHCS, Black-Oxide
4X [HD-BT0137] M3 x 8 Bolt, BHCS, Black-Oxide
2X [HD-BT0185] Black-Oxide Alloy Steel Socket Head Screw M3 x 0.5 mm Thread, 16 mm Long
2X [HD-MS0471] Round compression spring .22OD 21lbs/in D11450
2X [PC-BD0109] Filament Sensor PCBA Rev B
1X [PP-GP0416] Sensor Cover R
1X [PP-GP0417] Sensor Cover L
2X [EL-MS0531] G8 RADIAL MULTIPOLE RING - 1/2" 20 pole, G8-H-125-50-20
2X [HD-BT0041] Metric Class 12.9 Socket Head Cap Screw Alloy Steel, M3 Thread, 25mm Length, 0.50mm Pitch
4X [HD-MS0467] Oil-Resistant Buna-N O-Ring 3 mm Wide, 11 mm ID
4X [HD-MS0470] Two side Rubber seal Bearing, 623-2RS, ABEC1 grade
2X [HD-NT0001] Metric Zinc-Plated Steel Nylon-Insert Locknut, Class 8, M3 Screw sz, .5MM pitch, 5.5MM W, 4MM H
12X [HD-WA0038] Black-Oxide 18-8 Steel Flat Washer, M3 Screw Size, 3.2mm ID, 7.0mm OD
2X [PP-GP0414] filament wheel
1X [PP-GP0418] bearing mount
4X [PP-IS0114] Filament Sensor Mount with Inserts
1X [HD-BT0224] Black-Oxide Alloy Steel Hex Drive Flat Head Screw M3 x 0.5 mm Thread, 30 mm Long
2X 9.5mm [HD-TB0007] Feed Tube, 0.187 ID X .250 OD NAT PTFE Tube
1X [PP-IS0108] Dual tube clamp with inserts
2X [HD-BT0118] M3 x 14 Bolt FHCS, Black-Oxide
6X [HD-MS0470] Two side Rubber seal Bearing, 623-2RS, ABEC1 grade
2X [PP-IS0109] Sensor idler with inserts

Material Palette

2 Assembling the Dual Tube Clamp

Cut out 2x 9.5mm [HD-TB0007] Feed tubes and slide them into the Dual tube clamp with inserts [PP-IS0108].

Fasten the clamp end of the dual tube clamp using an M3X30mm FHCS [HD-BT0224].
Do not tighten, this will serve to hold the filament tubes firmly in place.

Cut and prepare the feed tubes

Inserting the feed tubes

Preparing the clamp

Fixing the clamp into place

3 Assembling the Encoder Wheel

Start by taking an M3X25mm SHCS [HD-BT0041] fastener, sliding on an M3 washer [HD-WA0038], and rubber sealed bearing [HD-MS0470], and followed up by another washer [HD-WA0038]. Insert the rubber sealed bearing through the first ring on the Bearing Mount [PP-GP0414].

Slide another M3 washer [HD-WA0038] along the screw and push the fastener through a Multipole ring [EL-MS0531]. Follow it up with another washer [HD-WA0038] and then slide the rubber sealed bearing [HD-MS0470] into the second ring of the mount.
Follow this up with another washer [HD-WA0038].

Take the Filament Wheel [PP-GP0418] and install 2x O-rings [HD-MS0467] into the grooves and an M3 Nyloc Nut [HD-NT0001] into the provided slot on the plastic part with the nylon side facing out.

Slide it on to the stack and fasten the screw until it sits tight with no side to side movement.

Repeat these steps for the other side.

Laying out the encoder stack

Washer first

Bearing then washer

Inserting the first bearing

Inserting the multipole ring

Inserting the o-ring

Fastening the encoder ring

4 Mounting the Filament Sensor

Fasten the encoder wheel on to the Dual Tube Clamp using 3x M3X10mm FHCS [HD-BT0116].
Torque to 5in*lbs

Fasten the Filament Sensor Mount w/ Inserts [PP-IS0114] to the Dual Tube Clamp using 2x- M3X14 FHCS [HD-BT0118], making sure that the slant of the mount is fitting over the encoder wheel.
Torque to 5in*lbs

Prepare the encoder wheel and dual clamp assembly

Fasten the encoder wheel to the dual clamp

Prepare the filament sensor mount and dual clamp with the encoder wheel

Fasten the filament mount

5 Installing Filament Sensor Boards & Covers

Place the Filament Sensor Board [PC-BD0109] to the left side of the filament sensor mount with the connector facing towards the front of the assembly.

Slide the Sensor Cover L [PP-GP0417] over top of the sensor board before fastening it down with 2x- M3X8 BHCS [HD-BT0137] with washers [HD-WA0038].
Push the filament sensor board towards the bottom of the assembly before tightening Torque to 3in*lbs

Repeat this for the right side using Sensor Cover R [PP-GP0416];
Place the Filament Sensor Board [PC-BD0109] to the right side of the filament sensor mount with the connector facing towards the front of the assembly.
Slide the Sensor Cover R [PP-GP0416] over top of the sensor board before fastening it down with 2x- M3X8 BHCS [HD-BT0137] with washers [HD-WA0038].
Push the filament sensor board towards the bottom of the assembly before tightening
Torque to 3in*lbs

Turn the encoder through several rotations to make sure that it does not rub on the filament sensor board.

Prepareing the assembly and filament sensor board

Fasten the filament sensor board and cover to the assembly

Almost done!

6 Installing the Sensor Idler with Inserts

Fasten the rubber sealed bearing [HD-MS0470] to the Sensor Idler w/ Inserts [PP-IS0109] using an M3X14 FHCS HD-BT0118].
Torque to 3in*lbs

Fasten the sensor idler to the filament sensor assembly with an M3X16 SHCS [HD-BT0185] from the outside left/right.
Tighten until screw head rests against printed idler; too much tension will prevent the idler from moving properly.

Slide one Round Compression Spring [HD-MS0471] onto an M3x14 FHCS [HD-BT0118]
Thread one through the front of each Filament Idler (2 total) and into the insert behind it.
This should not be tightened all the way.

Prepare the idler assembly

Assemble the idler

Prepare the filament idler

Fasten the filament idler to the dual clamp

Fasten the springs to the main assembly

Finished!

7 Testing the Filament Sensor Sub-Assembly

You will need a Filament Sensor Tester, plug it in to power and ensure the POWER LED is lit
Connect the connector on the green side to the test box lead labeled "1"
Connect the connector on the black side to the test box lead labeled "2"

By hand or with a 2.5mm driver, spin the encoder wheels of the filament sensor individually while observing the corresponding light flashing on the test box.
Ensure the light flashes consistently for one full rotation of the encoder wheel.

Ensure both encoder wheels spin freely without contacting (rubbing) the filament sensor board.

If both sensors respond correctly, the test is complete.
Disconnect from the filament sensor test box, and you're done!

Good job!

Filament sensor connected to tester

Spin # 1, the light should blink rapidly

Spin # 2, the light should blink rapidly

8 Complete Quality Assurance Check

The final step is to complete the Quality Assurance Record.

To complete the Quality Assurance Record, verify the following:

Filament can be fed through the feed tube freely.
The pin state is changing when filament is fed through the sensor.
The filament sensor wheel is aligned with the hole where the filament goes in.
The Filament sensor idler spring compression is set as intended.

To complete the final inspection step, another crew member must inspect the Filament Sensor and verify the Quality Assurance Record has been completed.

Once completed, initial the 'Inspected By" sticker and place the sticker on the back of the Filament Sensor.

Great Job! This sub-assembly is complete!

Inspected By Sticker

Project Dashboard TAZ Pro Filament Sensor Sub-Assembly Workflow