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README.md
260
README.md
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@ -1,259 +1,3 @@
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# sv06-belt-recovery-stress-tests
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# motion-diagnostics-suite
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Belt tension recovery and motion stability test models for bed-slinger 3D printers (e.g., SV06-class machines).
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---
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## Purpose
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These models are designed to help recover from situations where printer motion accuracy has been degraded, typically due to:
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* Adjusting belt tension without a reference baseline
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* Experiencing layer shifts during prints
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* Replacing belts or modifying mechanical components
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This project provides:
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* Parametric OpenSCAD models
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* A structured test procedure
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* Guidance for interpreting failure modes
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---
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## When To Use This
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Use these tests if you observe:
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* Sudden layer shifts (e.g., 3-5 mm offsets)
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* Inconsistent dimensional accuracy
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* Audible belt skipping or motor stutter
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* After adjusting belt tensioners
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Here's an example of a case for a hand held radio where the top suddendly shift at the 20mm height.
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---
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## Models Included
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### 1. Cube (Baseline Test)
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* Dimensions: 40 × 40 × 40 mm
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* Purpose:
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* Verify basic printer stability
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* Detect gross mechanical issues
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---
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### 2. Y-Bar (Axis Stress Test)
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* Dimensions: 20 × 150 × 50 mm
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* Purpose:
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* Stress the Y-axis (bed movement)
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* Detect belt slip under momentum and direction reversal
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**Important:**
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* Orient the 150 mm dimension front-to-back on the bed
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---
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### 3. Tower (Long-Duration Test)
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* Dimensions: 18 × 18 × 120 mm
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* Purpose:
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* Reveal issues that appear only over time
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* Detect cumulative drift, resonance, or late-stage layer shifts
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---
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## Print Procedure (Recommended Order)
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Run each model as a **separate print job**:
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1. **Cube**
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* Confirms system is not fundamentally broken
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2. **Y-Bar**
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* Directly tests axis tension and inertia behavior
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3. **Tower**
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* Tests stability over time and height
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---
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## Suggested Slicer Settings (Orca Slicer)
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### Cube
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* Layer height: 0.20 mm
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* Perimeters: 3
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* Infill: 20-25% (grid or gyroid)
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### Y-Bar
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* Layer height: 0.20 mm
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* Perimeters: 3
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* Infill: 15-25% (grid recommended)
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### Tower
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* Layer height: 0.20 mm
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* Perimeters: 3
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* Infill: 0-10%
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* Brim: optional (only if adhesion is an issue)
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See the settings folder for settings used in Orca Slicer.
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---
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## Belt Tension Guidance
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This project assumes GT2 belts (typical for most hobby printers).
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### Frequency Method (Recommended)
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Using a phone-based spectrum analyzer:
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* Target range: **90-110 Hz**
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* Reference: ~110 Hz ? ~2 lb tension (Voron baseline)
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Procedure:
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1. Move bed so belt span ~ 150 mm
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2. Pluck belt
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3. Measure frequency
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4. Adjust tensioner
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5. Repeat until stable
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### Notes
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* Too loose:
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* Low frequency (<70 Hz)
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* Layer shifts likely
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* Too tight:
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* High frequency (>120-130 Hz)
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* Motor strain, possible missed steps
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---
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## Interpreting Results
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### Good Result
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* Clean vertical alignment
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* No sudden offsets
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* Consistent layer stacking
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---
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### Failure Modes
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#### Sudden Layer Shift
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* Cause:
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* Belt too loose
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* Pulley slipping
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* Action:
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* Increase tension slightly
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* Check motor pulley set screws
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---
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#### Repeated Shift at Same Height
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* Cause:
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* Mechanical obstruction
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* Cable snag
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* Action:
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* Inspect motion path
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* Check wiring harness clearance
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---
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#### Gradual Lean / Drift
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* Cause:
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* Frame or axis alignment issue
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* Action:
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* Inspect rails, wheels, or rods
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---
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#### Ringing / Ghosting (No Shift)
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* Cause:
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* High acceleration
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* Action:
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* Reduce acceleration (not a belt issue)
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---
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## Notes on Methodology
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These tests intentionally:
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* Emphasize repeated motion in one axis
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* Increase inertial load with height
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* Create conditions where marginal tension fails visibly
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This approach isolates motion system issues rather than general print quality.
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---
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## OpenSCAD Usage
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Generate models:
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```bash
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openscad -D 'model="cube"' -o cube_$(date +%Y%m%d_%H%M).stl stress_test_models.scad
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openscad -D 'model="ybar"' -o ybar_$(date +%Y%m%d_%H%M).stl stress_test_models.scad
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openscad -D 'model="tower"' -o tower_$(date +%Y%m%d_%H%M).stl stress_test_models.scad
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```
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---
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## Provenance
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Generated with:
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* OpenSCAD
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* Orca Slicer (recommended)
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* Frequency-based belt tuning derived from:
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* Voron Design tuning methodology
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This project was developed with ChatGPT.
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---
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## License
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Recommend: MIT or CC-BY 4.0 for broad reuse.
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---
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## Contributing
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Improvements welcome:
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* Additional test geometries
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* Axis-specific stress models
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* Automated calibration workflows
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---
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Parametric OpenSCAD models and procedures for diagnosing layer shifts, belt tension, and motion instability in FDM 3D printers.
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||||
Binary file not shown.
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Before Width: | Height: | Size: 1.5 MiB |
Binary file not shown.
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Before Width: | Height: | Size: 235 KiB |
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@ -147,48 +147,8 @@ module rounded_box_uncentered(x, y, z, r) {
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square([x, y], center=false);
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}
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module place_top_label(txt, x, y, z, center_it=false) {
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// --- parameters ---
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margin = 2; // mm clearance from edges
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// usable space
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usable_x = x - margin;
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usable_y = y - margin;
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// choose orientation: run along long axis
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rotate_text = (y > x);
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// limiting width after orientation
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limit = rotate_text ? usable_y : usable_x;
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// crude text width estimate factor (~0.6 * size * chars)
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est_char_width = 1.0;
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est_len = len(txt) * est_char_width;
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// compute size that fits
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auto_size = limit / est_len;
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// clamp to your preferred max size
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final_size = min(label_size, auto_size);
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// placement
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tx = center_it ? 0 : x/2;
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ty = center_it ? 0 : y/2;
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tz = center_it ? z/2 : z;
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translate([tx, ty, tz - label_depth])
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rotate([0, 0, rotate_text ? 90 : 0])
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linear_extrude(height=label_depth + 0.02)
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text(
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txt,
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size=final_size,
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font=label_font,
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halign="center",
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valign="center"
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);
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}
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module place_top_labelOLD(txt, x, y, z, center_it=false) {
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tx = center_it ? 0 : x/2;
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ty = center_it ? 0 : y/2;
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tz = center_it ? z/2 : z;
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|
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166
openscad/stress_test_models.scad~
Normal file
166
openscad/stress_test_models.scad~
Normal file
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@ -0,0 +1,166 @@
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#!/usr/bin/openscad -o /tmp/ignore.stl
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//
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// stress_test_models.scad
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// 20260317 ChatGPT
|
||||
// $Id$
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// $HeadURL$
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//
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// Example command lines:
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||||
//
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// openscad -D 'model="cube"' -o cube_20260317_1335.stl stress_test_models.scad
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// openscad -D 'model="ybar"' -o ybar_20260317_1335.stl stress_test_models.scad
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// openscad -D 'model="tower"' -o tower_20260317_1335.stl stress_test_models.scad
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// openscad -D 'model="all"' -o all_20260317_1335.stl stress_test_models.scad
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//
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// Suggested slicer use:
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//
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// 1) Print each model as a SEPARATE run.
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// 2) For ybar, orient the LONG dimension along the printer's Y axis
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||||
// so the bed moves the long way front-to-back.
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// 3) Infill is set in Orca Slicer, not here.
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//
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// Suggested slicer settings:
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//
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// cube: 0.20 layer, 3 perimeters, 20-25% grid or gyroid
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// ybar: 0.20 layer, 3 perimeters, 15-25% grid
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// tower: 0.20 layer, 3 perimeters, 0-10% infill, no brim at first;
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// add brim only if adhesion becomes the issue rather than motion
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//
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/* [General] */
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model = "all"; // [cube,ybar,tower,all]
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center_models = false; // true / false
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add_labels = true; // true / false
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/* [Cube Dimensions] */
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cube_x = 40;
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cube_y = 40;
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cube_z = 40;
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/* [Y Bar Dimensions] */
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ybar_x = 20;
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ybar_y = 150;
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ybar_z = 50;
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/* [Tower Dimensions] */
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tower_x = 18;
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tower_y = 18;
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tower_z = 120;
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/* [Edge Treatment] */
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corner_radius = 1.2; // 0 for sharp corners
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$fn = 48;
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/* [Labeling] */
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label_depth = 0.6;
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label_size = 7;
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label_font = "Liberation Sans:style=Bold";
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/* [Layout For model="all"] */
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gap_between_models = 20;
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// --------------------------------------------------
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// Main
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// --------------------------------------------------
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if (model == "cube") {
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make_cube();
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}
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else if (model == "ybar") {
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make_ybar();
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}
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else if (model == "tower") {
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make_tower();
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}
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else if (model == "all") {
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make_all();
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}
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else {
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echo("ERROR: model must be one of: cube, ybar, tower, all");
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}
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// --------------------------------------------------
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// Assemblies
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// --------------------------------------------------
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module make_all() {
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x0 = 0;
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x1 = x0 + cube_x + gap_between_models;
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x2 = x1 + ybar_x + gap_between_models;
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translate([x0, 0, 0]) make_cube();
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translate([x1, 0, 0]) make_ybar();
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translate([x2, 0, 0]) make_tower();
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}
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module make_cube() {
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difference() {
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rounded_box(cube_x, cube_y, cube_z, corner_radius, center_models);
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if (add_labels)
|
||||
place_top_label("CUBE", cube_x, cube_y, cube_z, center_models);
|
||||
}
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||||
}
|
||||
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||||
|
||||
module make_ybar() {
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difference() {
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rounded_box(ybar_x, ybar_y, ybar_z, corner_radius, center_models);
|
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if (add_labels)
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place_top_label("YBAR", ybar_x, ybar_y, ybar_z, center_models);
|
||||
}
|
||||
}
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||||
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||||
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module make_tower() {
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||||
difference() {
|
||||
rounded_box(tower_x, tower_y, tower_z, corner_radius, center_models);
|
||||
if (add_labels)
|
||||
place_top_label("TOWER", tower_x, tower_y, tower_z, center_models);
|
||||
}
|
||||
}
|
||||
|
||||
|
||||
// --------------------------------------------------
|
||||
// Geometry helpers
|
||||
// --------------------------------------------------
|
||||
|
||||
module rounded_box(x, y, z, r=0, center_it=false) {
|
||||
if (r <= 0) {
|
||||
cube([x, y, z], center=center_it);
|
||||
} else {
|
||||
if (center_it) {
|
||||
translate([-x/2, -y/2, -z/2])
|
||||
rounded_box_uncentered(x, y, z, r);
|
||||
} else {
|
||||
rounded_box_uncentered(x, y, z, r);
|
||||
}
|
||||
}
|
||||
}
|
||||
|
||||
|
||||
module rounded_box_uncentered(x, y, z, r) {
|
||||
linear_extrude(height=z)
|
||||
offset(r=r)
|
||||
offset(delta=-r)
|
||||
square([x, y], center=false);
|
||||
}
|
||||
|
||||
|
||||
module place_top_label(txt, x, y, z, center_it=false) {
|
||||
tx = center_it ? 0 : x/2;
|
||||
ty = center_it ? 0 : y/2;
|
||||
tz = center_it ? z/2 : z;
|
||||
|
||||
translate([tx, ty, tz - label_depth])
|
||||
linear_extrude(height=label_depth + 0.02)
|
||||
text(
|
||||
txt,
|
||||
size=label_size,
|
||||
font=label_font,
|
||||
halign="center",
|
||||
valign="center"
|
||||
);
|
||||
}
|
||||
Binary file not shown.
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Load diff
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Load diff
File diff suppressed because it is too large
Load diff
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|
|
@ -1,5 +0,0 @@
|
|||
sync_info = create
|
||||
user_id =
|
||||
setting_id =
|
||||
base_id = OGFSL19
|
||||
updated_time = 0
|
||||
|
|
@ -1,16 +0,0 @@
|
|||
{
|
||||
"compatible_printers": [
|
||||
"Sovol SV06 ACE 0.4 nozzle"
|
||||
],
|
||||
"fan_cooling_layer_time": [
|
||||
"20"
|
||||
],
|
||||
"filament_settings_id": [
|
||||
"PolyLite PLA @System - Z-Tower"
|
||||
],
|
||||
"from": "User",
|
||||
"inherits": "PolyLite PLA @System",
|
||||
"is_custom_defined": "0",
|
||||
"name": "PolyLite PLA @System - Z-Tower",
|
||||
"version": "2.3.0.3"
|
||||
}
|
||||
|
|
@ -1,5 +0,0 @@
|
|||
sync_info = update
|
||||
user_id =
|
||||
setting_id =
|
||||
base_id = GP004
|
||||
updated_time = 0
|
||||
|
|
@ -1,24 +0,0 @@
|
|||
{
|
||||
"bottom_shell_layers": "5",
|
||||
"brim_type": "outer_only",
|
||||
"from": "User",
|
||||
"inherits": "0.20mm Standard @Sovol SV06 ACE",
|
||||
"initial_layer_line_width": "0.42",
|
||||
"initial_layer_print_height": "0.2",
|
||||
"inner_wall_speed": "80",
|
||||
"is_custom_defined": "0",
|
||||
"line_width": "0.42",
|
||||
"name": "Y-bar_20260317_final",
|
||||
"only_one_wall_top": "0",
|
||||
"outer_wall_acceleration": "1500",
|
||||
"outer_wall_line_width": "0.42",
|
||||
"outer_wall_speed": "60",
|
||||
"print_settings_id": "Y-bar_20260317_final",
|
||||
"skirt_loops": "2",
|
||||
"sparse_infill_density": "20%",
|
||||
"sparse_infill_pattern": "gyroid",
|
||||
"top_shell_layers": "5",
|
||||
"top_solid_infill_flow_ratio": "1",
|
||||
"version": "2.3.0.3",
|
||||
"wall_loops": "3"
|
||||
}
|
||||
|
|
@ -1,5 +0,0 @@
|
|||
sync_info = update
|
||||
user_id =
|
||||
setting_id =
|
||||
base_id = GP004
|
||||
updated_time = 0
|
||||
|
|
@ -1,26 +0,0 @@
|
|||
{
|
||||
"bottom_shell_layers": "5",
|
||||
"brim_type": "outer_only",
|
||||
"from": "User",
|
||||
"inherits": "0.20mm Standard @Sovol SV06 ACE",
|
||||
"initial_layer_line_width": "0.42",
|
||||
"initial_layer_print_height": "0.2",
|
||||
"inner_wall_speed": "80",
|
||||
"is_custom_defined": "0",
|
||||
"line_width": "0.42",
|
||||
"name": "Z-tower_20260317_final",
|
||||
"notes": "Orca serialization note\n\nIn Orca Slicer 2.3.0.3, some live profile values may not appear in the saved process JSON even when they are active in the UI. For the Z-tower profile, Sparse infill density was verified in the live UI as 10% before slicing, even though the saved JSON did not include a sparse_infill_density key.\n\nScreenshot was taken showing the 10% value, 20260318_184351_Wed.png",
|
||||
"only_one_wall_top": "0",
|
||||
"outer_wall_acceleration": "1500",
|
||||
"outer_wall_line_width": "0.42",
|
||||
"outer_wall_speed": "40",
|
||||
"print_settings_id": "Z-tower_20260317_final",
|
||||
"seam_gap": "0",
|
||||
"seam_position": "back",
|
||||
"skirt_loops": "2",
|
||||
"sparse_infill_pattern": "line",
|
||||
"top_shell_layers": "5",
|
||||
"top_solid_infill_flow_ratio": "1",
|
||||
"version": "2.3.0.3",
|
||||
"wall_loops": "3"
|
||||
}
|
||||
|
|
@ -1,5 +0,0 @@
|
|||
sync_info = create
|
||||
user_id =
|
||||
setting_id =
|
||||
base_id = GP004
|
||||
updated_time = 0
|
||||
|
|
@ -1,23 +0,0 @@
|
|||
{
|
||||
"bottom_shell_layers": "5",
|
||||
"brim_type": "no_brim",
|
||||
"from": "User",
|
||||
"inherits": "0.20mm Standard @Sovol SV06 ACE",
|
||||
"initial_layer_line_width": "0.42",
|
||||
"initial_layer_print_height": "0.2",
|
||||
"inner_wall_speed": "80",
|
||||
"is_custom_defined": "0",
|
||||
"line_width": "0.42",
|
||||
"name": "cube_20260317_final",
|
||||
"only_one_wall_top": "0",
|
||||
"outer_wall_acceleration": "1500",
|
||||
"outer_wall_line_width": "0.42",
|
||||
"outer_wall_speed": "60",
|
||||
"print_settings_id": "cube_20260317_final",
|
||||
"seam_position": "back",
|
||||
"skirt_loops": "2",
|
||||
"sparse_infill_pattern": "grid",
|
||||
"top_shell_layers": "5",
|
||||
"top_solid_infill_flow_ratio": "1",
|
||||
"version": "2.3.0.3"
|
||||
}
|
||||
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