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garethky / Slice-Mosquito-Direct-Tool-Head

Models and Instructions for making a Mosquito/Bondtech direct drive toolhead for the E3D Tool Changer platform
GNU General Public License v3.0
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5015 fan makes a loud noise during some moves #4

Closed garethky closed 3 years ago

garethky commented 3 years ago

The Sunon "Vapo-Brearing" fans that I am using float on their shafts, unlike ball bearing fans that are locked to the shaft by the bearings. If the fan gets excited by resonance in the motion system it can vibrate and amplify this noise, causing a loud screech.

One possible solution is to use silicone vibration isolation mounts. Luckily we get 4 of these in the package with the Noctua 40mm cooling fan so this would not be an extra cost to the builder. This requires space to be mounted so the fan will have to be moved away from the extruder body.

For builders that want to use a ball bearing fan there should be an option for hard mounting the fan. This requires 2 parts in the build.

garethky commented 3 years ago

Comited a "Soft Mount" bracket that allows the 5015 to be mounted.

One unhandled problem is what to do with the narrow "ends" of the soft mounts. They can be cut off but that makes it hard to use them more than once. They can be stuffed under the fan but its not really secure. Some kind of bracket is needed to retain them out of the way.

garethky commented 3 years ago

Noise is improves but not eliminated. The fan is still coupled to the cooling nozzle which is directly coupled to the frame. Running tests with no nozzle shows that the noise in almost completely eliminated. The speed where it is worst on my machine (with 0.9 degree motors) is 55mm/sec. This is a pretty common speed for some slower print moves.

Next step here is to investigate isolating the fan from the part cooler. Maybe with some of the same material that is already isolating the fan, as that would keep the parts list short.

garethky commented 3 years ago

I've been doing a separate deep dive investigation into using StealthChop on the ToolChanger. My ToolChanger was not correctly executing the requires auto calibration procedure to optimize StealthChop. The calibration procedure now runs as part of my homeall.g and the result is an incredibly quiet and smooth machine. As a result I no longer have any noise due to the fan.

If someone is running in Spread Cycle mode and wants to argue for further improvements in this area feel free to open the issue back up.