Gh Enterprise 116030-01 Smart Shaper User Manual (+ PDF)

The Smart Shaper uses input shaping algorithms to suppress
vibrations characterized by a particular frequency and dumping
ratio. The dumping ratio is assumed to be 10%, and the frequency
should be estimated experimentally for both axes.

Requirements

The Smart Shaper requires a TMC 2225 driver, a power supply
voltage of 5.5V-36V, and a logic supply voltage of 3V-5V.

Hardware

TMC 2225 Driver Specifications

Power Supply
- GND Ground
- VM Motor Supply Voltage 5.5V-36V
- VCCIO Logic Supply Voltage 3V-5V
Motor Outputs
- OA2 Motor Coil 1
- OA1 Motor Coil 1
- OB1 Motor Coil 2
- OB2 Motor Coil 2
Control Inputs
- STEP STEP input (internal pull-down resistor)
- DIR DIR input (internal pull-down resistor)
- TMC2225 EN Enable Motor Outputs: GND=on, VIO=off
- 11: 1/32 MS2 –
- RXD UART RX, Directly connected to the PDN
- TXD UART TX, Connected to the PDN via a 1K resistor on
  board
- DIAG Diagnostic output. Hi level upon driver error. Reset by
  ENN=high.
- VREF Analog Reference Voltage

Motor Current Regulation

The motor current should match the current tolerated from your
step motors. The current can be adjusted using the onboard
potentiometer. The value of VREF in Volt corresponds to the value
of Peak Current Imax in Ampere.

Dissipation Recommendation

If the TMC2225 is not well cooled, it goes into a thermal
protection state and stops working. It is highly recommended to
provide adequate cooling.

Resonance Frequency Measurement

Print Calibration Model

For Cartesian printing, the calibration model prepared for
frequency estimation consists of a simple L Model printed with the
walls aligned along X and Y axes.

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ENGLISH
User Manual
NAME: SMART SHAPER MODEL: 116030-01
116030SmartShaperUserManualV1-04

INDEX:

Smart Shaper 116030SmartShaperUserManualV1-04

1. INTRODUCTION…………………………………………………………………………………………………3

2. REQUIREMENTS……………………………………………………………………………………………….3

3. HARDWARE

3.1. TMC 2225 DRIVER SPECIFICATIONS 4

3.2. PINOUT

3.3. MOTOR CURRENT REGULATION

3.4. DISSIPATION RECOMMENDATION

4. RESONANCE FREQUENCY MEASUREMENT……………………………………………………..6

4.1. PRINT CALIBRATION MODEL 6

4.2. FREQUENCY MEASUREMENT 7

5. BOARDS CONFIGURATION……………………………………………………………………………….8

5.1. G-CODE GENERATOR 8

5.2. G-CODE CONFIGURATION SEQUENCE 8

5.3. SMART SHAPER G-CODE GENERATOR 1.1 9

5.4. SEQUENCE GENERATOR

5.5. PRINTER WITH DIFFERENT AXES RESOLUTIONS 10

5.6. PRINT WITH INPUT SHAPING 10

5.7. STATUS LED INFORMATION 11

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Smart Shaper 116030SmartShaperUserManualV1-04
1. Introduction
Input shaping algorithms are designed to suppress the vibrations characterized by a particular frequency and dumping ratio. Dumping ratio is difficult to estimate and it’s usually assumed to be 10%. Frequency should be estimated experimentally for both axes. The measure of the axes frequencies requires the following steps:
· Print of a reference model (see 4.1.) · Measurement of distance between ringing peaks (see 4.2.) · Frequency calculation by given formula (see 4.2.) Next it will be explained how to configure the boards with the frequencies previously found and the preferred Input Shaping algorithm (see 5.1.) Finally It will possible to print again the reference model but with Input Shaping Enabled (see 5.6.) in order to verify the correct values of frequencies and the performance of the algorithm.
2. Requirements
The following instructions are intended for the following setup: · Cartesian and Core XY/YX printers. · X/Y (or A/B for Core XY/YX printer) axes driven by Smart Shaper Boards. · X/Y axes resolution 80 steps/mm ( for axes with different resolutions see 5.5. ) · Max Step Rate 48Khz. · Cartesian printer max printing speed is 600 mm/s with 80 step/mm. · Core XY/YX printer max printing speed is 300 mm/s with 80 step/mm. · TMC2225 configured with 16 microsteps resolution and interpolation. · TMC2225 configuration can be done via UART or bootstrap pins.
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3. Hardware
3.1. TMC 2225 Driver Specifications
· TMC2225-SA stepper motor controller & driver · Supply voltage 5.5-36V · Continuous Iphase = 1.4ARMS · Iphase up to 1.77ARMS = 2,5Apeak for a short time · Quiet operation with StealthChop · Sensorless homing with StallGuard · Energy saving with CoolStep · Configuration and extended diagnostic via UART · Control via Step&Dir interface · Board width 0.6″. board height 0.8″ · 2×8 pin 0.1″ head rows for pins/connectors
3.2. Pinout

Power Supply

GND Ground

VM Motor Supply Voltage 5.5V-36V

VCCIO Logic Supply Voltage 3V-5V

Motor Outputs

OA2 Motor Coil 1

OA1 Motor Coil 1

OB1 Motor Coil 2

OB2 Motor Coil 2

Control Inputs

STEP STEP input (internal pull-down resistor)

DIR DIR input (internal pull-down resistor)

TMC2225

EN Enable Motor Outputs: GND=on, VIO=off

Microsteps resolution configuration (internal pullMS1 down resistors) MS2, MS1: 00: ¼, 01: , 10: 1/16,
11: 1/32

MS2 –

RXD UART RX, Directly connected to the PDN

TXD

UART TX, Connected to the PDN via a 1K resistor on board

DIAG

Diagnostic output. Hi level upon driver error. Reset by ENN=high.

VREF Analog Reference Voltage

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3.3. Motor Current Regulation

Smart Shaper 116030SmartShaperUserManualV1-04

Driver motor current should match the current tolerated from your step motors. The current can be adjusted the value of VREF using the onboard potentiometer. VREF [V]= (Irms * 2.5V) / 1.77A = Irms * 1.41 = Imax [A] The value of VREF in Volt corresponds to the value of Peak Current Imax in Ampere. In the following picture are indicated how to measure VREF. TheSmartShaper board should be installed on the motion board and the VM power supply should be present.
Pay attention to avoid any short circuits when using screwdriver on potentiometer
3.4. Dissipation recommendation TMC2225 if not well cooled goes in to thermal protection state and stops to work. It’s highly recommended to:
· Install the Heat Sinks provided with installation set · Use a 3D motion control board equipped with a cooling fan system.
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4. Resonance Frequency Measurement

Smart Shaper 116030SmartShaperUserManualV1-04

4.1. Print Calibration Model
For Cartesian printing the calibration model prepared for frequency estimation consists in a simple L Model printed with the walls aligned along X and Y axes.

The printed part has one wall marked with X label and another one marked with Y label. The X Label is on the wall aligned along the Y axes and the Y Label is on the wall aligned along the X axis. The reason is that the ringing due to Y acceleration/deceleration are visible on X axis and vice-versa. The walls are printed at 100 mm/s ( this speed value is fundamental for the correct frequency calculation using the formula in 4.2. ).
Acceleration is linearly increased from 500 mm/s2 (Bottom) to 18000 mm/s2 (Top) in order to increase the vibrations. TMC2225 is configured in current mode to support high acceleration through G-code sequence. X and Y Coordinates will not exceed 145 mm. Material should be PLA (using a red color improves the measurement of ringings) and nozzle diameter 0.4 mm. Print the model. It’s possible that at some height the printer start to loose steps because acceleration is too high to be tolerated by mechanics. If it happens just stop the printer. Now extract the printed part from the printer and analyze it.
For Core XY/YX printers the print calibration model is different from that for Cartesian printers, because the model is rotated of 45 degrees respect to the cartesian plane and the label to reference axes are called A and B, but it has the same characteristics as the model for cartesians printers.
The calibration models can be downloaded from the web site. https://gh-enterprise.com/en/3d-printer-controller/
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4.2. Frequency Measurement To find the ringing frequency it should be measured the distance between two peaks of the oscillations. The easiest way is:
· put the part under a light beam parallel to the surface
· mark each visible oscillation peaks · measure with a caliper the total distance D in mm between the first mark and last
mark
· calculate the oscillation frequency (Hz) using the formula f =V ( N -1) D
where · V =100 mm/s · N is the number of marks
Example of a Y axis oscillation frequency measurement. We marked 7 oscillation peaks. The measured distance was about 19.8 so the frequency was:
f = 100(7-1)31 Hz 19.8
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5. Boards Configuration

Smart Shaper 116030SmartShaperUserManualV1-04

5.1. G-Code Generator The G-Code generator is Online version on the GH Enterprise web site ( https://gh-enterprise.com/smart-shaper-generator-1.1/smartshaper_gcode.html )

5.2. G-Code configuration sequence Each Smart Shaper board can be programmed via a specific G-Code sequence generated by Smart Shaper G-Code Generator 1.1 (see 5.3. for description).
An example of such sequences can be found in the file CartesianSmartShaperCalibration.gcode (lines 32-129). In this case they have been inserted two sequences, one for X driver and one for the Y driver, that DISABLE the Input Shaping filter to detect ringings.

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5.3. Smart Shaper G-Code Generator 1.1

Smart Shaper 116030SmartShaperUserManualV1-04

CARTESIAN AXES X to select Driver on X axis. Y to select Driver on Y axis.
CORE XY / CORE YX A to select Driver on A axis. B to select Driver on B axis.
DAMPING RATIO Range: 0-99.

DRIVE MODE Current or Voltage.
USE CURRENT FOR HIGH ACCELERATIONS.
START POSITION Position along the relative axis where the G-Code sequence is executed.

SHAPING ALGORITHM Select DISABLED to bypass Input Shaper or (ZV,MZV,ZVD, EI) to ENABLE the relative Shaping Algorithm.

VIBRATION FREQ [Hz] Insert the frequency measured found previously.
PRINTER KINEMATICS Select the printer type, CARTESIAN or CORE XY/YX.

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5.4. Sequence Generator The Smart Shaper G-Code Generator 1.1 is the tool to generate the G-Code configuration sequence. Once the correct settings have been entered, a Gcode will be created in the right column to be copied and pasted into the gcode to be printed.
5.5. Printer with different axes resolutions For the programming with G-Code to be correct, the resolution of the axes must be 80 step/mm. If the resolutions is different, for example 100 step/mm for the X axis, proceed as follows: – First of all insert the M92 X80 G-Code command before the programming part made with
Smart Shaper G-Code Generator 1.1. – After the programming G-Code insert the M92 X100 G-Code command to set the
correct resolution of the axis. The maximum print speed will be slower with higher resolution.
5.6. Print with Input Shaping Generate a G-Code configuration sequence for each axes according to the measured frequencies.
Due to the high accelerations of Calibration Model, the TMC2225 SHOULD BE CONFIGURED IN CURRENT MODE. Replace the two original sequences in the SmartShaperCalibration.gcode (lines 32-129) with the new generated ones. Print the modified G-Code. Just after homing procedure the two configuration sequence will be executed.
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5.7. Status Led Information

A red led is placed on each Smart Shaper board. The blinking frequency provide some

information about the board.

Just after the startup the Led will blink as many times related to the version of the installed

firmware (Ex. Firmware is 1.3 will blink 3 times).

After startup the Led will indicate the current status of the board as shown in the following

table.

Frequency (Hz)

Meaning

0.5

Input Shaper Off