Head carriage plate - X5SA Pro to E3D Toolchange
Description
This is a replacement X Axis head assembly to suit a TronXY X5SA Pro and convert it to take an E3D Tool changer system. One of the main parts is a flat rectangular plate to take the track rollers and their adjusters Full CAD files are included in the archive. I had it made in aluminium through "Machining-4u" but it may work as a 3D print, in a suitably strong and rigid material. It needs track rollers installing using correct screws, with M5 Form C washers between the rollers and plate. The top two screw directly in to the plate, in tapped holes. The lower two are fitted with eccentric adjusters which go in the recesses in the rear of the plate. The ones I got were 6mm thick and needed cutting down to 4mm to fit flush in the plate. The roller screws also needed trimming flush. You could use the parts from the original head plate, or they are all available separately on such as Aliexpress. A large printed part fits over the plate assembly after the rollers and toolchange mechanics are fitted and adjusted. All screws for attachments other than the top cable anchor have provision for nuts to be slotted in, which ensure extremely solid fixings. It has attachment points the timing belts, for a slotted opto switch for the Y reference and a BLTouch probe, with wiring channels through it for their cables and the tool clamp motor cable. It's a very snug fit on the plate and will need careful cleaning up and preparation, both to fit it to the plate assembly and for the cable channels to ensure the wires will thread through easily. Open all fixing holes other than the two in the top to clearance size for the various screws, fit the nuts in the cutouts and ensure the screws fit OK and engage the nuts properly before going any further with the assembly. The top two need drilling 2.5mm and either tapping out or use M3 "taptite" screws, at least to create the threads (my preference). Add two short offcuts of timing belt, around 11mm long, to the inside backs of the clamp cavities at each end of the head top; each should be in line with but away from the respective belt entry channels so the belt end can thread through past them when assembling the machine. Use superglue and temporarily fit the clamp block to hold them firmly in place for the adhesive to set. The tool change kit is fitted using a combination of M3 8mm and 10mm male/female threaded spacers and though threaded spacers, plus M3 threaded rod and a few washers etc. Note that the overall distance between the front and back halves of the toolchange assembly is critical - there should be an absolute minimum clearance between the motor mounting plate and the back of the TronXY Y rail. Adjust the spacing to keep everything as tight in as practical! See the photos for details. After installing everything and getting it running, I found the BLTouch was slightly too high - I added an M4 nut as a spacer on each fitting screw and that gave a good working trigger height, just below the tool nozzle. You will also need the various E3D toolchanger parts, both the mechanical kit and various printed pats from the files E3D link to with the toolchanger documents. The toolholder mount blocks needed to fit the tool receivers to the machine frame & the limit switch parts will be uploaded separately. The photo showing the new X axis carriage plate alongside the original X carriage is purely to demonstrate the proportions - the new carriage completely replaces the original. You will also need a completely new control system that can manage the toolchange operation, such as a Duet. The frame side parts - tool holders, limits etc. are here: https://www.thingiverse.com/thing:5150890 An overview of the end result here: https://www.youtube.com/watch?v=x-ut81sn-io I will be posting another video detailing all the conversion parts and how everything fits together.
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