Light assist Season 3

I upgraded the printer due to quality and failure rate on my homemade klipper bed slinger.

There is a promotion for 459€ shipped for anycubic cobra combo, it is a 250x250 core xy with 4 color changer and filament drying fonction.

Going from 350 mm to 250mm bed however :smiling_face_with_tear:


2 Likes

These rtlecs pogo pins - they turned out to be reliable in the long run?

some corrosion, but mostly OK. I use grease or silicon spray. The latest version of the assist has a better seal concept.

1 Like

So even if corrosion happens, it can be cleaned, I guess, (though the coating can be damaged). But you are confident that contacts remain functioning no matter what…it is great.

These xt90 are spark protected , right? I see some are black inside. Did it happen to you that the spark protection of the connector stopped working?

Started with waterproof XT90, but since I improved the seal I will use XT90S instead. The sparking is pretty intense on plug-in, and controller side with male pins is not replaceable after potting…

For the pogo, yes they can be cleaned, I had a few where the coating got damaged from salt water droplets. With 35E cells, I mostly just check the balance from time to time with a multimeter, I don’t need to use the balancer so much if at all.

BTW, do you have feedback about BAK 45D?

That sparking is not good, I have built a battery with a built-in connector and connector got destroyed. Since then I will use battery built-in connector only if adding mosfet ramp up.

I use that bak 45d cell in my batteries, it performs very well as expected. Battery stays cooler and run longer than p42

1 Like

BTW it would be great if we could use eve 4695e 30ah cell. It is lighter, cheaper and more performant. But for 670wh capacity we can chain only 6s. Maybe use higher kv motors.
'EVE 4695E 3.7V 30Ah power cylindrical lithium ion batteries

Got the controller and finished wiring up the test p45b battery

Craftcloud order has been shipped with pod and controller base

3 Likes

I tried many settings and couldn’t take off in FOC mode. Next time I’ll try BDLC

Weight reference. 450gr less for the 12s1p

Craftcloud parts will be here next week. Paid 33€ taxes on it.

Will start with the maytech motor on the pod, and will be able to directly compare both systems :

  • v3 40mm 12s2p 35E with 6384 three blade alu, 84100hp vesc
  • v4 25mm 12s1p p45b with maytech 6374 three blade PA12, harry M vesc



1 Like

Do you use any covers to protect the balance connector contacts from water?

When the battery press into the controller, the foam seals both flat surface, and prevents water into the XT90 and into the pogo.

With the new flat seal concept, I can run normal XT90S and seal the pogo better.
Just a head up, XT90S plugs are thought, so during potting, make sure they are fully soldered, or that you added some sealing inside to prevent epoxy weeping from the connector.

3 Likes

That is, the seal only works when the battery is installed, the rest of the time the pogo contacts are open?

Yes this is right, have to be carefull during storage and battery swap in water. This is why I still silicon grease the contacts.

Printed a dummy controller part to check wiring.

The initial plan with rx mounting is not ideal, and I reworked the layout a little.
Next I have to prepare signal wiring and make it clean, then I can test it all before installation in the alu part. I will aslo design a part to hold the electronics and wires all together and reduce potting volume and weight where possible.

Regarding the rx antenna, I did not yet fully think about a clever solution. I should have added a tray such as in v2/v3, it is a working and simple solution.




Edit, all wired up, pretty happy about how the layout turned out!


5 Likes

image

I would recommend to add some insulation between the top of the capacitors and the wires, usually the capacitor housing is connected to either the + or - of the cap.

2 Likes

Not visible in the picture, but there are extra spacers below the +/- lugs to raise them above the caps. Will add barley paper in critical areas, like between the phase wires of MR60 (very tight with 8AWG, 12AWG would be OK for assist use) and below the RX to insulate the pins from alu.

Below the controller, I will add a layer of kapton tape, then thermal glue.

2 Likes

Nice!
For adhesion I like this product:

It has very good thermal and adhesive properties and is elec. insulating. 3-in-1 :smiley:

3 Likes

All is assembled and works as intended.

Programming and motor detection went smoothly, next test is in the water next week-end.

Tx and rx were reversed for some reason, maybe the pads on the breakout board were already labelled for the matching side.

Missed the dhl courrier with craftcloud parts, has to wait wednesday.


3 Likes




Should be 2800-2900 gr finished
Some photos of the seals concept for phase and battery. The hole on the side of the pod is for potting for the mr60 from the back.

Final assembly and tests in the next few days

8 Likes

What if to put a normally open reed switch in line for each pogo pin and use a magnet during charging, should not add much weight, those that 500ma.

1 Like