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update docs
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charlespick committed Sep 18, 2021
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60 changes: 46 additions & 14 deletions docs/Dual_Carriage.md
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Expand Up @@ -28,6 +28,9 @@ relative to each other.
Because Klipper configures this by the endstop position, you will
need to calibrate your [rotation distance](Rotation_Distance.md) first.

For the finest accuracy, you should consider calibrating the homing
[endstop phase](endstop_phase.md) of your x axis motors.

## Step 1 (~5mm)
Start by literally eyeballing it. Put a piece of tape on your bed or
use a line or other graphic already on your bed as a reference point.
Expand Down Expand Up @@ -59,7 +62,11 @@ Note the lines should be colinear. If they are not, adjust your
`position_endstop` setting as noted in step 1. Once they are visually
aligned, proceed to step 3.

## Step 3 (~0.05mm)
At this point you should re-tune your mins and maxes for each axis when
the other is parked by issuing slow, small movements until they
collide.

## Step 3 (~.1 - .025mm)
While the measuring process of this step accounts for symmetric
horizontal expansion, you will likely achieve better results by
calibrating the flow, temperature, and pressure advance for the
Expand All @@ -69,24 +76,49 @@ that can be printed without a heated bed.

Use a slicer to generate g-code for the multi-part print found in
[docs/prints/calibrate_idex.stl](prints/calibrate_idex.stl).
Align the slot down the middle with the axis of your `dual_carriage`.
Configure your slicer to print the 2 parts using extruders on opposite
carriages. I highly recommend using identical filaments printed with
the same temperature, etc. Nothing else matters as long as the wall
quality is smooth. Print the object.
Align the long direction of the print perpendicular to the axis of your
`dual_carriage`. Configure your slicer to print the upper part using
the right extruder. I highly recommend using identical filaments printed with
the same temperature, etc. Use a rather coarse layer height since you
have not yet calibrated your Z offset. Print the object.

Use calipers or better, a micrometer to measure the 2 measureing points
(refer to the image below). Complete the following table:

Use calipers to measure the inner and outer distances as follows.
Average your inner and outer measurements, calculate the difference
from the nominal value (which is 40mm), and adjust your `position_endstop`
setting as noted in step 1.
| Part | Measurement | Calculation |
|:--:|:--:|:--:|
| Front | (mm) | 20 - (mm) |
| Back | (mm) | (mm) - 20 |
| Offset | | ^ Average ^ |

![measuring print](img/separation-block.png)

# Next steps
At this point you should re-tune your mins and maxes for each axis when
the other is parked by issuing slow, small movements until they
collide.
You should be left with the adjustment that should be made to compensate
for any alignment error. Save this to the printer by running:
```
SET_SEPARATION X_ADJUST={your calculated value}
```
If this sounds confusing, you can check your work with the following analysis:
if the front measurement is more than 20mm by more than the difference of the back
measurement and 20, the right extruder is printing too far to the right. The
`X_ADJUST` value should be negative because the offset needs to move to
the left, towards the origin (or negative if your origin is centered).

Repeat this step if nessesary until you are happy with the alignment and with the Y axis if nessesary.

## Step 4 (required for high quality printing)
To print with low layer thicknesses, you'll probably find that the error
between your nozzles in the Z axis is more than your layer height itself.

Start with a piece of paper and switch between the extruders until the pressure feels roughly the same on both extruders. Make sure you're testing the exact same point on
your bed.

Prepare to print a square about 10x10x5mm. Slice the object twice with the only difference being which extruder is used. MAKE SURE IT IS IN THE SAME PLACE ON YOUR BED.

Use calipers or better, a micrometer to measure the height of the two samples and
adjust the Z offset as nessesary.

# Next steps
Configure a homing override to make sure that the inactive carriage is
fully parked in all scenarios.

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