filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=2.85;
   4
   5 slop=0.5;
   6 bigslop=slop*2;
   7
   8 function selsz(sm,lg) = fdia < 2 ? sm : lg;
   9 function usedove() = selsz(true,false);
  10
  11 exteffrad = 70;
  12 hubeffrad = 30;
  13 hubbigrad = 20;
  14 hublwidth = 3;
  15 hubstemwidth = 2;
  16 hublthick = 10;
  17 hubaxlelen = 25;
  18 hubaxlerad = 5;
  19 totalheightfromtower = 240;
  20 axletowerfudgebend = 0;
  21 axleaxlefudgebend = 3;
  22 axlepadlen = 1.0;
  23
  24 prongthick=selsz(5,7);
  25 prongwidth=selsz(5,7);
  26 ratchetstep=15;
  27 ratchettooth=3;
  28 ratchettoothheight=5;
  29 ratchettoothsmoothr=1;
  30 ratchettoothslope=0.75;
  31 overlap=0.5;
  32 cupwidth=selsz(40,60);
  33 cupheight=selsz(55,75);
  34
  35 propxshift = 0;
  36
  37 doveclipheight = 10;
  38
  39 teethh=3;
  40 teethgapx=4+fdia;
  41
  42 prongstalkxwidth=3;
  43
  44 stalklength=selsz(35,55);
  45 overclipcupgap=5;
  46 overclipdepth=15;
  47 overcliproundr=2.0;
  48 overclipthick=1.0;
  49 overclipcupnextgap=20;
  50
  51 overclipsmaller=-2.5;
  52 overclipbigger=0.0;
  53
  54 wingspoke=3;
  55 wingsize=6;
  56 wingthick=3;
  57
  58 armendwallthick=2.5;
  59 armendbasethick=1.2;
  60
  61 axlehorizoffset = 12.5;
  62 axlevertheight = 100;
  63 towercliph = 16;
  64 towerclipcount = 3;
  65 towerpillarw = 5;
  66
  67 axlepinrad = 2;
  68 axlepintabrad = 5;
  69
  70 washerthick = 1.2;
  71 washerthinthick = 0.8;
  72 washerverythinthick = 0.4;
  73 washerrad = hubaxlerad + 7.5;
  74 frictionwasherarmwidth = 3;
  75 frictionwasherextrapush = 1.0;
  76
  77 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  78
  79 nondove_armbase = 100;
  80 nondove_armhole_x = 60;
  81 nondove_armhole_hole = 4;
  82
  83 include <doveclip.scad>
  84 include <cliphook.scad>
  85 include <filamentteeth.scad>
  86 include <axlepin.scad>
  87
  88 channelwidth = prongthick + slop;
  89 channeldepth = prongwidth + ratchettoothheight;
  90 totalwidth = armendwallthick*2 + channelwidth;
  91 totalheight = channeldepth + armendbasethick;
  92 stalkwidth = prongwidth + prongstalkxwidth;
  93
  94 module ArmEnd(length=120){ ////toplevel
  95   if (usedove()) {
  96     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  97       rotate([0,0,-90])
  98         DoveClipPairBase(h=doveclipheight);
  99     }
 100   } else {
 101     difference(){
 102       translate([1, -armendwallthick, -armendbasethick])
 103         mirror([1,0,0])
 104         cube([nondove_armbase+1, totalwidth, totalheight]);
 105       translate([-nondove_armbase + nondove_armhole_x,
 106                  -armendwallthick + totalwidth/2,
 107                  -armendbasethick -1])
 108         cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
 109     }
 110   }
 111
 112   difference(){
 113     translate([0, -armendwallthick, -armendbasethick])
 114       cube([length, totalwidth, totalheight]);
 115     translate([-1, 0, 0])
 116       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
 117     translate([-1, 0, ratchettoothheight])
 118       cube([length+2, channelwidth, channeldepth+1]);
 119   }
 120   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
 121     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
 122       rotate([90,0,0])
 123         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 124       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 125                         [       0,      1,      0,      0       ],
 126                         [       0,      0,      1,      0       ],
 127                         [       0,      0,      0,      1       ]])
 128         cube([ratchettooth - ratchettoothsmoothr*2,
 129               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 130     }
 131   }
 132 }
 133
 134 module FilamentCupHandle(){
 135   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 136   mirror([0,1,0]) {
 137     cube([stalklength, stalkwidth, prongthick]);
 138     translate([stalklength, stalkwidth/2, 0])
 139       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 140     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 141       minkowski(){
 142         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 143         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 144                         [       0,      1,      0,      0       ],
 145                         [       0,      0,      1,      0       ],
 146                         [       0,      0,      0,      1       ]])
 147           cube([pawlusewidth,
 148                 ratchettoothheight - ratchettoothsmoothr,
 149                 prongthick - 1]);
 150       }
 151     }
 152   }
 153 }
 154
 155 module FilamentCupCup(){
 156   for (my=[0,1]) mirror([0,my,0]) {
 157     translate([0,cupwidth/2,0])
 158       cube([cupheight + prongwidth, prongwidth, prongthick]);
 159   }
 160 }
 161
 162 module FilamentCup() { ////toplevel
 163   FilamentCupHandle();
 164
 165   gapy = prongwidth;
 166   dy = cupwidth/2 + gapy + overclipcupgap;
 167
 168   translate([0, dy, 0])
 169     FilamentCupCup();
 170   translate([0, -1, 0]);
 171   cube([prongwidth, dy+1+cupwidth/2, prongthick]);
 172
 173   midrad = cupwidth/2 + prongwidth/2;
 174
 175   propshift = stalklength - overclipdepth - prongthick + propxshift;
 176   proptaken = propshift;
 177   echo(midrad, propshift, proptaken);
 178
 179   translate([propshift, -1, 0]) {
 180     // something is wrong with the y calculation
 181     cube([prongwidth,
 182           gapy+2,
 183           prongthick]);
 184   }
 185   for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
 186     translate([0, y, 0])
 187       rotate([0,0, 102 + fdia])
 188       FilamentTeeth(fdia=fdia, h=teethh);
 189   }
 190   for (x = [-0.3, -1.3]) {
 191     translate([cupheight + overclipcupnextgap*x, dy+cupwidth/2 + prongthick, 0])
 192       rotate([0,0, 12 + fdia])
 193       FilamentTeeth(fdia=fdia, h=teethh);
 194   }
 195 }
 196
 197 module CupSecuringClipSolid(w,d,h1,h2){
 198   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 199     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 200   }
 201 }
 202
 203 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 204   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 205   minkowski(){
 206     CupSecuringClipSolid(w=totalwidth,
 207                          d=overclipdepth + xdepth,
 208                          h1=hbase - overclipsmaller,
 209                          h2=hbase + overclipbigger);
 210     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 211   }
 212 }
 213
 214 module CupSecuringClip(){ ////toplevel
 215   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 216   difference(){
 217     union(){
 218       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 219       translate([-wingswidth/2, -wingsize/2, 0])
 220         cube([wingswidth, wingsize, wingthick]);
 221       translate([-wingsize/2, -wingswidth/2, 0])
 222         cube([wingsize, wingswidth, wingthick]);
 223     }
 224     translate([0,0,-0.1])
 225       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 226   }
 227 }
 228
 229 module ArmDoveClipPin(){ ////toplevel
 230   DoveClipPin(h=doveclipheight);
 231 }
 232
 233 module TowerDoveClipPin(){ ////toplevel
 234   DoveClipPin(h=towercliph/2);
 235 }
 236
 237 module Hub(){ ////toplevel
 238   difference(){
 239     cylinder($fn=60, h=hublthick, r=hubbigrad);
 240     translate([0,0,-1])
 241       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 242   }
 243   axlerad = hubaxlerad + slop;
 244   difference(){
 245     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 246     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 247   }
 248   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 249   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 250   for (ang=[0,120,240])
 251     rotate([0,0,ang]) {
 252       difference() {
 253         translate([hubeffrad,0,0])
 254           DoveClipPairSane(h=doveclipheight,
 255                            baseextend = (hubeffrad - DoveClip_depth()
 256                                          - hubbigrad + hublwidth));
 257         if (hole>hublwidth && holewidth > 2) {
 258           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 259             cube([hole, holewidth, hublthick+2]);
 260         }
 261       }
 262     }
 263   xmin = axlerad+hublwidth/2;
 264   xmax = hubbigrad-hublwidth/2;
 265   for (ang = [0 : 60 : 359])
 266     rotate([0,0,ang]) rotate([90,0,0]) {
 267       translate([0,0,-hublwidth/2])
 268         linear_extrude(height=hublwidth)
 269         polygon([[xmin,0.05], [xmax,0.05],
 270                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 271     }
 272 }
 273
 274 module ArmExtender(){ ////toplevel
 275   DoveClipExtender(length=exteffrad-hubeffrad,
 276                    ha=doveclipheight,
 277                    hb=doveclipheight);
 278 }
 279
 280 module FsAxlePin(){ ////toplevel
 281   AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
 282 }
 283
 284 module Axle(){ ////toplevel
 285   pillarswidth = DoveClipPairSane_width(towerclipcount);
 286
 287   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 288   translate([-axlehorizoffset, -axlevertheight, 0]) {
 289     rotate([0,0,-axletowerfudgebend])
 290     rotate([0,0,-90])
 291       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 292     translate([0, DoveClip_depth(), 0])
 293     rotate([0,0,90])
 294       ExtenderPillars(axlevertheight - DoveClip_depth(),
 295                       pillarswidth, towercliph,
 296                       pillarw=towerpillarw);
 297   }
 298
 299   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 300   axlerad = hubaxlerad-slop;
 301   bump = axlerad * 0.2;
 302   shift = axlerad-bump;
 303   joinbelowallow = 3;
 304
 305   intersection(){
 306     translate([0, 0, shift]) {
 307       difference() {
 308         union(){
 309           translate([-1, 0, 0])
 310             rotate([0,90,0])
 311             cylinder($fn=60,
 312                      r = axlerad,
 313                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 314           mirror([1,0,0]) rotate([0,90,0])
 315             cylinder(r = axlerad*1.75, h = 3);
 316           intersection(){
 317             mirror([1,0,0])
 318               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 319               rotate([0,90,0])
 320               cylinder($fn=60,
 321                        r = towercliph - shift,
 322                        h = pillarswidth);
 323             translate([-50, -joinbelowallow, -50])
 324               cube([100, joinbelowallow+50, 100]);
 325           }
 326         }
 327         rotate([90,0,0])
 328         translate([axleclearlen + axlepinrad/2, 0, -25])
 329           cylinder(r = axlepinrad + slop, h=50);
 330       }
 331     }
 332     translate([-50,-50,0]) cube([100,100,100]);
 333   }
 334 }
 335
 336 module washer(thick){
 337   Washer(hubaxlerad, washerrad, thick, slop);
 338 }
 339
 340 module AxleWasher(){ ////toplevel
 341   washer(thick=washerthick);
 342 }
 343
 344 module AxleThinWasher(){ ////toplevel
 345   washer(thick=washerthinthick);
 346 }
 347
 348 module AxleVeryThinWasher(){ ////toplevel
 349   washer(thick=washerverythinthick);
 350 }
 351
 352 module AxleFrictionWasher(){ ////toplevel
 353   difference(){
 354     cylinder(h=washerthick, r=washerrad);
 355     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 356   }
 357   frarmr = hubbigrad;
 358   frarmw = frictionwasherarmwidth;
 359   frarmpawlr = hublwidth;
 360   frarmpawlpush = slop*4 + frictionwasherextrapush;
 361   for (ang=[0,180]) rotate([0,0,ang]) {
 362     translate([washerrad-1, -frarmw/2, 0])
 363       cube([frarmr - washerrad + 1, frarmw, washerthick]);
 364     intersection(){
 365       translate([frarmr - frarmpawlr, -50, 0])
 366         cube([frarmpawlr, 100, 50]);
 367       rotate([0,90,0])
 368         cylinder(h = 50, r = frarmpawlpush, $fn=36);
 369     }
 370   }
 371 }
 372
 373 module TowerExtender(){ ////toplevel
 374   l = totalheightfromtower - axlevertheight;
 375   echo("TowerExtender",l);
 376   DoveClipExtender(length = l,
 377                    ha = towercliph, hb = towercliph,
 378                    counta = towerclipcount, countb = towerclipcount,
 379                    pillarw = towerpillarw);
 380 }
 381
 382 module FilamentCupPair(){ ////toplevel
 383   FilamentCup();
 384   translate([cupheight + prongthick*3,
 385              cupwidth/2*1.7,
 386              0])
 387     rotate([0,0,180]) FilamentCup();
 388 }
 389
 390 //ArmEnd();
 391 //FilamentCup();
 392 //FilamentCupPair();
 393 //CupSecuringClip();
 394 Hub();
 395 //ArmExtender();
 396 //Axle();
 397 //AxleWasher();
 398 //AxlePin();
 399 //AxleFrictionWasher();