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 num_arms = selsz(3,4);
  12
  13 exteffrad = 70;
  14 hubeffrad = selsz(30, 50);
  15 hubbigrad = selsz(20, 45);
  16 hublwidth = selsz(3, 5);
  17 hubstemwidth = 2;
  18 hublthick = 10;
  19 hubaxlerad = selsz(5, 17/2);
  20 totalheightfromtower = 240;
  21 axletowerfudgebend = 0;
  22 axleaxlefudgebend = 3;
  23 axlepadlen = 1.0;
  24
  25 prongthick=selsz(5,5);
  26 prongwidth=selsz(5,5);
  27 prongribwidth=3;
  28 prongribheight=selsz(0,4);
  29 ratchetstep=15;
  30 ratchettooth=3;
  31 ratchettoothheight=5;
  32 ratchettoothsmoothr=1;
  33 ratchettoothslope=0.75;
  34 overlap=0.5;
  35 cupwidth=selsz(40,60);
  36 cupheight=selsz(55,75);
  37
  38 cupstrong_dx=selsz(0,-10);
  39
  40 propxshift = 0;
  41
  42 doveclipheight = 10;
  43
  44 teethh=3;
  45 teethgapx=4+fdia;
  46
  47 prongstalkxwidth=3;
  48
  49 stalklength=selsz(35,55);
  50 overclipcupgap=5;
  51 overclipdepth=15;
  52 overcliproundr=2.0;
  53 overclipthick=1.0;
  54 overclipcupnextgap=20;
  55
  56 hubaxlelen = selsz(25, cupwidth);
  57
  58 overclipsmaller=-2.5;
  59 overclipbigger=0.0;
  60
  61 wingspoke=3;
  62 wingsize=6;
  63 wingthick=3;
  64
  65 armendwallthick=2.5;
  66 armendbasethick=1.2;
  67
  68 axlehorizoffset = 12.5;
  69 axlevertheight = 100;
  70 towercliph = 16;
  71 towerclipcount = 3;
  72 towerpillarw = 5;
  73
  74 axlepinrad = 2;
  75 axlepintabrad = 5;
  76
  77 washerthick = 1.2;
  78 washerthinthick = 0.8;
  79 washerverythinthick = 0.4;
  80 washerrad = hubaxlerad + 7.5;
  81 frictionwasherarmwidth = 3;
  82 frictionwasherextrapush = 1.0;
  83
  84 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  85
  86 nondove_armbase = 100;
  87 nondove_armhole_x = 32;
  88 nondove_armhole_hole = 4;
  89 nondove_armhole_support = 7;
  90 nondove_armhole_wall = 4;
  91 nondove_armhole_slop = 0.5;
  92 nondove_armhole_slop_x = 0.5;
  93
  94 echo(nondove_armbase);
  95
  96 include <doveclip.scad>
  97 include <cliphook.scad>
  98 include <filamentteeth.scad>
  99 include <axlepin.scad>
 100
 101 channelwidth = prongthick + slop;
 102 channeldepth = prongwidth + ratchettoothheight;
 103 totalwidth = armendwallthick*2 + channelwidth;
 104 totalheight = channeldepth + armendbasethick;
 105 stalkwidth = prongwidth + prongstalkxwidth;
 106
 107 module ArmEnd(length=120){ ////toplevel
 108   if (usedove()) {
 109     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
 110       rotate([0,0,-90])
 111         DoveClipPairBase(h=doveclipheight);
 112     }
 113   } else {
 114     difference(){
 115       translate([1, -armendwallthick, -armendbasethick])
 116         mirror([1,0,0])
 117         cube([nondove_armbase+1, totalwidth, totalheight]);
 118       translate([-nondove_armbase + nondove_armhole_x,
 119                  -armendwallthick + totalwidth/2,
 120                  -armendbasethick -1])
 121         cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
 122     }
 123   }
 124
 125   difference(){
 126     translate([0, -armendwallthick, -armendbasethick])
 127       cube([length, totalwidth, totalheight]);
 128     translate([-1, 0, 0])
 129       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
 130     translate([-1, 0, ratchettoothheight])
 131       cube([length+2, channelwidth, channeldepth+1]);
 132   }
 133   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
 134     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
 135       rotate([90,0,0])
 136         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 137       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 138                         [       0,      1,      0,      0       ],
 139                         [       0,      0,      1,      0       ],
 140                         [       0,      0,      0,      1       ]])
 141         cube([ratchettooth - ratchettoothsmoothr*2,
 142               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 143     }
 144   }
 145 }
 146
 147 module FilamentCupHandle(){
 148   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 149   mirror([0,1,0]) {
 150     cube([stalklength, stalkwidth, prongthick]);
 151     translate([stalklength, stalkwidth/2, 0])
 152       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 153     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 154       minkowski(){
 155         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 156         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 157                         [       0,      1,      0,      0       ],
 158                         [       0,      0,      1,      0       ],
 159                         [       0,      0,      0,      1       ]])
 160           cube([pawlusewidth,
 161                 ratchettoothheight - ratchettoothsmoothr,
 162                 prongthick - 1]);
 163       }
 164     }
 165   }
 166 }
 167
 168 module FilamentCupCup(){
 169   for (my=[0,1]) mirror([0,my,0]) {
 170     translate([0, cupwidth/2, 0])
 171       cube([cupheight + prongwidth, prongwidth, prongthick]);
 172   }
 173 }
 174
 175 module FilamentCup() { ////toplevel
 176   FilamentCupHandle();
 177
 178   gapy = prongwidth;
 179   dy = cupwidth/2 + gapy + overclipcupgap;
 180   baselen = dy+cupwidth/2;
 181
 182   translate([0, dy, 0])
 183     FilamentCupCup();
 184   cube([prongwidth, baselen+1, prongthick]);
 185
 186   translate([cupstrong_dx, prongwidth, 0]) {
 187     cube([prongwidth, baselen-prongwidth, prongthick]);
 188     for (y = [0, .33, .67, 1])
 189       translate([0, (baselen - prongwidth) * y, 0])
 190         cube([-cupstrong_dx + 1, prongwidth, prongthick]);
 191   }
 192   if (cupstrong_dx != 0) {
 193     rotate([0,0,45])
 194       translate([-prongwidth*.55, -prongwidth*2.1, 0])
 195       cube([prongwidth*(2.65), prongwidth*4.2, prongthick]);
 196   }
 197
 198   translate([0, -0.2, 0])
 199     cube([prongribwidth, baselen, prongthick + prongribheight]);
 200
 201   if (prongribheight > 0) {
 202     translate([-prongwidth, baselen, 0])
 203       cube([cupheight/2, prongwidth + prongribheight, prongribwidth]);
 204   }
 205
 206   midrad = cupwidth/2 + prongwidth/2;
 207
 208   propshift = stalklength - overclipdepth - prongthick + propxshift;
 209   proptaken = propshift;
 210   echo(midrad, propshift, proptaken);
 211
 212   translate([propshift, -1, 0]) {
 213     // something is wrong with the y calculation
 214     cube([prongwidth,
 215           gapy+2,
 216           prongthick]);
 217   }
 218   for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
 219     translate([cupstrong_dx, y + prongwidth, 0])
 220       rotate([0,0, 102 + fdia])
 221       FilamentTeeth(fdia=fdia, h=teethh);
 222   }
 223   for (x = [-0.3, -1.3]) {
 224     translate([cupheight + overclipcupnextgap*x, baselen + prongwidth, 0])
 225       rotate([0,0, 12 + fdia])
 226       FilamentTeeth(fdia=fdia, h=teethh);
 227   }
 228 }
 229
 230 module CupSecuringClipSolid(w,d,h1,h2){
 231   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 232     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 233   }
 234 }
 235
 236 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 237   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 238   minkowski(){
 239     CupSecuringClipSolid(w=totalwidth,
 240                          d=overclipdepth + xdepth,
 241                          h1=hbase - overclipsmaller,
 242                          h2=hbase + overclipbigger);
 243     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 244   }
 245 }
 246
 247 module CupSecuringClip(){ ////toplevel
 248   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 249   difference(){
 250     union(){
 251       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 252       translate([-wingswidth/2, -wingsize/2, 0])
 253         cube([wingswidth, wingsize, wingthick]);
 254       translate([-wingsize/2, -wingswidth/2, 0])
 255         cube([wingsize, wingswidth, wingthick]);
 256     }
 257     translate([0,0,-0.1])
 258       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 259   }
 260 }
 261
 262 module ArmDoveClipPin(){ ////toplevel
 263   DoveClipPin(h=doveclipheight);
 264 }
 265
 266 module TowerDoveClipPin(){ ////toplevel
 267   DoveClipPin(h=towercliph/2);
 268 }
 269
 270 module Hub(){ ////toplevel
 271   axlerad = hubaxlerad + slop;
 272   xmin = axlerad+hublwidth/2;
 273   xmax = hubbigrad-hublwidth/2;
 274   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 275   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 276   nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
 277   difference(){
 278     union(){
 279       difference(){
 280         cylinder($fn=60, h=hublthick, r=hubbigrad);
 281         translate([0,0,-1])
 282           cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 283       }
 284       cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 285       for (ang=[0 : 360/num_arms : 359])
 286         rotate([0,0,ang]) {
 287           difference() {
 288             if (usedove()){
 289               translate([hubeffrad,0,0])
 290                 DoveClipPairSane(h=doveclipheight,
 291                                  baseextend = (hubeffrad - DoveClip_depth()
 292                                                - hubbigrad + hublwidth));
 293               if (hole>hublwidth && holewidth > 2) {
 294                 translate([hubbigrad + hublwidth, -holewidth/2, -1])
 295                   cube([hole, holewidth, hublthick+2]);
 296               }
 297             } else {
 298               difference(){
 299                 translate([0,
 300                            -nondove_allwidth/2,
 301                            0])
 302                   cube([hubeffrad + nondove_armhole_x
 303                         + nondove_armhole_hole/2 + nondove_armhole_support,
 304                         nondove_allwidth,
 305                         nondove_armhole_wall + totalheight]);
 306                 translate([hubeffrad - nondove_armhole_slop_x,
 307                            -nondove_allwidth/2
 308                            + nondove_armhole_wall - nondove_armhole_slop,
 309                            nondove_armhole_wall])
 310                   cube([nondove_armhole_x + 50,
 311                         totalwidth + nondove_armhole_slop*2,
 312                         totalheight + 1]);
 313                 translate([hubeffrad + nondove_armhole_x, 0, -20])
 314                    cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
 315               }
 316             }
 317           }
 318         }
 319       for (ang = [0 : 180/num_arms : 359])
 320         rotate([0,0,ang]) rotate([90,0,0]) {
 321           translate([0,0,-hublwidth/2])
 322             linear_extrude(height=hublwidth)
 323             polygon([[xmin,0.05], [xmax,0.05],
 324                      [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 325         }
 326     }
 327     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 328   }
 329 }
 330
 331 module ArmExtender(){ ////toplevel
 332   DoveClipExtender(length=exteffrad-hubeffrad,
 333                    ha=doveclipheight,
 334                    hb=doveclipheight);
 335 }
 336
 337 module FsAxlePin(){ ////toplevel
 338   AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
 339 }
 340
 341 module Axle(){ ////toplevel
 342   pillarswidth = DoveClipPairSane_width(towerclipcount);
 343
 344   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 345   translate([-axlehorizoffset, -axlevertheight, 0]) {
 346     rotate([0,0,-axletowerfudgebend])
 347     rotate([0,0,-90])
 348       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 349     translate([0, DoveClip_depth(), 0])
 350     rotate([0,0,90])
 351       ExtenderPillars(axlevertheight - DoveClip_depth(),
 352                       pillarswidth, towercliph,
 353                       pillarw=towerpillarw);
 354   }
 355
 356   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 357   axlerad = hubaxlerad-slop;
 358   bump = axlerad * 0.2;
 359   shift = axlerad-bump;
 360   joinbelowallow = 3;
 361
 362   intersection(){
 363     translate([0, 0, shift]) {
 364       difference() {
 365         union(){
 366           translate([-1, 0, 0])
 367             rotate([0,90,0])
 368             cylinder($fn=60,
 369                      r = axlerad,
 370                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 371           mirror([1,0,0]) rotate([0,90,0])
 372             cylinder(r = axlerad*1.75, h = 3);
 373           intersection(){
 374             mirror([1,0,0])
 375               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 376               rotate([0,90,0])
 377               cylinder($fn=60,
 378                        r = towercliph - shift,
 379                        h = pillarswidth);
 380             translate([-50, -joinbelowallow, -50])
 381               cube([100, joinbelowallow+50, 100]);
 382           }
 383         }
 384         rotate([90,0,0])
 385         translate([axleclearlen + axlepinrad/2, 0, -25])
 386           cylinder(r = axlepinrad + slop, h=50);
 387       }
 388     }
 389     translate([-50,-50,0]) cube([100,100,100]);
 390   }
 391 }
 392
 393 module washer(thick){
 394   Washer(hubaxlerad, washerrad, thick, slop);
 395 }
 396
 397 module AxleWasher(){ ////toplevel
 398   washer(thick=washerthick);
 399 }
 400
 401 module AxleThinWasher(){ ////toplevel
 402   washer(thick=washerthinthick);
 403 }
 404
 405 module AxleVeryThinWasher(){ ////toplevel
 406   washer(thick=washerverythinthick);
 407 }
 408
 409 module AxleFrictionWasher(){ ////toplevel
 410   difference(){
 411     cylinder(h=washerthick, r=washerrad);
 412     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 413   }
 414   frarmr = hubbigrad;
 415   frarmw = frictionwasherarmwidth;
 416   frarmpawlr = hublwidth;
 417   frarmpawlpush = slop*4 + frictionwasherextrapush;
 418   for (ang=[0,180]) rotate([0,0,ang]) {
 419     translate([washerrad-1, -frarmw/2, 0])
 420       cube([frarmr - washerrad + 1, frarmw, washerthick]);
 421     intersection(){
 422       translate([frarmr - frarmpawlr, -50, 0])
 423         cube([frarmpawlr, 100, 50]);
 424       rotate([0,90,0])
 425         cylinder(h = 50, r = frarmpawlpush, $fn=36);
 426     }
 427   }
 428 }
 429
 430 module TowerExtender(){ ////toplevel
 431   l = totalheightfromtower - axlevertheight;
 432   echo("TowerExtender",l);
 433   DoveClipExtender(length = l,
 434                    ha = towercliph, hb = towercliph,
 435                    counta = towerclipcount, countb = towerclipcount,
 436                    pillarw = towerpillarw);
 437 }
 438
 439 module FilamentCupPair(){ ////toplevel
 440   FilamentCup();
 441   translate([cupheight + prongthick*3,
 442              cupwidth/2*1.7,
 443              0])
 444     rotate([0,0,180]) FilamentCup();
 445 }
 446
 447 //ArmEnd();
 448 FilamentCup();
 449 //FilamentCupPair();
 450 //CupSecuringClip();
 451 //Hub();
 452 //ArmExtender();
 453 //Axle();
 454 //AxleWasher();
 455 //AxlePin();
 456 //AxleFrictionWasher();