filamentspool.scad

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