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