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
  48 overclipsmaller=-2.5;
  49 overclipbigger=0.0;
  50
  51 wingspoke=3;
  52 wingsize=6;
  53 wingthick=3;
  54
  55 armendwallthick=2.5;
  56 armendbasethick=1.2;
  57
  58 axlehorizoffset = 12.5;
  59 axlevertheight = 100;
  60 towercliph = 16;
  61 towerclipcount = 3;
  62 towerpillarw = 5;
  63
  64 axlepinrad = 2;
  65 axlepintabrad = 5;
  66
  67 washerthick = 1.2;
  68 washerrad = hubaxlerad + 7.5;
  69
  70 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  71
  72 include <doveclip.scad>
  73 include <cliphook.scad>
  74 include <filamentteeth.scad>
  75
  76 channelwidth = prongthick + slop;
  77 channeldepth = prongwidth + ratchettoothheight;
  78 totalwidth = armendwallthick*2 + channelwidth;
  79 totalheight = channeldepth + armendbasethick;
  80 stalkwidth = prongwidth + prongstalkxwidth;
  81
  82 module ArmEnd(length=120){ ////toplevel
  83   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  84     rotate([0,0,-90])
  85       DoveClipPairBase(h=doveclipheight);
  86   }
  87
  88   difference(){
  89     translate([0, -armendwallthick, -armendbasethick])
  90       cube([length, totalwidth, totalheight]);
  91     translate([-1, 0, 0])
  92       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  93     translate([-1, 0, ratchettoothheight])
  94       cube([length+2, channelwidth, channeldepth+1]);
  95   }
  96   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  97     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  98       rotate([90,0,0])
  99         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 100       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 101                         [       0,      1,      0,      0       ],
 102                         [       0,      0,      1,      0       ],
 103                         [       0,      0,      0,      1       ]])
 104         cube([ratchettooth - ratchettoothsmoothr*2,
 105               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 106     }
 107   }
 108 }
 109
 110 module FilamentCupHandle(){
 111   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 112   mirror([0,1,0]) {
 113     cube([stalklength, stalkwidth, prongthick]);
 114     translate([stalklength, stalkwidth/2, 0])
 115       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 116     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 117       minkowski(){
 118         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 119         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 120                         [       0,      1,      0,      0       ],
 121                         [       0,      0,      1,      0       ],
 122                         [       0,      0,      0,      1       ]])
 123           cube([pawlusewidth,
 124                 ratchettoothheight - ratchettoothsmoothr,
 125                 prongthick - 1]);
 126       }
 127     }
 128   }
 129 }
 130
 131 module FilamentCupCup(){
 132   xstraight = cupbigrad * xstraightmul;
 133   linear_extrude(height=prongthick) {
 134     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 135   }
 136   for (my=[0,1]) mirror([0,my,0]) {
 137     translate([0,cupbigrad,0])
 138       cube([xstraight, prongwidth, prongthick]);
 139   }
 140 }
 141
 142 module FilamentCup() { ////toplevel
 143   FilamentCupHandle();
 144
 145   dx = cupbigrad + prongwidth;
 146   gapy = prongwidth;
 147   dy = cupbigrad + gapy + overclipcupgap;
 148
 149   translate([dx, dy, 0])
 150     FilamentCupCup();
 151   translate([0, -1, 0]);
 152   cube([prongwidth, dy+1, prongthick]);
 153
 154   midrad = cupbigrad + prongwidth/2;
 155
 156   propshift = stalklength - overclipdepth - prongthick + propxshift;
 157   proptaken = propshift;
 158   echo(cupbigrad, dx, midrad, propshift, proptaken);
 159
 160   translate([propshift, -1, 0]) {
 161     // something is wrong with the y calculation
 162     cube([prongwidth,
 163           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 164           prongthick]);
 165   }
 166   translate([0, overclipcupgap, 0])
 167     rotate([0,0, 102 + fdia])
 168     FilamentTeeth(fdia=fdia, h=teethh);
 169 }
 170
 171 module CupSecuringClipSolid(w,d,h1,h2){
 172   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 173     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 174   }
 175 }
 176
 177 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 178   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 179   minkowski(){
 180     CupSecuringClipSolid(w=totalwidth,
 181                          d=overclipdepth + xdepth,
 182                          h1=hbase - overclipsmaller,
 183                          h2=hbase + overclipbigger);
 184     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 185   }
 186 }
 187
 188 module CupSecuringClip(){ ////toplevel
 189   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 190   difference(){
 191     union(){
 192       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 193       translate([-wingswidth/2, -wingsize/2, 0])
 194         cube([wingswidth, wingsize, wingthick]);
 195     }
 196     translate([0,0,-0.1])
 197       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 198   }
 199 }
 200
 201 module ArmDoveClipPin(){ ////toplevel
 202   DoveClipPin(h=doveclipheight);
 203 }
 204
 205 module TowerDoveClipPin(){ ////toplevel
 206   DoveClipPin(h=towercliph/2);
 207 }
 208
 209 module Hub(){ ////toplevel
 210   difference(){
 211     cylinder($fn=60, h=hublthick, r=hubbigrad);
 212     translate([0,0,-1])
 213       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 214   }
 215   axlerad = hubaxlerad + slop;
 216   difference(){
 217     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 218     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 219   }
 220   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 221   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 222   for (ang=[0,120,240])
 223     rotate([0,0,ang]) {
 224       difference() {
 225         translate([hubeffrad,0,0])
 226           DoveClipPairSane(h=doveclipheight,
 227                            baseextend = (hubeffrad - DoveClip_depth()
 228                                          - hubbigrad + hublwidth));
 229         if (hole>hublwidth && holewidth > 2) {
 230           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 231             cube([hole, holewidth, hublthick+2]);
 232         }
 233       }
 234     }
 235   xmin = axlerad+hublwidth/2;
 236   xmax = hubbigrad-hublwidth/2;
 237   for (ang = [0 : 60 : 359])
 238     rotate([0,0,ang]) rotate([90,0,0]) {
 239       translate([0,0,-hublwidth/2])
 240         linear_extrude(height=hublwidth)
 241         polygon([[xmin,0.05], [xmax,0.05],
 242                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 243     }
 244 }
 245
 246 module ArmExtender(){ ////toplevel
 247   DoveClipExtender(length=exteffrad-hubeffrad,
 248                    ha=doveclipheight,
 249                    hb=doveclipheight);
 250 }
 251
 252 module AxlePin(){ ////toplevel
 253   pinr = axlepinrad - slop;
 254   intersection(){
 255     translate([0, 0, pinr*0.7]) {
 256       translate([0, -washerrad, 0]) rotate([-90,0,0])
 257         cylinder(r=pinr, h=washerrad*2, $fn=10);
 258       translate([-axlepintabrad, hubaxlerad, -axlepinrad])
 259         cube([axlepintabrad*2, axlepinrad*2, axlepinrad*2]);
 260     }
 261     translate([-50,-50,0]) cube([100,100,50]);
 262   }
 263 }
 264
 265 module Axle(){ ////toplevel
 266   pillarswidth = DoveClipPairSane_width(towerclipcount);
 267
 268   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 269   translate([-axlehorizoffset, -axlevertheight, 0]) {
 270     rotate([0,0,-axletowerfudgebend])
 271     rotate([0,0,-90])
 272       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 273     translate([0, DoveClip_depth(), 0])
 274     rotate([0,0,90])
 275       ExtenderPillars(axlevertheight - DoveClip_depth(),
 276                       pillarswidth, towercliph,
 277                       pillarw=towerpillarw);
 278   }
 279
 280   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 281   axlerad = hubaxlerad-slop;
 282   bump = axlerad * 0.2;
 283   shift = axlerad-bump;
 284   joinbelowallow = 3;
 285
 286   intersection(){
 287     translate([0, 0, shift]) {
 288       difference() {
 289         union(){
 290           translate([-1, 0, 0])
 291             rotate([0,90,0])
 292             cylinder($fn=60,
 293                      r = axlerad,
 294                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 295           mirror([1,0,0]) rotate([0,90,0])
 296             cylinder(r = axlerad*1.75, h = 3);
 297           intersection(){
 298             mirror([1,0,0])
 299               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 300               rotate([0,90,0])
 301               cylinder($fn=60,
 302                        r = towercliph - shift,
 303                        h = pillarswidth);
 304             translate([-50, -joinbelowallow, -50])
 305               cube([100, joinbelowallow+50, 100]);
 306           }
 307         }
 308         rotate([90,0,0])
 309         translate([axleclearlen + axlepinrad/2, 0, -25])
 310           cylinder(r = axlepinrad + slop, h=50);
 311       }
 312     }
 313     translate([-50,-50,0]) cube([100,100,100]);
 314   }
 315 }
 316
 317 module AxleWasher(){ ////toplevel
 318   difference(){
 319     cylinder(h=washerthick, r=washerrad);
 320     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 321   }
 322 }
 323
 324 module TowerExtender(){ ////toplevel
 325   l = totalheightfromtower - axlevertheight;
 326   echo("TowerExtender",l);
 327   DoveClipExtender(length = l,
 328                    ha = towercliph, hb = towercliph,
 329                    counta = towerclipcount, countb = towerclipcount,
 330                    pillarw = towerpillarw);
 331 }
 332
 333 //ArmEnd();
 334 //FilamentCup();
 335 //CupSecuringClip();
 336 //Hub();
 337 //ArmExtender();
 338 //Axle();
 339 //AxleWasher();
 340 //AxlePin();