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 washerthinthick = 0.8;
  69 washerverythinthick = 0.4;
  70 washerrad = hubaxlerad + 7.5;
  71 frictionwasherarmwidth = 3;
  72 frictionwasherextrapush = 1.0;
  73
  74 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  75
  76 include <doveclip.scad>
  77 include <cliphook.scad>
  78 include <filamentteeth.scad>
  79
  80 channelwidth = prongthick + slop;
  81 channeldepth = prongwidth + ratchettoothheight;
  82 totalwidth = armendwallthick*2 + channelwidth;
  83 totalheight = channeldepth + armendbasethick;
  84 stalkwidth = prongwidth + prongstalkxwidth;
  85
  86 module ArmEnd(length=120){ ////toplevel
  87   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  88     rotate([0,0,-90])
  89       DoveClipPairBase(h=doveclipheight);
  90   }
  91
  92   difference(){
  93     translate([0, -armendwallthick, -armendbasethick])
  94       cube([length, totalwidth, totalheight]);
  95     translate([-1, 0, 0])
  96       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  97     translate([-1, 0, ratchettoothheight])
  98       cube([length+2, channelwidth, channeldepth+1]);
  99   }
 100   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
 101     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
 102       rotate([90,0,0])
 103         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 104       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 105                         [       0,      1,      0,      0       ],
 106                         [       0,      0,      1,      0       ],
 107                         [       0,      0,      0,      1       ]])
 108         cube([ratchettooth - ratchettoothsmoothr*2,
 109               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 110     }
 111   }
 112 }
 113
 114 module FilamentCupHandle(){
 115   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 116   mirror([0,1,0]) {
 117     cube([stalklength, stalkwidth, prongthick]);
 118     translate([stalklength, stalkwidth/2, 0])
 119       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 120     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 121       minkowski(){
 122         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 123         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 124                         [       0,      1,      0,      0       ],
 125                         [       0,      0,      1,      0       ],
 126                         [       0,      0,      0,      1       ]])
 127           cube([pawlusewidth,
 128                 ratchettoothheight - ratchettoothsmoothr,
 129                 prongthick - 1]);
 130       }
 131     }
 132   }
 133 }
 134
 135 module FilamentCupCup(){
 136   xstraight = cupbigrad * xstraightmul;
 137   linear_extrude(height=prongthick) {
 138     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 139   }
 140   for (my=[0,1]) mirror([0,my,0]) {
 141     translate([0,cupbigrad,0])
 142       cube([xstraight, prongwidth, prongthick]);
 143   }
 144 }
 145
 146 module FilamentCup() { ////toplevel
 147   FilamentCupHandle();
 148
 149   dx = cupbigrad + prongwidth;
 150   gapy = prongwidth;
 151   dy = cupbigrad + gapy + overclipcupgap;
 152
 153   translate([dx, dy, 0])
 154     FilamentCupCup();
 155   translate([0, -1, 0]);
 156   cube([prongwidth, dy+1, prongthick]);
 157
 158   midrad = cupbigrad + prongwidth/2;
 159
 160   propshift = stalklength - overclipdepth - prongthick + propxshift;
 161   proptaken = propshift;
 162   echo(cupbigrad, dx, midrad, propshift, proptaken);
 163
 164   translate([propshift, -1, 0]) {
 165     // something is wrong with the y calculation
 166     cube([prongwidth,
 167           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 168           prongthick]);
 169   }
 170   translate([0, overclipcupgap, 0])
 171     rotate([0,0, 102 + fdia])
 172     FilamentTeeth(fdia=fdia, h=teethh);
 173 }
 174
 175 module CupSecuringClipSolid(w,d,h1,h2){
 176   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 177     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 178   }
 179 }
 180
 181 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 182   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 183   minkowski(){
 184     CupSecuringClipSolid(w=totalwidth,
 185                          d=overclipdepth + xdepth,
 186                          h1=hbase - overclipsmaller,
 187                          h2=hbase + overclipbigger);
 188     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 189   }
 190 }
 191
 192 module CupSecuringClip(){ ////toplevel
 193   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 194   difference(){
 195     union(){
 196       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 197       translate([-wingswidth/2, -wingsize/2, 0])
 198         cube([wingswidth, wingsize, wingthick]);
 199     }
 200     translate([0,0,-0.1])
 201       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 202   }
 203 }
 204
 205 module ArmDoveClipPin(){ ////toplevel
 206   DoveClipPin(h=doveclipheight);
 207 }
 208
 209 module TowerDoveClipPin(){ ////toplevel
 210   DoveClipPin(h=towercliph/2);
 211 }
 212
 213 module Hub(){ ////toplevel
 214   difference(){
 215     cylinder($fn=60, h=hublthick, r=hubbigrad);
 216     translate([0,0,-1])
 217       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 218   }
 219   axlerad = hubaxlerad + slop;
 220   difference(){
 221     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 222     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 223   }
 224   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 225   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 226   for (ang=[0,120,240])
 227     rotate([0,0,ang]) {
 228       difference() {
 229         translate([hubeffrad,0,0])
 230           DoveClipPairSane(h=doveclipheight,
 231                            baseextend = (hubeffrad - DoveClip_depth()
 232                                          - hubbigrad + hublwidth));
 233         if (hole>hublwidth && holewidth > 2) {
 234           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 235             cube([hole, holewidth, hublthick+2]);
 236         }
 237       }
 238     }
 239   xmin = axlerad+hublwidth/2;
 240   xmax = hubbigrad-hublwidth/2;
 241   for (ang = [0 : 60 : 359])
 242     rotate([0,0,ang]) rotate([90,0,0]) {
 243       translate([0,0,-hublwidth/2])
 244         linear_extrude(height=hublwidth)
 245         polygon([[xmin,0.05], [xmax,0.05],
 246                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 247     }
 248 }
 249
 250 module ArmExtender(){ ////toplevel
 251   DoveClipExtender(length=exteffrad-hubeffrad,
 252                    ha=doveclipheight,
 253                    hb=doveclipheight);
 254 }
 255
 256 module AxlePin(){ ////toplevel
 257   pinr = axlepinrad - slop;
 258   intersection(){
 259     translate([0, 0, pinr*0.7]) {
 260       translate([0, -washerrad, 0]) rotate([-90,0,0])
 261         cylinder(r=pinr, h=washerrad*2, $fn=10);
 262       translate([-axlepintabrad, hubaxlerad, -axlepinrad])
 263         cube([axlepintabrad*2, axlepinrad*2, axlepinrad*2]);
 264     }
 265     translate([-50,-50,0]) cube([100,100,50]);
 266   }
 267 }
 268
 269 module Axle(){ ////toplevel
 270   pillarswidth = DoveClipPairSane_width(towerclipcount);
 271
 272   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 273   translate([-axlehorizoffset, -axlevertheight, 0]) {
 274     rotate([0,0,-axletowerfudgebend])
 275     rotate([0,0,-90])
 276       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 277     translate([0, DoveClip_depth(), 0])
 278     rotate([0,0,90])
 279       ExtenderPillars(axlevertheight - DoveClip_depth(),
 280                       pillarswidth, towercliph,
 281                       pillarw=towerpillarw);
 282   }
 283
 284   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 285   axlerad = hubaxlerad-slop;
 286   bump = axlerad * 0.2;
 287   shift = axlerad-bump;
 288   joinbelowallow = 3;
 289
 290   intersection(){
 291     translate([0, 0, shift]) {
 292       difference() {
 293         union(){
 294           translate([-1, 0, 0])
 295             rotate([0,90,0])
 296             cylinder($fn=60,
 297                      r = axlerad,
 298                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 299           mirror([1,0,0]) rotate([0,90,0])
 300             cylinder(r = axlerad*1.75, h = 3);
 301           intersection(){
 302             mirror([1,0,0])
 303               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 304               rotate([0,90,0])
 305               cylinder($fn=60,
 306                        r = towercliph - shift,
 307                        h = pillarswidth);
 308             translate([-50, -joinbelowallow, -50])
 309               cube([100, joinbelowallow+50, 100]);
 310           }
 311         }
 312         rotate([90,0,0])
 313         translate([axleclearlen + axlepinrad/2, 0, -25])
 314           cylinder(r = axlepinrad + slop, h=50);
 315       }
 316     }
 317     translate([-50,-50,0]) cube([100,100,100]);
 318   }
 319 }
 320
 321 module washer(thick){
 322   difference(){
 323     cylinder(h=thick, r=washerrad);
 324     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 325   }
 326 }
 327
 328 module AxleWasher(){ ////toplevel
 329   washer(thick=washerthick);
 330 }
 331
 332 module AxleThinWasher(){ ////toplevel
 333   washer(thick=washerthinthick);
 334 }
 335
 336 module AxleVeryThinWasher(){ ////toplevel
 337   washer(thick=washerverythinthick);
 338 }
 339
 340 module AxleFrictionWasher(){ ////toplevel
 341   difference(){
 342     cylinder(h=washerthick, r=washerrad);
 343     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 344   }
 345   frarmr = hubbigrad;
 346   frarmw = frictionwasherarmwidth;
 347   frarmpawlr = hublwidth;
 348   frarmpawlpush = slop*4 + frictionwasherextrapush;
 349   for (ang=[0,180]) rotate([0,0,ang]) {
 350     translate([washerrad-1, -frarmw/2, 0])
 351       cube([frarmr - washerrad + 1, frarmw, washerthick]);
 352     intersection(){
 353       translate([frarmr - frarmpawlr, -50, 0])
 354         cube([frarmpawlr, 100, 50]);
 355       rotate([0,90,0])
 356         cylinder(h = 50, r = frarmpawlpush, $fn=36);
 357     }
 358   }
 359 }
 360
 361 module TowerExtender(){ ////toplevel
 362   l = totalheightfromtower - axlevertheight;
 363   echo("TowerExtender",l);
 364   DoveClipExtender(length = l,
 365                    ha = towercliph, hb = towercliph,
 366                    counta = towerclipcount, countb = towerclipcount,
 367                    pillarw = towerpillarw);
 368 }
 369
 370 //ArmEnd();
 371 //FilamentCup();
 372 //CupSecuringClip();
 373 //Hub();
 374 //ArmExtender();
 375 //Axle();
 376 //AxleWasher();
 377 //AxlePin();
 378 //AxleFrictionWasher();