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
  18 prongthick=5;
  19 prongwidth=5;
  20 ratchetstep=15;
  21 ratchettooth=3;
  22 ratchettoothheight=5;
  23 ratchettoothsmoothr=1;
  24 ratchettoothslope=0.75;
  25 overlap=0.5;
  26 cupbigrad=20;
  27
  28 xstraightmul = 1.75;
  29
  30 propxshift = 0;
  31
  32 doveclipheight = 10;
  33
  34 teethh=3;
  35 teethgapx=4+fdia;
  36
  37 prongstalkxwidth=3;
  38
  39 stalklength=35;
  40 overclipcupgap=5;
  41 overclipdepth=15;
  42 overcliproundr=2.0;
  43 overclipthick=0.5;
  44
  45 overclipsmaller=-2.5;
  46 overclipbigger=0.0;
  47
  48 wingspoke=3;
  49 wingsize=6;
  50 wingthick=3;
  51
  52 armendwallthick=2.5;
  53 armendbasethick=1.2;
  54
  55 axlehorizoffset = 12.5;
  56 axlevertheight = 80;
  57 towercliph = 16;
  58 towerclipcount = 3;
  59 towerpillarw = 5;
  60
  61 axlepinrad = 2;
  62 axlepintabrad = 5;
  63
  64 washerthick = 1.2;
  65 washerrad = hubaxlerad + 7.5;
  66
  67 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  68
  69 include <doveclip.scad>
  70 include <cliphook.scad>
  71 include <filamentteeth.scad>
  72
  73 channelwidth = prongthick + slop;
  74 channeldepth = prongwidth + ratchettoothheight;
  75 totalwidth = armendwallthick*2 + channelwidth;
  76 totalheight = channeldepth + armendbasethick;
  77 stalkwidth = prongwidth + prongstalkxwidth;
  78
  79 module ArmEnd(length=120){ ////toplevel
  80   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  81     rotate([0,0,-90])
  82       DoveClipPairBase(h=doveclipheight);
  83   }
  84
  85   difference(){
  86     translate([0, -armendwallthick, -armendbasethick])
  87       cube([length, totalwidth, totalheight]);
  88     translate([-1, 0, 0])
  89       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  90     translate([-1, 0, ratchettoothheight])
  91       cube([length+2, channelwidth, channeldepth+1]);
  92   }
  93   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  94     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  95       rotate([90,0,0])
  96         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
  97       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
  98                         [       0,      1,      0,      0       ],
  99                         [       0,      0,      1,      0       ],
 100                         [       0,      0,      0,      1       ]])
 101         cube([ratchettooth - ratchettoothsmoothr*2,
 102               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 103     }
 104   }
 105 }
 106
 107 module FilamentCupHandle(){
 108   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 109   mirror([0,1,0]) {
 110     cube([stalklength, stalkwidth, prongthick]);
 111     translate([stalklength, stalkwidth/2, 0])
 112       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 113     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 114       minkowski(){
 115         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 116         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 117                         [       0,      1,      0,      0       ],
 118                         [       0,      0,      1,      0       ],
 119                         [       0,      0,      0,      1       ]])
 120           cube([pawlusewidth,
 121                 ratchettoothheight - ratchettoothsmoothr,
 122                 prongthick - 1]);
 123       }
 124     }
 125   }
 126 }
 127
 128 module FilamentCupCup(){
 129   xstraight = cupbigrad * xstraightmul;
 130   linear_extrude(height=prongthick) {
 131     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 132   }
 133   for (my=[0,1]) mirror([0,my,0]) {
 134     translate([0,cupbigrad,0])
 135       cube([xstraight, prongwidth, prongthick]);
 136   }
 137 }
 138
 139 module FilamentCup() { ////toplevel
 140   FilamentCupHandle();
 141
 142   dx = cupbigrad + prongwidth;
 143   gapy = prongwidth;
 144   dy = cupbigrad + gapy + overclipcupgap;
 145
 146   translate([dx, dy, 0])
 147     FilamentCupCup();
 148   translate([0, -1, 0]);
 149   cube([prongwidth, dy+1, prongthick]);
 150
 151   midrad = cupbigrad + prongwidth/2;
 152
 153   propshift = stalklength - overclipdepth - prongthick + propxshift;
 154   proptaken = propshift;
 155   echo(cupbigrad, dx, midrad, propshift, proptaken);
 156
 157   translate([propshift, -1, 0]) {
 158     // something is wrong with the y calculation
 159     cube([prongwidth,
 160           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 161           prongthick]);
 162   }
 163   translate([0, overclipcupgap, 0])
 164     rotate([0,0, 102 + fdia])
 165     FilamentTeeth(fdia=fdia, h=teethh);
 166 }
 167
 168 module CupSecuringClipSolid(w,d,h1,h2){
 169   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 170     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 171   }
 172 }
 173
 174 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 175   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 176   minkowski(){
 177     CupSecuringClipSolid(w=totalwidth,
 178                          d=overclipdepth + xdepth,
 179                          h1=hbase - overclipsmaller,
 180                          h2=hbase + overclipbigger);
 181     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 182   }
 183 }
 184
 185 module CupSecuringClip(){ ////toplevel
 186   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 187   difference(){
 188     union(){
 189       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 190       translate([-wingswidth/2, -wingsize/2, 0])
 191         cube([wingswidth, wingsize, wingthick]);
 192     }
 193     translate([0,0,-0.1])
 194       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 195   }
 196 }
 197
 198 module ArmDoveClipPin(){ ////toplevel
 199   DoveClipPin(h=doveclipheight);
 200 }
 201
 202 module Hub(){ ////toplevel
 203   difference(){
 204     cylinder($fn=60, h=hublthick, r=hubbigrad);
 205     translate([0,0,-1])
 206       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 207   }
 208   axlerad = hubaxlerad + slop;
 209   difference(){
 210     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 211     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 212   }
 213   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 214   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 215   for (ang=[0,120,240])
 216     rotate([0,0,ang]) {
 217       difference() {
 218         translate([hubeffrad,0,0])
 219           DoveClipPairSane(h=doveclipheight,
 220                            baseextend = (hubeffrad - DoveClip_depth()
 221                                          - hubbigrad + hublwidth));
 222         if (hole>hublwidth && holewidth > 2) {
 223           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 224             cube([hole, holewidth, hublthick+2]);
 225         }
 226       }
 227     }
 228   xmin = axlerad+hublwidth/2;
 229   xmax = hubbigrad-hublwidth/2;
 230   for (ang = [0 : 60 : 359])
 231     rotate([0,0,ang]) rotate([90,0,0]) {
 232       translate([0,0,-hublwidth/2])
 233         linear_extrude(height=hublwidth)
 234         polygon([[xmin,0.05], [xmax,0.05],
 235                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 236     }
 237 }
 238
 239 module ArmExtender(){ ////toplevel
 240   DoveClipExtender(length=exteffrad-hubeffrad,
 241                    ha=doveclipheight,
 242                    hb=doveclipheight);
 243 }
 244
 245 module AxlePin(){ ////toplevel
 246   pinr = axlepinrad - slop;
 247   intersection(){
 248     translate([0, 0, pinr*0.7]) {
 249       translate([0, -washerrad, 0]) rotate([-90,0,0])
 250         cylinder(r=pinr, h=washerrad*2, $fn=10);
 251       translate([-axlepintabrad, hubaxlerad, -axlepinrad])
 252         cube([axlepintabrad*2, axlepinrad*2, axlepinrad*2]);
 253     }
 254     translate([-50,-50,0]) cube([100,100,50]);
 255   }
 256 }
 257
 258 module Axle(){ ////toplevel
 259   pillarswidth = DoveClipPairSane_width(towerclipcount);
 260
 261 if(0)
 262   translate([-axlehorizoffset, -axlevertheight, 0]) {
 263     rotate([0,0,-90])
 264       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 265     translate([0, DoveClip_depth(), 0])
 266     rotate([0,0,90])
 267       ExtenderPillars(axlevertheight - DoveClip_depth(),
 268                       pillarswidth, towercliph,
 269                       pillarw=towerpillarw);
 270   }
 271
 272   axleclearlen = hubaxlelen + slop*3 + washerthick*2;
 273   axlerad = hubaxlerad-slop;
 274   bump = axlerad * 0.2;
 275   shift = axlerad-bump;
 276   joinbelowallow = 3;
 277
 278   intersection(){
 279     translate([0, 0, shift]) {
 280       difference() {
 281         union(){
 282           translate([-1, 0, 0])
 283             rotate([0,90,0])
 284             cylinder(r = axlerad, h = 1 + axleclearlen + 3 + 2);
 285           mirror([1,0,0]) rotate([0,90,0])
 286             cylinder(r = washerrad, h = 3);
 287 if(0)
 288           intersection(){
 289             mirror([1,0,0]) rotate([0,90,0])
 290               cylinder(r = towercliph - shift,
 291                        h = pillarswidth/2 + axlehorizoffset);
 292             translate([-50, -joinbelowallow, -50])
 293               cube([100, joinbelowallow+50, 100]);
 294           }
 295         }
 296         rotate([90,0,0])
 297         translate([axleclearlen + axlepinrad/2, 0, -25])
 298           cylinder(r=axlepinrad, h=50);
 299       }
 300     }
 301     translate([-50,-50,0]) cube([100,100,100]);
 302   }
 303 }
 304
 305 module AxleWasher(){ ////toplevel
 306   difference(){
 307     cylinder(h=washerthick, r=washerrad);
 308     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 309   }
 310 }
 311
 312 module TowerExtender(){ ////toplevel
 313   l = totalheightfromtower - axlevertheight;
 314   echo("TowerExtender",l);
 315   DoveClipExtender(length = l,
 316                    ha = towercliph, hb = towercliph,
 317                    counta = towerclipcount, countb = towerclipcount,
 318                    pillarw = towerpillarw);
 319 }
 320
 321 //ArmEnd();
 322 //FilamentCup();
 323 //CupSecuringClip();
 324 //Hub();
 325 //ArmExtender();
 326 //Axle();
 327 //AxleWasher();
 328 //AxlePin();