filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=1.75;
   4
   5 slop=0.5;
   6 bigslop=slop*2;
   7
   8 exteffrad = 85;
   9 hubeffrad = 30;
  10 hubbigrad = 20;
  11 hublwidth = 3;
  12 hubstemwidth = 2;
  13 hublthick = 10;
  14 hubaxlelen = 25;
  15 hubaxlerad = 5;
  16
  17 prongthick=5;
  18 prongwidth=5;
  19 ratchetstep=15;
  20 ratchettooth=3;
  21 ratchettoothheight=5;
  22 ratchettoothsmoothr=1;
  23 ratchettoothslope=0.75;
  24 overlap=0.5;
  25 cupbigrad=20;
  26
  27 xstraightmul = 1.75;
  28
  29 propxshift = 0;
  30
  31 doveclipheight = 10;
  32
  33 teethh=3;
  34 teethgapx=4+fdia;
  35
  36 prongstalkxwidth=3;
  37
  38 stalklength=35;
  39 overclipcupgap=5;
  40 overclipdepth=15;
  41 overcliproundr=2.0;
  42 overclipthick=0.5;
  43
  44 overclipsmaller=-2.5;
  45 overclipbigger=0.0;
  46
  47 wingspoke=3;
  48 wingsize=6;
  49 wingthick=3;
  50
  51 armendwallthick=2.5;
  52 armendbasethick=1.2;
  53
  54 axlehorizoffset = 12.5;
  55 axlevertheight = 80;
  56 towercliph = 16;
  57 towerclipcount = 3;
  58 towerpillarw = 5;
  59
  60 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  61
  62 include <doveclip.scad>
  63 include <cliphook.scad>
  64 include <filamentteeth.scad>
  65
  66 channelwidth = prongthick + slop;
  67 channeldepth = prongwidth + ratchettoothheight;
  68 totalwidth = armendwallthick*2 + channelwidth;
  69 totalheight = channeldepth + armendbasethick;
  70 stalkwidth = prongwidth + prongstalkxwidth;
  71
  72 module ArmEnd(length=120){ ////toplevel
  73   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  74     rotate([0,0,-90])
  75       DoveClipPairBase(h=doveclipheight);
  76   }
  77
  78   difference(){
  79     translate([0, -armendwallthick, -armendbasethick])
  80       cube([length, totalwidth, totalheight]);
  81     translate([-1, 0, 0])
  82       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  83     translate([-1, 0, ratchettoothheight])
  84       cube([length+2, channelwidth, channeldepth+1]);
  85   }
  86   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  87     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  88       rotate([90,0,0])
  89         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
  90       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
  91                         [       0,      1,      0,      0       ],
  92                         [       0,      0,      1,      0       ],
  93                         [       0,      0,      0,      1       ]])
  94         cube([ratchettooth - ratchettoothsmoothr*2,
  95               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
  96     }
  97   }
  98 }
  99
 100 module FilamentCupHandle(){
 101   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 102   mirror([0,1,0]) {
 103     cube([stalklength, stalkwidth, prongthick]);
 104     translate([stalklength, stalkwidth/2, 0])
 105       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 106     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 107       minkowski(){
 108         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 109         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 110                         [       0,      1,      0,      0       ],
 111                         [       0,      0,      1,      0       ],
 112                         [       0,      0,      0,      1       ]])
 113           cube([pawlusewidth,
 114                 ratchettoothheight - ratchettoothsmoothr,
 115                 prongthick - 1]);
 116       }
 117     }
 118   }
 119 }
 120
 121 module FilamentCupCup(){
 122   xstraight = cupbigrad * xstraightmul;
 123   linear_extrude(height=prongthick) {
 124     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 125   }
 126   for (my=[0,1]) mirror([0,my,0]) {
 127     translate([0,cupbigrad,0])
 128       cube([xstraight, prongwidth, prongthick]);
 129   }
 130 }
 131
 132 module FilamentCup() { ////toplevel
 133   FilamentCupHandle();
 134
 135   dx = cupbigrad + prongwidth;
 136   gapy = prongwidth;
 137   dy = cupbigrad + gapy + overclipcupgap;
 138
 139   translate([dx, dy, 0])
 140     FilamentCupCup();
 141   translate([0, -1, 0]);
 142   cube([prongwidth, dy+1, prongthick]);
 143
 144   midrad = cupbigrad + prongwidth/2;
 145
 146   propshift = stalklength - overclipdepth - prongthick + propxshift;
 147   proptaken = propshift;
 148   echo(cupbigrad, dx, midrad, propshift, proptaken);
 149
 150   translate([propshift, -1, 0]) {
 151     // something is wrong with the y calculation
 152     cube([prongwidth,
 153           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 154           prongthick]);
 155   }
 156   translate([0, overclipcupgap, 0])
 157     rotate([0,0, 102 + fdia])
 158     FilamentTeeth(fdia=fdia, h=teethh);
 159 }
 160
 161 module CupSecuringClipSolid(w,d,h1,h2){
 162   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 163     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 164   }
 165 }
 166
 167 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 168   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 169   minkowski(){
 170     CupSecuringClipSolid(w=totalwidth,
 171                          d=overclipdepth + xdepth,
 172                          h1=hbase - overclipsmaller,
 173                          h2=hbase + overclipbigger);
 174     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 175   }
 176 }
 177
 178 module CupSecuringClip(){ ////toplevel
 179   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 180   difference(){
 181     union(){
 182       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 183       translate([-wingswidth/2, -wingsize/2, 0])
 184         cube([wingswidth, wingsize, wingthick]);
 185     }
 186     translate([0,0,-0.1])
 187       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 188   }
 189 }
 190
 191 module ArmDoveClipPin(){ ////toplevel
 192   DoveClipPin(h=doveclipheight);
 193 }
 194
 195 module Hub(){ ////toplevel
 196   difference(){
 197     cylinder($fn=60, h=hublthick, r=hubbigrad);
 198     translate([0,0,-1])
 199       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 200   }
 201   axlerad = hubaxlerad + slop;
 202   difference(){
 203     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 204     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 205   }
 206   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 207   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 208   for (ang=[0,120,240])
 209     rotate([0,0,ang]) {
 210       difference() {
 211         translate([hubeffrad,0,0])
 212           DoveClipPairSane(h=doveclipheight,
 213                            baseextend = (hubeffrad - DoveClip_depth()
 214                                          - hubbigrad + hublwidth));
 215         if (hole>hublwidth && holewidth > 2) {
 216           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 217             cube([hole, holewidth, hublthick+2]);
 218         }
 219       }
 220     }
 221   xmin = axlerad+hublwidth/2;
 222   xmax = hubbigrad-hublwidth/2;
 223   for (ang = [0 : 60 : 359])
 224     rotate([0,0,ang]) rotate([90,0,0]) {
 225       translate([0,0,-hublwidth/2])
 226         linear_extrude(height=hublwidth)
 227         polygon([[xmin,0.05], [xmax,0.05],
 228                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 229     }
 230 }
 231
 232 module ArmExtender(){ ////toplevel
 233   DoveClipExtender(length=exteffrad-hubeffrad,
 234                    ha=doveclipheight,
 235                    hb=doveclipheight);
 236 }
 237
 238 module Axle(){ ////toplevel
 239   pillarswidth = DoveClipPairSane_width(towerclipcount);
 240
 241   translate([-axlehorizoffset, -axlevertheight, 0]) {
 242     rotate([0,0,-90])
 243       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 244     translate([0, DoveClip_depth(), 0])
 245     rotate([0,0,90])
 246       ExtenderPillars(axlevertheight - DoveClip_depth(),
 247                       pillarswidth, towercliph,
 248                       pillarw=towerpillarw);
 249   }
 250 }
 251
 252 //ArmEnd();
 253 //FilamentCup();
 254 //CupSecuringClip();
 255 //Hub();
 256 //ArmExtender();
 257 Axle();