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