filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=2.85;
   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 function selsz(sm,lg) = fdia < 2 ? sm : lg;
  22 function usedove() = selsz(true,false);
  23
  24 prongthick=selsz(5,7);
  25 prongwidth=selsz(5,7);
  26 ratchetstep=15;
  27 ratchettooth=3;
  28 ratchettoothheight=5;
  29 ratchettoothsmoothr=1;
  30 ratchettoothslope=0.75;
  31 overlap=0.5;
  32 cupwidth=selsz(40,60);
  33 cupheight=selsz(55,75);
  34
  35 propxshift = 0;
  36
  37 doveclipheight = 10;
  38
  39 teethh=3;
  40 teethgapx=4+fdia;
  41
  42 prongstalkxwidth=3;
  43
  44 stalklength=selsz(35,55);
  45 overclipcupgap=5;
  46 overclipdepth=15;
  47 overcliproundr=2.0;
  48 overclipthick=1.0;
  49 overclipcupnextgap=20;
  50
  51 overclipsmaller=-2.5;
  52 overclipbigger=0.0;
  53
  54 wingspoke=3;
  55 wingsize=6;
  56 wingthick=3;
  57
  58 armendwallthick=2.5;
  59 armendbasethick=1.2;
  60
  61 axlehorizoffset = 12.5;
  62 axlevertheight = 100;
  63 towercliph = 16;
  64 towerclipcount = 3;
  65 towerpillarw = 5;
  66
  67 axlepinrad = 2;
  68 axlepintabrad = 5;
  69
  70 washerthick = 1.2;
  71 washerthinthick = 0.8;
  72 washerverythinthick = 0.4;
  73 washerrad = hubaxlerad + 7.5;
  74 frictionwasherarmwidth = 3;
  75 frictionwasherextrapush = 1.0;
  76
  77 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  78
  79 include <doveclip.scad>
  80 include <cliphook.scad>
  81 include <filamentteeth.scad>
  82 include <axlepin.scad>
  83
  84 channelwidth = prongthick + slop;
  85 channeldepth = prongwidth + ratchettoothheight;
  86 totalwidth = armendwallthick*2 + channelwidth;
  87 totalheight = channeldepth + armendbasethick;
  88 stalkwidth = prongwidth + prongstalkxwidth;
  89
  90 module ArmEnd(length=120){ ////toplevel
  91   if (usedove()) {
  92     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  93       rotate([0,0,-90])
  94         DoveClipPairBase(h=doveclipheight);
  95     }
  96   }
  97
  98   difference(){
  99     translate([0, -armendwallthick, -armendbasethick])
 100       cube([length, totalwidth, totalheight]);
 101     translate([-1, 0, 0])
 102       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
 103     translate([-1, 0, ratchettoothheight])
 104       cube([length+2, channelwidth, channeldepth+1]);
 105   }
 106   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
 107     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
 108       rotate([90,0,0])
 109         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 110       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 111                         [       0,      1,      0,      0       ],
 112                         [       0,      0,      1,      0       ],
 113                         [       0,      0,      0,      1       ]])
 114         cube([ratchettooth - ratchettoothsmoothr*2,
 115               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 116     }
 117   }
 118 }
 119
 120 module FilamentCupHandle(){
 121   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 122   mirror([0,1,0]) {
 123     cube([stalklength, stalkwidth, prongthick]);
 124     translate([stalklength, stalkwidth/2, 0])
 125       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 126     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 127       minkowski(){
 128         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 129         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 130                         [       0,      1,      0,      0       ],
 131                         [       0,      0,      1,      0       ],
 132                         [       0,      0,      0,      1       ]])
 133           cube([pawlusewidth,
 134                 ratchettoothheight - ratchettoothsmoothr,
 135                 prongthick - 1]);
 136       }
 137     }
 138   }
 139 }
 140
 141 module FilamentCupCup(){
 142   for (my=[0,1]) mirror([0,my,0]) {
 143     translate([0,cupwidth/2,0])
 144       cube([cupheight + prongwidth, prongwidth, prongthick]);
 145   }
 146 }
 147
 148 module FilamentCup() { ////toplevel
 149   FilamentCupHandle();
 150
 151   gapy = prongwidth;
 152   dy = cupwidth/2 + gapy + overclipcupgap;
 153
 154   translate([0, dy, 0])
 155     FilamentCupCup();
 156   translate([0, -1, 0]);
 157   cube([prongwidth, dy+1+cupwidth/2, prongthick]);
 158
 159   midrad = cupwidth/2 + prongwidth/2;
 160
 161   propshift = stalklength - overclipdepth - prongthick + propxshift;
 162   proptaken = propshift;
 163   echo(midrad, propshift, proptaken);
 164
 165   translate([propshift, -1, 0]) {
 166     // something is wrong with the y calculation
 167     cube([prongwidth,
 168           gapy+2,
 169           prongthick]);
 170   }
 171   for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
 172     translate([0, y, 0])
 173       rotate([0,0, 102 + fdia])
 174       FilamentTeeth(fdia=fdia, h=teethh);
 175   }
 176   for (x = [-0.3, -1.3]) {
 177     translate([cupheight + overclipcupnextgap*x, dy+cupwidth/2 + prongthick, 0])
 178       rotate([0,0, 12 + fdia])
 179       FilamentTeeth(fdia=fdia, h=teethh);
 180   }
 181 }
 182
 183 module CupSecuringClipSolid(w,d,h1,h2){
 184   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 185     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 186   }
 187 }
 188
 189 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 190   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 191   minkowski(){
 192     CupSecuringClipSolid(w=totalwidth,
 193                          d=overclipdepth + xdepth,
 194                          h1=hbase - overclipsmaller,
 195                          h2=hbase + overclipbigger);
 196     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 197   }
 198 }
 199
 200 module CupSecuringClip(){ ////toplevel
 201   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 202   difference(){
 203     union(){
 204       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 205       translate([-wingswidth/2, -wingsize/2, 0])
 206         cube([wingswidth, wingsize, wingthick]);
 207       translate([-wingsize/2, -wingswidth/2, 0])
 208         cube([wingsize, wingswidth, wingthick]);
 209     }
 210     translate([0,0,-0.1])
 211       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 212   }
 213 }
 214
 215 module ArmDoveClipPin(){ ////toplevel
 216   DoveClipPin(h=doveclipheight);
 217 }
 218
 219 module TowerDoveClipPin(){ ////toplevel
 220   DoveClipPin(h=towercliph/2);
 221 }
 222
 223 module Hub(){ ////toplevel
 224   difference(){
 225     cylinder($fn=60, h=hublthick, r=hubbigrad);
 226     translate([0,0,-1])
 227       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 228   }
 229   axlerad = hubaxlerad + slop;
 230   difference(){
 231     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 232     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 233   }
 234   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 235   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 236   for (ang=[0,120,240])
 237     rotate([0,0,ang]) {
 238       difference() {
 239         translate([hubeffrad,0,0])
 240           DoveClipPairSane(h=doveclipheight,
 241                            baseextend = (hubeffrad - DoveClip_depth()
 242                                          - hubbigrad + hublwidth));
 243         if (hole>hublwidth && holewidth > 2) {
 244           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 245             cube([hole, holewidth, hublthick+2]);
 246         }
 247       }
 248     }
 249   xmin = axlerad+hublwidth/2;
 250   xmax = hubbigrad-hublwidth/2;
 251   for (ang = [0 : 60 : 359])
 252     rotate([0,0,ang]) rotate([90,0,0]) {
 253       translate([0,0,-hublwidth/2])
 254         linear_extrude(height=hublwidth)
 255         polygon([[xmin,0.05], [xmax,0.05],
 256                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 257     }
 258 }
 259
 260 module ArmExtender(){ ////toplevel
 261   DoveClipExtender(length=exteffrad-hubeffrad,
 262                    ha=doveclipheight,
 263                    hb=doveclipheight);
 264 }
 265
 266 module FsAxlePin(){ ////toplevel
 267   AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
 268 }
 269
 270 module Axle(){ ////toplevel
 271   pillarswidth = DoveClipPairSane_width(towerclipcount);
 272
 273   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 274   translate([-axlehorizoffset, -axlevertheight, 0]) {
 275     rotate([0,0,-axletowerfudgebend])
 276     rotate([0,0,-90])
 277       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 278     translate([0, DoveClip_depth(), 0])
 279     rotate([0,0,90])
 280       ExtenderPillars(axlevertheight - DoveClip_depth(),
 281                       pillarswidth, towercliph,
 282                       pillarw=towerpillarw);
 283   }
 284
 285   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 286   axlerad = hubaxlerad-slop;
 287   bump = axlerad * 0.2;
 288   shift = axlerad-bump;
 289   joinbelowallow = 3;
 290
 291   intersection(){
 292     translate([0, 0, shift]) {
 293       difference() {
 294         union(){
 295           translate([-1, 0, 0])
 296             rotate([0,90,0])
 297             cylinder($fn=60,
 298                      r = axlerad,
 299                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 300           mirror([1,0,0]) rotate([0,90,0])
 301             cylinder(r = axlerad*1.75, h = 3);
 302           intersection(){
 303             mirror([1,0,0])
 304               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 305               rotate([0,90,0])
 306               cylinder($fn=60,
 307                        r = towercliph - shift,
 308                        h = pillarswidth);
 309             translate([-50, -joinbelowallow, -50])
 310               cube([100, joinbelowallow+50, 100]);
 311           }
 312         }
 313         rotate([90,0,0])
 314         translate([axleclearlen + axlepinrad/2, 0, -25])
 315           cylinder(r = axlepinrad + slop, h=50);
 316       }
 317     }
 318     translate([-50,-50,0]) cube([100,100,100]);
 319   }
 320 }
 321
 322 module washer(thick){
 323   Washer(hubaxlerad, washerrad, thick, slop);
 324 }
 325
 326 module AxleWasher(){ ////toplevel
 327   washer(thick=washerthick);
 328 }
 329
 330 module AxleThinWasher(){ ////toplevel
 331   washer(thick=washerthinthick);
 332 }
 333
 334 module AxleVeryThinWasher(){ ////toplevel
 335   washer(thick=washerverythinthick);
 336 }
 337
 338 module AxleFrictionWasher(){ ////toplevel
 339   difference(){
 340     cylinder(h=washerthick, r=washerrad);
 341     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 342   }
 343   frarmr = hubbigrad;
 344   frarmw = frictionwasherarmwidth;
 345   frarmpawlr = hublwidth;
 346   frarmpawlpush = slop*4 + frictionwasherextrapush;
 347   for (ang=[0,180]) rotate([0,0,ang]) {
 348     translate([washerrad-1, -frarmw/2, 0])
 349       cube([frarmr - washerrad + 1, frarmw, washerthick]);
 350     intersection(){
 351       translate([frarmr - frarmpawlr, -50, 0])
 352         cube([frarmpawlr, 100, 50]);
 353       rotate([0,90,0])
 354         cylinder(h = 50, r = frarmpawlpush, $fn=36);
 355     }
 356   }
 357 }
 358
 359 module TowerExtender(){ ////toplevel
 360   l = totalheightfromtower - axlevertheight;
 361   echo("TowerExtender",l);
 362   DoveClipExtender(length = l,
 363                    ha = towercliph, hb = towercliph,
 364                    counta = towerclipcount, countb = towerclipcount,
 365                    pillarw = towerpillarw);
 366 }
 367
 368 module FilamentCupPair(){ ////toplevel
 369   FilamentCup();
 370   translate([cupheight + prongthick*3,
 371              cupwidth/2*1.7,
 372              0])
 373     rotate([0,0,180]) FilamentCup();
 374 }
 375
 376 //ArmEnd();
 377 //FilamentCup();
 378 //FilamentCupPair();
 379 CupSecuringClip();
 380 //Hub();
 381 //ArmExtender();
 382 //Axle();
 383 //AxleWasher();
 384 //AxlePin();
 385 //AxleFrictionWasher();