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