filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=2.85;
   4
   5 slop=0.5;
   6 bigslop=slop*2;
   7
   8 function selsz(sm,lg) = fdia < 2 ? sm : lg;
   9 function usedove() = selsz(true,false);
  10
  11 num_arms = selsz(3,4);
  12
  13 exteffrad = 70;
  14 hubeffrad = selsz(30, 60);
  15 hubbigrad = selsz(20, 50);
  16 hublwidth = selsz(3, 5);
  17 hubstemwidth = 2;
  18 hublthick = 10;
  19 hubaxlerad = selsz(5, 17/2);
  20 totalheightfromtower = 240;
  21 axletowerfudgebend = 0;
  22 axleaxlefudgebend = 3;
  23 axlepadlen = 1.0;
  24
  25 prongthick=selsz(5,7);
  26 prongwidth=selsz(5,7);
  27 ratchetstep=15;
  28 ratchettooth=3;
  29 ratchettoothheight=5;
  30 ratchettoothsmoothr=1;
  31 ratchettoothslope=0.75;
  32 overlap=0.5;
  33 cupwidth=selsz(40,60);
  34 cupheight=selsz(55,75);
  35
  36 propxshift = 0;
  37
  38 doveclipheight = 10;
  39
  40 teethh=3;
  41 teethgapx=4+fdia;
  42
  43 prongstalkxwidth=3;
  44
  45 stalklength=selsz(35,55);
  46 overclipcupgap=5;
  47 overclipdepth=15;
  48 overcliproundr=2.0;
  49 overclipthick=1.0;
  50 overclipcupnextgap=20;
  51
  52 hubaxlelen = selsz(25, cupwidth);
  53
  54 overclipsmaller=-2.5;
  55 overclipbigger=0.0;
  56
  57 wingspoke=3;
  58 wingsize=6;
  59 wingthick=3;
  60
  61 armendwallthick=2.5;
  62 armendbasethick=1.2;
  63
  64 axlehorizoffset = 12.5;
  65 axlevertheight = 100;
  66 towercliph = 16;
  67 towerclipcount = 3;
  68 towerpillarw = 5;
  69
  70 axlepinrad = 2;
  71 axlepintabrad = 5;
  72
  73 washerthick = 1.2;
  74 washerthinthick = 0.8;
  75 washerverythinthick = 0.4;
  76 washerrad = hubaxlerad + 7.5;
  77 frictionwasherarmwidth = 3;
  78 frictionwasherextrapush = 1.0;
  79
  80 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  81
  82 nondove_armbase = 100;
  83 nondove_armhole_x = 60;
  84 nondove_armhole_hole = 4;
  85 nondove_armhole_support = 7;
  86 nondove_armhole_wall = 4;
  87 nondove_armhole_slop = 0.5;
  88
  89 include <doveclip.scad>
  90 include <cliphook.scad>
  91 include <filamentteeth.scad>
  92 include <axlepin.scad>
  93
  94 channelwidth = prongthick + slop;
  95 channeldepth = prongwidth + ratchettoothheight;
  96 totalwidth = armendwallthick*2 + channelwidth;
  97 totalheight = channeldepth + armendbasethick;
  98 stalkwidth = prongwidth + prongstalkxwidth;
  99
 100 module ArmEnd(length=120){ ////toplevel
 101   if (usedove()) {
 102     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
 103       rotate([0,0,-90])
 104         DoveClipPairBase(h=doveclipheight);
 105     }
 106   } else {
 107     difference(){
 108       translate([1, -armendwallthick, -armendbasethick])
 109         mirror([1,0,0])
 110         cube([nondove_armbase+1, totalwidth, totalheight]);
 111       translate([-nondove_armbase + nondove_armhole_x,
 112                  -armendwallthick + totalwidth/2,
 113                  -armendbasethick -1])
 114         cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
 115     }
 116   }
 117
 118   difference(){
 119     translate([0, -armendwallthick, -armendbasethick])
 120       cube([length, totalwidth, totalheight]);
 121     translate([-1, 0, 0])
 122       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
 123     translate([-1, 0, ratchettoothheight])
 124       cube([length+2, channelwidth, channeldepth+1]);
 125   }
 126   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
 127     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
 128       rotate([90,0,0])
 129         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 130       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 131                         [       0,      1,      0,      0       ],
 132                         [       0,      0,      1,      0       ],
 133                         [       0,      0,      0,      1       ]])
 134         cube([ratchettooth - ratchettoothsmoothr*2,
 135               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 136     }
 137   }
 138 }
 139
 140 module FilamentCupHandle(){
 141   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 142   mirror([0,1,0]) {
 143     cube([stalklength, stalkwidth, prongthick]);
 144     translate([stalklength, stalkwidth/2, 0])
 145       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 146     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 147       minkowski(){
 148         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 149         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 150                         [       0,      1,      0,      0       ],
 151                         [       0,      0,      1,      0       ],
 152                         [       0,      0,      0,      1       ]])
 153           cube([pawlusewidth,
 154                 ratchettoothheight - ratchettoothsmoothr,
 155                 prongthick - 1]);
 156       }
 157     }
 158   }
 159 }
 160
 161 module FilamentCupCup(){
 162   for (my=[0,1]) mirror([0,my,0]) {
 163     translate([0,cupwidth/2,0])
 164       cube([cupheight + prongwidth, prongwidth, prongthick]);
 165   }
 166 }
 167
 168 module FilamentCup() { ////toplevel
 169   FilamentCupHandle();
 170
 171   gapy = prongwidth;
 172   dy = cupwidth/2 + gapy + overclipcupgap;
 173
 174   translate([0, dy, 0])
 175     FilamentCupCup();
 176   translate([0, -1, 0]);
 177   cube([prongwidth, dy+1+cupwidth/2, prongthick]);
 178
 179   midrad = cupwidth/2 + prongwidth/2;
 180
 181   propshift = stalklength - overclipdepth - prongthick + propxshift;
 182   proptaken = propshift;
 183   echo(midrad, propshift, proptaken);
 184
 185   translate([propshift, -1, 0]) {
 186     // something is wrong with the y calculation
 187     cube([prongwidth,
 188           gapy+2,
 189           prongthick]);
 190   }
 191   for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
 192     translate([0, y, 0])
 193       rotate([0,0, 102 + fdia])
 194       FilamentTeeth(fdia=fdia, h=teethh);
 195   }
 196   for (x = [-0.3, -1.3]) {
 197     translate([cupheight + overclipcupnextgap*x, dy+cupwidth/2 + prongthick, 0])
 198       rotate([0,0, 12 + fdia])
 199       FilamentTeeth(fdia=fdia, h=teethh);
 200   }
 201 }
 202
 203 module CupSecuringClipSolid(w,d,h1,h2){
 204   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 205     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 206   }
 207 }
 208
 209 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 210   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 211   minkowski(){
 212     CupSecuringClipSolid(w=totalwidth,
 213                          d=overclipdepth + xdepth,
 214                          h1=hbase - overclipsmaller,
 215                          h2=hbase + overclipbigger);
 216     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 217   }
 218 }
 219
 220 module CupSecuringClip(){ ////toplevel
 221   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 222   difference(){
 223     union(){
 224       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 225       translate([-wingswidth/2, -wingsize/2, 0])
 226         cube([wingswidth, wingsize, wingthick]);
 227       translate([-wingsize/2, -wingswidth/2, 0])
 228         cube([wingsize, wingswidth, wingthick]);
 229     }
 230     translate([0,0,-0.1])
 231       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 232   }
 233 }
 234
 235 module ArmDoveClipPin(){ ////toplevel
 236   DoveClipPin(h=doveclipheight);
 237 }
 238
 239 module TowerDoveClipPin(){ ////toplevel
 240   DoveClipPin(h=towercliph/2);
 241 }
 242
 243 module Hub(){ ////toplevel
 244   axlerad = hubaxlerad + slop;
 245   xmin = axlerad+hublwidth/2;
 246   xmax = hubbigrad-hublwidth/2;
 247   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 248   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 249   nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
 250   difference(){
 251     union(){
 252       difference(){
 253         cylinder($fn=60, h=hublthick, r=hubbigrad);
 254         translate([0,0,-1])
 255           cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 256       }
 257       cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 258       for (ang=[0 : 360/num_arms : 359])
 259         rotate([0,0,ang]) {
 260           difference() {
 261             if (usedove()){
 262               translate([hubeffrad,0,0])
 263                 DoveClipPairSane(h=doveclipheight,
 264                                  baseextend = (hubeffrad - DoveClip_depth()
 265                                                - hubbigrad + hublwidth));
 266               if (hole>hublwidth && holewidth > 2) {
 267                 translate([hubbigrad + hublwidth, -holewidth/2, -1])
 268                   cube([hole, holewidth, hublthick+2]);
 269               }
 270             } else {
 271               difference(){
 272                 translate([0,
 273                            -nondove_allwidth/2,
 274                            0])
 275                   cube([hubeffrad + nondove_armhole_x
 276                         + nondove_armhole_hole/2 + nondove_armhole_support,
 277                         nondove_allwidth,
 278                         nondove_armhole_wall + totalheight]);
 279                 translate([hubeffrad,
 280                            -nondove_allwidth/2
 281                            + nondove_armhole_wall - nondove_armhole_slop,
 282                            nondove_armhole_wall])
 283                   cube([nondove_armhole_x + 50,
 284                         totalwidth + nondove_armhole_slop*2,
 285                         totalheight + 1]);
 286                 translate([hubeffrad + nondove_armhole_x, 0, -20])
 287                    cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
 288               }
 289             }
 290           }
 291         }
 292       for (ang = [0 : 180/num_arms : 359])
 293         rotate([0,0,ang]) rotate([90,0,0]) {
 294           translate([0,0,-hublwidth/2])
 295             linear_extrude(height=hublwidth)
 296             polygon([[xmin,0.05], [xmax,0.05],
 297                      [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 298         }
 299     }
 300     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 301   }
 302 }
 303
 304 module ArmExtender(){ ////toplevel
 305   DoveClipExtender(length=exteffrad-hubeffrad,
 306                    ha=doveclipheight,
 307                    hb=doveclipheight);
 308 }
 309
 310 module FsAxlePin(){ ////toplevel
 311   AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
 312 }
 313
 314 module Axle(){ ////toplevel
 315   pillarswidth = DoveClipPairSane_width(towerclipcount);
 316
 317   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 318   translate([-axlehorizoffset, -axlevertheight, 0]) {
 319     rotate([0,0,-axletowerfudgebend])
 320     rotate([0,0,-90])
 321       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 322     translate([0, DoveClip_depth(), 0])
 323     rotate([0,0,90])
 324       ExtenderPillars(axlevertheight - DoveClip_depth(),
 325                       pillarswidth, towercliph,
 326                       pillarw=towerpillarw);
 327   }
 328
 329   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 330   axlerad = hubaxlerad-slop;
 331   bump = axlerad * 0.2;
 332   shift = axlerad-bump;
 333   joinbelowallow = 3;
 334
 335   intersection(){
 336     translate([0, 0, shift]) {
 337       difference() {
 338         union(){
 339           translate([-1, 0, 0])
 340             rotate([0,90,0])
 341             cylinder($fn=60,
 342                      r = axlerad,
 343                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 344           mirror([1,0,0]) rotate([0,90,0])
 345             cylinder(r = axlerad*1.75, h = 3);
 346           intersection(){
 347             mirror([1,0,0])
 348               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 349               rotate([0,90,0])
 350               cylinder($fn=60,
 351                        r = towercliph - shift,
 352                        h = pillarswidth);
 353             translate([-50, -joinbelowallow, -50])
 354               cube([100, joinbelowallow+50, 100]);
 355           }
 356         }
 357         rotate([90,0,0])
 358         translate([axleclearlen + axlepinrad/2, 0, -25])
 359           cylinder(r = axlepinrad + slop, h=50);
 360       }
 361     }
 362     translate([-50,-50,0]) cube([100,100,100]);
 363   }
 364 }
 365
 366 module washer(thick){
 367   Washer(hubaxlerad, washerrad, thick, slop);
 368 }
 369
 370 module AxleWasher(){ ////toplevel
 371   washer(thick=washerthick);
 372 }
 373
 374 module AxleThinWasher(){ ////toplevel
 375   washer(thick=washerthinthick);
 376 }
 377
 378 module AxleVeryThinWasher(){ ////toplevel
 379   washer(thick=washerverythinthick);
 380 }
 381
 382 module AxleFrictionWasher(){ ////toplevel
 383   difference(){
 384     cylinder(h=washerthick, r=washerrad);
 385     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 386   }
 387   frarmr = hubbigrad;
 388   frarmw = frictionwasherarmwidth;
 389   frarmpawlr = hublwidth;
 390   frarmpawlpush = slop*4 + frictionwasherextrapush;
 391   for (ang=[0,180]) rotate([0,0,ang]) {
 392     translate([washerrad-1, -frarmw/2, 0])
 393       cube([frarmr - washerrad + 1, frarmw, washerthick]);
 394     intersection(){
 395       translate([frarmr - frarmpawlr, -50, 0])
 396         cube([frarmpawlr, 100, 50]);
 397       rotate([0,90,0])
 398         cylinder(h = 50, r = frarmpawlpush, $fn=36);
 399     }
 400   }
 401 }
 402
 403 module TowerExtender(){ ////toplevel
 404   l = totalheightfromtower - axlevertheight;
 405   echo("TowerExtender",l);
 406   DoveClipExtender(length = l,
 407                    ha = towercliph, hb = towercliph,
 408                    counta = towerclipcount, countb = towerclipcount,
 409                    pillarw = towerpillarw);
 410 }
 411
 412 module FilamentCupPair(){ ////toplevel
 413   FilamentCup();
 414   translate([cupheight + prongthick*3,
 415              cupwidth/2*1.7,
 416              0])
 417     rotate([0,0,180]) FilamentCup();
 418 }
 419
 420 //ArmEnd();
 421 //FilamentCup();
 422 //FilamentCupPair();
 423 //CupSecuringClip();
 424 Hub();
 425 //ArmExtender();
 426 //Axle();
 427 //AxleWasher();
 428 //AxlePin();
 429 //AxleFrictionWasher();