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