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