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bike-lipo-box: TestWall: replace ad-hoc with S1930_Negative (nfc)
[reprap-play.git] / filamentspool.scad
1 // -*- C -*-
2
3 // filamentspool.scad
4 // 3D design for filament spools to hold coils as supplied by Faberdashery
5 //
6
7 //
8 // Copyright 2012,2013,2016 Ian Jackson
9 //
10 // This work is free software: you can redistribute it and/or modify
11 // it under the terms of the GNU General Public License as published by
12 // the Free Software Foundation, either version 3 of the License, or
13 // (at your option) any later version.
14 //
15 // This work is distributed in the hope that it will be useful,
16 // but WITHOUT ANY WARRANTY; without even the implied warranty of
17 // MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.  See the
18 // GNU General Public License for more details.
19 //
20 // You should have received a copy of the GNU General Public License
21 // along with this work.  If not, see <http://www.gnu.org/licenses/>
22 //
23
24 //
25 // Each spool is a hub with 3 or 4 arms.  Each arm has a cup for
26 // holding the filament.  The effective diameter can be adjusted by
27 // setting the cup into a different seat in the arm.  The cups are
28 // held on with simple clips, so the filement coil can easily be
29 // removed and replaced.
30 //
31 // This file (and its includes) can generate:
32 //
33 // ===== Heavy duty 4-armed spool for 3mm x 100m coil =====
34 //
35 // A heavy duty 4-armed spool suitable for holding a 100m
36 // Faberdashery coil on the spool arm of a Lulzbot TAZ-5.
37 //
38 //     Set
39 //           fdia=2.85
40 //           lightduty=false
41 //     And print following parts
42 //            Hub
43 //            ArmEnd x 4
44 //            FilamentCup x 4  (or FilamentCupPair x 2)
45 //            CupSecuringClip x 4
46 //
47 //     You will also need  4 x M4 machine screws and nuts.
48 //
49 //     This is the default.
50 //
51 // ===== Light duty 3-armed spool for 3mm x <=30m coil =====
52 //
53 // A light duty 3-armed spool suitable for up to around 30m
54 // of Faberdashery 2.85mm PLA.
55 //
56 //     Set
57 //           fdia=2.85
58 //           lightduty=true
59 //     (or look in filamentspool-lt.scad).
60 //
61 //     And print following parts
62 //           Hub
63 //           ArmEnd x 3
64 //           FilamentCup x 3  (or FilamentCup + FilamentCupPair)
65 //           CupSecuringClip x 3
66 //           TowerDoveClipPin x 6
67 //
68 //     When assembling, insert one TowerDoveClipPin from each side,
69 //     joining each ArmEnd to the Hub with two TowerDoveClipPins.
70 //     Modest force with pliers is good to seat them properly.
71 //
72 //     (note that the light duty and heavy duty CupSecuringClips
73 //      are slightly different)
74 //
75 // ===== Notes regarding both the above spools =====
76 //
77 // When mounting either spool on the TAZ-5 spool arm, put the `pointy'
78 // end of the hub towards the printer - ie, put put the spool on
79 // `backwards'.  This ensures that the spool's arms will clear the
80 // printer framework.
81 //
82 // For the above, I generally used the Cura `Standard' PLA profile.
83 //
84 // ===== TAZ-5 feed tube adjustment kit =====
85 //
86 // With a TAZ-5 I recommend using this kit to improve the feed
87 // reliability:
88 //
89 //       Set
90 //           fdia=2.85
91 //     And print following parts
92 //           FilamentGuideSpacer (ideally, at `high detail')
93 //           FilamentGuideArmPrint (optional; `high detail' or `standard')
94 //
95 //     And possibly also
96 //           t-nut_jig_0.2.stl
97 //     from Aleph Objects - look here:
98 //           http://download.lulzbot.com/TAZ/accessories/tool_heads/version_2/Dual_Extruder_v2/production_parts/stl/
99 //
100 // The spacer clips onto the filament guide tube holder arm, on the
101 // inside, with the pointy flanged end towards the filament guide
102 // tube.  It stops the filament guide tube angle (and so the
103 // filament's natural pickup location) changing as the print head moves.
104 //
105 // The FilamentGuideArm[Print] is a replacement for the arm supplied
106 // with your TAZ-5.  It's longer, so that the filament pickup point is
107 // closer to the middle of the coil.  Use the t-nut_jig to stop the
108 // T-nuts in the aluminium channel from annoyingly sliding down to the
109 // bottom while you swap out the arm.
110 //
111 // (Faberdashery coils, and therefore both the above spools, have a
112 // larger diameter than the flat-walled spools often supplied by other
113 // vendors.  And the spools above have individual arms rather than a
114 // continuous disc.  If the filament `unhooks' from the arm, it can
115 // pull taught around the hub and stop feeding properly.)
116 //
117 // ===== Spool storage arm, for mounting on walls =====
118 //
119 // A storage arm suitable for screwing to walls, bookshelves,
120 // etc. (requires non-countersunk M4 screws); will hold two heavy duty
121 // spools each with a 100m coil.
122 //
123 //     Set
124 //           fdia=2.85
125 //           lightduty=false
126 //     (or look in filamentspool-sm.scad).
127 //
128 //     And print one of these, according to taste
129 //            StorageArmLeft
130 //            StorageArmRight
131 //
132 //     NB that the `light duty' version of this is shorter and
133 //     will only take two `light duty' spools.
134 //
135 // For the above, I used the Cura `High detail' PLA profile because
136 // I wanted it pretty, but the `Standard' profile should do fine.
137 //
138 // ===== Spools for 1.75mm filament =====
139 //
140 // Spool (in many parts) for handing 1.75mm filament, printable
141 // on, and with parts for mounting on, a Reprappro Huxley.
142
143
144 fdia=2.85; // or 1.75
145 lightduty=false; // or true
146
147
148 slop=0.5;
149 bigslop=slop*2;
150
151 function selsz(sm,lt,lg) = fdia < 2 ? sm : lightduty ? lt : lg;
152 function usedove() = selsz(true,true,false);
153
154 num_arms = selsz(3,3,4);
155
156 channelslop=selsz(slop,0.75,slop);
157
158 exteffrad = 70;
159 hubeffrad = selsz(30, 82, 40);
160 hubbigrad = selsz(20, 38, 38);
161 hublwidth = selsz(3, 2.5, 3.0);
162 hubstemwidth = 2;
163 hublthick = 10;
164 hubaxlerad = selsz(5, 28/2, 28/2);
165 totalheightfromtower = 240;
166 axletowerfudgebend = 0;
167 axleaxlefudgebend = 3;
168 axlepadlen = 1.0;
169
170 armend_length = 120;
171
172 prongthick=selsz(5,4,5);
173 prongwidth=selsz(5,4,5);
174 prongribwidth=3;
175 prongribheight=selsz(0,0,4);
176 ratchetstep=15;
177 ratchettooth=3;
178 ratchettoothheight=5;
179 ratchettoothsmoothr=1;
180 ratchettoothslope=0.75;
181 overlap=0.5;
182 cupwidth=selsz(40,25,50);
183 cupheight=selsz(55,25,55);
184
185 cupstrong_dx=selsz(0,0,-10);
186
187 propxshift = -6;
188
189 doveclipheight = 10;
190
191 teethh=3;
192 teethgapx=4+fdia;
193
194 prongstalkxwidth=3;
195
196 stalklength=selsz(35,25,55);
197 overclipcupgap=5;
198 overclipdepth=15;
199 overcliproundr=2.0;
200 overclipthick=1.0;
201 overclipcupnextgap=selsz(20,15,20);
202
203 hubaxlelen = selsz(25, 62.5, 77.5);
204 echo(hubaxlelen);
205
206 overclipsmaller=-2.5;
207 overclipbigger=0.0;
208
209 wingspoke=2.5;
210 wingsize=6;
211 wingthick=3;
212
213 armendwallthick=selsz(2.5, 1.8, 2.5);
214 armendbasethick=selsz(1.2, 1.2, 1.2);
215
216 numbers_relief = 0.7;
217 numbers_tick_len = 8;
218 numbers_tick_width = 0.75;
219 numbers_tick_linespc = 1.0;
220 numbers_height_allow = 8;
221
222 axlehorizoffset = 12.5;
223 axlevertheight = 100;
224 towercliph = 16;
225 towerclipcount = 3;
226 towerpillarw = 5;
227
228 axlepinrad = 2;
229 axlepintabrad = 5;
230
231 washerthick = 1.2;
232 washerthinthick = 0.8;
233 washerverythinthick = 0.4;
234 washerrad = hubaxlerad + 7.5;
235 frictionwasherarmwidth = 3;
236 frictionwasherextrapush = 1.0;
237
238 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
239
240 nondove_armhole_x = 32;
241 nondove_armhole_hole = 4 + 0.8;
242 nondove_armhole_support = 7;
243 nondove_armhole_wall = 3.2;
244 nondove_armhole_slop = 0.5;
245 nondove_armhole_slop_x = 0.5;
246
247 nondove_armbase = nondove_armhole_x + nondove_armhole_hole/2 +
248   nondove_armhole_support;
249 echo(nondove_armbase);
250
251 include <doveclip.scad>
252 include <cliphook.scad>
253 include <filamentteeth.scad>
254 include <axlepin.scad>
255 include <commitid.scad>
256
257 hub_clip_baseextend = (hubeffrad - DoveClip_depth()
258                        - hubbigrad + hublwidth);
259
260 real_exteffrad = selsz(exteffrad + hub_clip_baseextend,
261                        hubeffrad + DoveClip_depth(),
262                        hubeffrad + nondove_armbase);
263
264 channelwidth = prongthick + channelslop;
265 channeldepth = prongwidth + ratchettoothheight;
266 totalwidth = armendwallthick*2 + channelwidth;
267 totalheight = channeldepth + armendbasethick;
268 stalkwidth = prongwidth + prongstalkxwidth;
269
270 tau = PI*2;
271
272 module ArmEnd(length=armend_length){ ////toplevel
273   if (usedove()) {
274     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
275       rotate([0,0,-90])
276         DoveClipPairBase(h=doveclipheight);
277     }
278   } else {
279     difference(){
280       translate([1, -armendwallthick, -armendbasethick])
281         mirror([1,0,0])
282         cube([nondove_armbase+1, totalwidth, totalheight]);
283       translate([-nondove_armbase + nondove_armhole_x,
284                  -armendwallthick + totalwidth/2,
285                  -armendbasethick -1])
286         cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
287       translate([-nondove_armbase, -armendwallthick, -armendbasethick])
288         rotate([90,0,0])
289         Commitid_BestCount([nondove_armbase, totalwidth]);
290     }
291   }
292
293   difference(){
294     union(){
295       difference(){
296         translate([0, -armendwallthick, -armendbasethick])
297           cube([length, totalwidth, totalheight]);
298         translate([-1, 0, 0])
299           cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
300         translate([-1, 0, ratchettoothheight])
301           cube([length+2, channelwidth, channeldepth+1]);
302       }
303       for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
304         translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
305           rotate([90,0,0])
306             cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
307           multmatrix([  [       1, 0, ratchettoothslope, 0      ],
308                             [   0,      1,      0,      0       ],
309                             [   0,      0,      1,      0       ],
310                             [   0,      0,      0,      1       ]])
311             cube([ratchettooth - ratchettoothsmoothr*2,
312                   channelwidth, ratchettoothheight - ratchettoothsmoothr]);
313         }
314       }
315     }
316
317     for (otherside=[0,1]) {
318       for (circum = [300:100:1500]) {
319         assign(rad = circum / tau)
320           assign(fn = str("filamentspool-number-n",circum,".dxf"))
321           assign(rotateoffset = [0, totalwidth/2, 0])
322           assign(xlen = rad - real_exteffrad) {
323           if (xlen >= numbers_tick_width/2
324               + (otherside ? numbers_height_allow : 0) &&
325               xlen <= length - (otherside ? 0 : numbers_height_allow))
326             translate([xlen, -armendwallthick,
327                        -armendbasethick + (totalheight - numbers_tick_len)/2])
328             translate(rotateoffset)
329             rotate([0,0, otherside*180])
330             translate(-rotateoffset){
331               translate([-numbers_tick_width/2, -1, 0])
332                 cube([numbers_tick_width, numbers_relief+1, numbers_tick_len]);
333               translate([numbers_tick_width/2 + numbers_tick_linespc,
334                          1,
335                          numbers_tick_len])
336                 rotate([90,0,0])
337                 rotate([0,0,-90])
338                 linear_extrude(height= numbers_relief+1)
339                 //    scale(templatescale)
340                 import(file=fn, convexity=100);
341             }
342         }
343       }
344     }
345
346     if (usedove()){
347       translate([0, -armendwallthick, -armendbasethick])
348         Commitid_BestCount_M([length/3, totalwidth]);
349     }
350   }
351 }
352
353 module FilamentCupHandle(){
354   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
355   mirror([0,1,0]) {
356     cube([stalklength, stalkwidth, prongthick]);
357     translate([stalklength, stalkwidth/2, 0])
358       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
359     translate([ratchettoothsmoothr, stalkwidth, 0]) {
360       minkowski(){
361         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
362         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
363                         [       0,      1,      0,      0       ],
364                         [       0,      0,      1,      0       ],
365                         [       0,      0,      0,      1       ]])
366           cube([pawlusewidth,
367                 ratchettoothheight - ratchettoothsmoothr,
368                 prongthick - 1]);
369       }
370     }
371   }
372 }
373
374 module FilamentCupCup(){
375   for (my=[0,1]) mirror([0,my,0]) {
376     translate([0, cupwidth/2, 0])
377       cube([cupheight + prongwidth, prongwidth, prongthick]);
378   }
379 }
380
381 module FilamentCupPositive() {
382   FilamentCupHandle();
383
384   gapy = prongwidth;
385   dy = cupwidth/2 + gapy + overclipcupgap;
386   baselen = dy+cupwidth/2;
387
388   translate([0, dy, 0])
389     FilamentCupCup();
390   cube([prongwidth, baselen+1, prongthick]);
391
392   translate([cupstrong_dx, prongwidth, 0]) {
393     cube([prongwidth, baselen-prongwidth, prongthick]);
394     for (y = [0, .33, .67, 1])
395       translate([0, (baselen - prongwidth) * y, 0])
396         cube([-cupstrong_dx + 1, prongwidth, prongthick]);
397   }
398   if (cupstrong_dx != 0) {
399     rotate([0,0,45])
400       translate([-prongwidth*.55, -prongwidth*2.1, 0])
401       cube([prongwidth*(2.65), prongwidth*4.2, prongthick]);
402   }
403
404   translate([0, -0.2, 0])
405     cube([prongribwidth, baselen, prongthick + prongribheight]);
406
407   if (prongribheight > 0) {
408     translate([-prongwidth, baselen, 0])
409       cube([cupheight/2, prongwidth + prongribheight, prongribwidth]);
410   }
411
412   midrad = cupwidth/2 + prongwidth/2;
413
414   propshift = stalklength - overclipdepth - prongthick + propxshift;
415   proptaken = propshift;
416   echo(midrad, propshift, proptaken);
417
418   translate([propshift, -1, 0]) {
419     // something is wrong with the y calculation
420     cube([prongwidth,
421           gapy+2,
422           prongthick]);
423   }
424   for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
425     translate([cupstrong_dx, y + prongwidth, 0])
426       rotate([0,0, 102 + fdia])
427       FilamentTeeth(fdia=fdia, h=teethh);
428   }
429   for (x = [-0.3, -1.3]) {
430     translate([cupheight + overclipcupnextgap*x, baselen + prongwidth, 0])
431       rotate([0,0, 12 + fdia])
432       FilamentTeeth(fdia=fdia, h=teethh);
433   }      
434 }
435
436 module FilamentCup() { ////toplevel
437   difference(){
438     FilamentCupPositive();
439     translate([0, -stalkwidth, 0])
440       Commitid_BestCount_M([stalklength - stalkwidth, stalkwidth]);
441   }
442 }
443
444 module CupSecuringClipSolid(w,d,h1,h2){
445   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
446     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
447   }
448 }
449
450 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
451   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
452   minkowski(){
453     CupSecuringClipSolid(w=totalwidth,
454                          d=overclipdepth + xdepth,
455                          h1=hbase - overclipsmaller,
456                          h2=hbase + overclipbigger);
457     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
458   }
459 }
460
461 module CupSecuringClip(){ ////toplevel
462   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
463   difference(){
464     union(){
465       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
466       translate([-wingswidth/2, -wingsize/2, 0])
467         cube([wingswidth, wingsize, wingthick]);
468       translate([-wingsize/2, -wingswidth/2, 0])
469         cube([wingsize, wingswidth, wingthick]);
470     }
471     translate([0,0,-0.1])
472       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
473   }
474 }
475
476 module ArmDoveClipPin(){ ////toplevel
477   DoveClipPin(h=doveclipheight);
478 }
479
480 module TowerDoveClipPin(){ ////toplevel
481   DoveClipPin(h=towercliph/2);
482 }
483
484 module Hub(){ ////toplevel
485   axlerad = hubaxlerad + slop;
486   xmin = axlerad+hublwidth/2;
487   xmax = hubbigrad-hublwidth/2;
488   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
489   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
490   nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
491   difference(){
492     union(){
493       difference(){
494         cylinder($fn=60, h=hublthick, r=hubbigrad);
495         translate([0,0,-1])
496           cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
497       }
498       cylinder(h=hubaxlelen, r=axlerad+hublwidth);
499       for (ang=[0 : 360/num_arms : 359])
500         rotate([0,0,ang]) {
501           if (usedove()){
502             difference() {
503               translate([hubeffrad,0,0])
504                 DoveClipPairSane(h=doveclipheight,
505                                  baseextend = hub_clip_baseextend);
506               if (hole>hublwidth && holewidth > 2) {
507                 translate([hubbigrad + hublwidth, -holewidth/2, -1])
508                   cube([hole, holewidth, hublthick+2]);
509               }
510             }
511           } else {
512             difference(){
513               translate([0,
514                          -nondove_allwidth/2,
515                          0])
516                 cube([hubeffrad + nondove_armhole_x
517                       + nondove_armhole_hole/2 + nondove_armhole_support,
518                       nondove_allwidth,
519                       nondove_armhole_wall + totalheight]);
520               translate([hubeffrad - nondove_armhole_slop_x,
521                          -nondove_allwidth/2
522                          + nondove_armhole_wall - nondove_armhole_slop,
523                          nondove_armhole_wall])
524                 cube([nondove_armhole_x + 50,
525                       totalwidth + nondove_armhole_slop*2,
526                       totalheight + 1]);
527               translate([hubeffrad + nondove_armhole_x, 0, -20])
528                 cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
529             }
530           }
531         }
532       for (ang = [0 : 180/num_arms : 359])
533         rotate([0,0,ang]) rotate([90,0,0]) {
534           translate([0,0,-hublwidth/2])
535             linear_extrude(height=hublwidth)
536             polygon([[xmin,0.05], [xmax,0.05],
537                      [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
538         }
539     }
540     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
541
542     rotate([0,0, selsz(0,0,45)])
543       translate([axlerad+hublwidth,
544                  -hublwidth/2,
545                  0])
546       rotate([90,0,0])
547       Commitid_BestCount([(hubbigrad-hublwidth) - (axlerad+hublwidth),
548                           hublthick +
549                           hublwidth/2 * hubaxlelen/(hubbigrad-axlerad),
550                           ]);
551   }
552 }
553
554 module ArmExtender(){ ////toplevel
555   DoveClipExtender(length=exteffrad-hubeffrad,
556                    ha=doveclipheight,
557                    hb=doveclipheight);
558 }
559
560 module FsAxlePin(){ ////toplevel
561   AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
562 }
563
564 module Axle(){ ////toplevel
565   pillarswidth = DoveClipPairSane_width(towerclipcount);
566
567   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
568   translate([-axlehorizoffset, -axlevertheight, 0]) {
569     rotate([0,0,-axletowerfudgebend])
570     rotate([0,0,-90])
571       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
572     translate([0, DoveClip_depth(), 0])
573     rotate([0,0,90])
574       ExtenderPillars(axlevertheight - DoveClip_depth(),
575                       pillarswidth, towercliph,
576                       pillarw=towerpillarw);
577   }
578
579   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
580   axlerad = hubaxlerad-slop;
581   bump = axlerad * 0.2;
582   shift = axlerad-bump;
583   joinbelowallow = 3;
584
585   intersection(){
586     translate([0, 0, shift]) {
587       difference() {
588         union(){
589           translate([-1, 0, 0])
590             rotate([0,90,0])
591             cylinder($fn=60,
592                      r = axlerad,
593                      h = 1 + axleclearlen + axlepinrad*2 + 2);
594           mirror([1,0,0]) rotate([0,90,0])
595             cylinder(r = axlerad*1.75, h = 3);
596           intersection(){
597             mirror([1,0,0])
598               translate([axlehorizoffset - pillarswidth/2, 0, 0])
599               rotate([0,90,0])
600               cylinder($fn=60,
601                        r = towercliph - shift,
602                        h = pillarswidth);
603             translate([-50, -joinbelowallow, -50])
604               cube([100, joinbelowallow+50, 100]);
605           }
606         }
607         rotate([90,0,0])
608         translate([axleclearlen + axlepinrad/2, 0, -25])
609           cylinder(r = axlepinrad + slop, h=50);
610       }
611     }
612     translate([-50,-50,0]) cube([100,100,100]);
613   }
614 }
615
616 module washer(thick){
617   Washer(hubaxlerad, washerrad, thick, slop);
618 }
619
620 module AxleWasher(){ ////toplevel
621   washer(thick=washerthick);
622 }
623
624 module AxleThinWasher(){ ////toplevel
625   washer(thick=washerthinthick);
626 }
627
628 module AxleVeryThinWasher(){ ////toplevel
629   washer(thick=washerverythinthick);
630 }
631
632 module AxleFrictionWasher(){ ////toplevel
633   difference(){
634     cylinder(h=washerthick, r=washerrad);
635     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
636   }
637   frarmr = hubbigrad;
638   frarmw = frictionwasherarmwidth;
639   frarmpawlr = hublwidth;
640   frarmpawlpush = slop*4 + frictionwasherextrapush;
641   for (ang=[0,180]) rotate([0,0,ang]) {
642     translate([washerrad-1, -frarmw/2, 0])
643       cube([frarmr - washerrad + 1, frarmw, washerthick]);
644     intersection(){
645       translate([frarmr - frarmpawlr, -50, 0])
646         cube([frarmpawlr, 100, 50]);
647       rotate([0,90,0])
648         cylinder(h = 50, r = frarmpawlpush, $fn=36);
649     }
650   }
651 }
652
653 module TowerExtender(){ ////toplevel
654   l = totalheightfromtower - axlevertheight;
655   echo("TowerExtender",l);
656   DoveClipExtender(length = l,
657                    ha = towercliph, hb = towercliph,
658                    counta = towerclipcount, countb = towerclipcount,
659                    pillarw = towerpillarw);
660 }
661
662 module FilamentCupPair(){ ////toplevel
663   FilamentCup();
664   translate([cupheight + prongthick*3,
665              cupwidth/2*1.7,
666              0])
667     rotate([0,0,180]) FilamentCup();
668 }
669
670 //----- storarm -----
671
672 storarm_hooklen = 8;
673 storarm_hookheight = 5;
674 storarm_thick = 10;
675 storarm_axleslop = 4;
676
677 storarm_base_w = 30;
678 storarm_base_h = 100;
679 storarm_base_d = 15;
680 storarm_base_mind = 2;
681
682 storarm_cope_hubaxle_mk1 = true;
683
684 storarm_screw_hole = 4;
685 storarm_screw_hole_slop = 0.5;
686 storarm_besides_hole = 4;
687
688 storarm_under_hole = 5;
689 storarm_screw_hole_head = 8.8;
690 storarm_screw_hole_head_slop = 1.5;
691
692 // calculated
693
694 storarm_axlerad = hubaxlerad - storarm_axleslop;
695 storarm_mainlen = hubaxlelen*2 + storarm_axleslop
696   + (storarm_cope_hubaxle_mk1 ? 10 : 0);
697 storarm_totlen = storarm_mainlen + storarm_hooklen;
698
699 storarm_mid_off_y = storarm_axlerad;
700
701 storarm_base_off_y = storarm_mid_off_y + storarm_base_h/2;
702
703 module StorageArmDiagPartSide(xmin, xmax){
704   xsz = xmax-xmin;
705   yuse = storarm_thick/2;
706
707   intersection(){
708     translate([xmin-1, -storarm_axlerad, storarm_thick/2])
709       rotate([0,90,0])
710       cylinder(r=storarm_axlerad, h=xsz+2, $fn=60);
711     translate([xmin, -yuse, 0])
712       cube([xsz, yuse, storarm_thick]);
713   }
714 }
715
716 module StorageArmDiagPart(xmin, xmax, shear, adjbot){
717   hull(){
718     StorageArmDiagPartSide(xmin,xmax);
719
720     multmatrix([[1,0,0,0],
721                 [shear,1,0,0],
722                 [0,0,1,0],
723                 [0,0,0,1]])
724       translate([0, -storarm_axlerad*2 + adjbot, 0])
725       mirror([0,1,0])
726       StorageArmDiagPartSide(xmin,xmax);
727   }
728 }
729
730 module StorageArmBaseTemplate(){
731   square([storarm_base_w, storarm_base_h]);
732 }
733
734 module StorageArmAtMountingHoles(){
735   bes = storarm_besides_hole + storarm_screw_hole;
736
737   x0 = bes;
738   x1 = storarm_base_w-bes;
739   y1 = storarm_base_h - bes;
740   y0 = bes;
741
742   for (pos=[ [x0, y1],
743              [x1, y1],
744              [x1, y0] ]) {
745     rotate([0,90,0])
746       translate([pos[0] - storarm_base_w,
747                  pos[1] - storarm_base_off_y, -storarm_base_d])
748       children();
749   }
750 }
751
752 module StorageArmRight(){ ////toplevel
753   shear = storarm_hookheight / (storarm_mainlen/2);
754
755   StorageArmDiagPart(-1, storarm_mainlen/2+1, shear, 0);
756   StorageArmDiagPart(storarm_mainlen/2-1, storarm_mainlen+1, shear/2,
757                      storarm_hookheight/2);
758
759   translate([0, storarm_hookheight, 0])
760     StorageArmDiagPart(storarm_mainlen, storarm_totlen,
761                        shear/2, -storarm_hookheight/2);
762
763   difference(){
764     union(){
765       hull(){
766         translate([-storarm_base_d, -storarm_base_off_y, storarm_base_w])
767           rotate([0,90,0])
768           linear_extrude(height=storarm_base_mind)
769           StorageArmBaseTemplate();
770         StorageArmDiagPart(-1, 0, shear, 0);
771       }
772       StorageArmAtMountingHoles(){
773         cylinder(r= storarm_screw_hole_head/2,
774                  h=10);
775       }
776     }
777     StorageArmAtMountingHoles(){
778       translate([0,0,-1])
779         cylinder(r= (storarm_screw_hole + storarm_screw_hole_slop)/2 ,
780                  h=20);
781       translate([0,0,storarm_under_hole])
782         cylinder(r= (storarm_screw_hole_head + storarm_screw_hole_head_slop)/2,
783                  h=20);
784     }
785   }
786 }
787
788 module StorageArmLeft(){ ////toplevel
789   mirror([1,0,0]) StorageArmRight();
790 }
791
792 module StorArmHoleTest(){ ////toplevel
793   sz = storarm_screw_hole_head + storarm_besides_hole*2;
794   intersection(){
795     StorageArmRight();
796     translate([-50, -storarm_base_off_y, -1])
797       cube([100, sz, sz+1]);
798   }
799 }
800
801
802 //----- filament guide spacer -----
803
804 guide_armdia = 15.0;
805 guide_armwidth = 10.2;
806 guide_armcorelen = 25.0;
807 guide_clipcirclethick = 10.0;
808
809 guidefilclip_outerdia = 22.8;
810
811 guidespacer_armslop = 0.75;
812 guidespacer_armlenslop = 1.05;
813
814 guidespacer_prongprotrude = 4;
815 guidespacer_thick = 1.6;
816
817 // calculated
818
819 guidespacer_armdia = guide_armdia + guidespacer_armslop;
820 guidespacer_armwidth = guide_armwidth + guidespacer_armslop;
821 guidespacer_len = guide_armcorelen - guide_clipcirclethick
822   + guidespacer_armlenslop;
823
824 guidespacer_wingheight = (guidefilclip_outerdia - guidespacer_armdia)/2;
825
826 module FilamentGuideArmTemplate(extra=0){
827   intersection(){
828     circle(r= (guidespacer_armdia/2) + extra);
829     square(center=true, [guidespacer_armwidth+extra*2,
830                          guidespacer_armdia + extra*2 + 10]);
831   }
832 }
833
834 module FilamentGuideSpacerInnerTemplate(){
835   FilamentGuideArmTemplate();
836   translate([0, -guidespacer_armdia/2])
837     square(center=true, [guidespacer_armwidth - guidespacer_prongprotrude,
838                          guidespacer_armdia]);
839 }
840
841 module FilamentGuideSpacer(){ ////toplevel
842   difference(){
843     union(){
844       linear_extrude(height= guidespacer_len)
845         FilamentGuideArmTemplate(extra= guidespacer_thick);
846       for (angle=[26, 60]) {
847         for (m=[0,1]) {
848           mirror([m,0,0]) {
849             rotate([0,0,angle]) {
850               hull(){
851                 for (t=[[0, guidespacer_wingheight],
852                         [guidespacer_len-1, -guidespacer_wingheight]])
853                   translate([0,0, t[0] + 0.5])
854                     cube([guidespacer_thick, guidespacer_armdia + t[1]*2,
855                       1],
856                          center=true);
857               }
858             }
859           }
860         }
861       }
862     }
863     translate([0,0,-1])
864       linear_extrude(height= guidespacer_len+5)
865       FilamentGuideSpacerInnerTemplate();
866   }
867 }
868
869
870 //----- replacement filament guide arm for TAZ-5 -----
871
872 guidearm_armslop = 0.25;
873 guidearm_armlenslop = 0.25;
874
875 guidearm_hookprotr = 3;
876 guidearm_hookprotrflat = 1;
877 guidearm_hookslope = 0.3;
878
879 guidearm_totallen = 60;
880
881 guidearm_screwplatesz = 12;
882 guidearm_screwplateth = 4;
883 guidearm_screwplatewd = 15;
884 guidearm_screwhole = 5 + 0.5;
885
886 guidearm_bendlen = 40;
887 guidearm_bendslot = 4.5;
888
889 guidearm_stopthick = 4;
890 guidearm_protrslop = 1.0;
891
892 // calculated
893
894 guidearm_armdia = guide_armdia - guidearm_armslop;
895 guidearm_armwidth = guide_armwidth - guidearm_armslop;
896 guidearm_armcorelen = guide_armcorelen + guidearm_armlenslop;
897
898 guidearm_base_z0 = -(guidearm_totallen - guidearm_armcorelen);
899
900 guidearm_realbendlen = min(guidearm_bendlen,
901                            guidearm_totallen - guidearm_screwplateth - 0.1);
902 guidearm_slopelen = guidearm_hookprotr/guidearm_hookslope;
903
904 module FilamentGuideArmStop(h){
905   for (ts=[-1,+1]) {
906     translate([ts * guidearm_hookprotr, 0,0])
907       cylinder(r=guidearm_armdia/2, h, $fn=80);
908   }
909 }
910
911 module FilamentGuideArmShaftPositive(){
912   r = guidearm_armdia/2;
913
914   translate([0,0, guidearm_base_z0+1])
915     cylinder(r=r, h= guidearm_totallen, $fn=80);
916   translate([0,0, guidearm_armcorelen]){
917     hull(){
918       FilamentGuideArmStop(guidearm_hookprotrflat);
919       translate([0,0, guidearm_slopelen])
920         cylinder(r=r, h=guidearm_hookprotrflat, $fn=80);
921     }
922   }
923   mirror([0,0,1])
924     FilamentGuideArmStop(guidearm_stopthick);
925 }
926
927 module FilamentGuideArmBase(){
928   translate([0,
929              (guidearm_screwplatewd - guidearm_armwidth)/2,
930              guidearm_base_z0]){
931     difference(){
932       translate([0,0, guidearm_screwplateth/2])
933         cube(center=true,
934              [guidearm_armdia + guidearm_screwplatesz*2,
935               guidearm_screwplatewd,
936               guidearm_screwplateth]);
937       for (ts=[-1,+1]) {
938         translate([ts * (guidearm_armdia/2 + guidearm_screwplatesz/2),
939                    0,
940                    -20])
941           cylinder(r= guidearm_screwhole/2, h=40, $fn=20);
942       }
943     }
944   }
945 }
946
947 module FilamentGuideArm(){ ///toplevel
948   intersection(){
949     difference(){
950       FilamentGuideArmShaftPositive();
951       translate([-guidearm_bendslot/2,
952                  -50,
953                  -guidearm_realbendlen + guidearm_armcorelen])
954         cube([guidearm_bendslot,
955               100,
956               guidearm_realbendlen + 100]);
957       hull(){
958         for (zx=[ [ 0, guidearm_bendslot ],
959                   [ guidearm_armcorelen + guidearm_slopelen,
960                     guidearm_hookprotr*2 + guidearm_protrslop ]
961                   ]) {
962           translate([-zx[1]/2, -50, zx[0]])
963           cube([zx[1], 100, 1]);
964         }
965       }
966     }
967     cube(center=true,
968          [guidearm_armdia*2,
969           guidearm_armwidth,
970           guidearm_totallen*3]);
971   }
972   FilamentGuideArmBase();
973 }
974
975 module FilamentGuideArmPrint(){ ////toplevel
976   rotate([90,0,0])
977     FilamentGuideArm();
978 }
979
980 module Demo(){ ////toplevel
981   translate([-real_exteffrad,-20,0]) Hub();
982   ArmEnd();
983   translate([ratchettooth*2, 30, 0]) FilamentCup();
984   if (selsz(true,false,false)) {
985     translate([-exteffrad + hubeffrad - hub_clip_baseextend, -10, 0])
986       ArmExtender();
987   }
988 }
989
990 //ArmEnd();
991 //FilamentCup();
992 //FilamentCupPair();
993 //CupSecuringClip();
994 //Hub();
995 //ArmExtender();
996 //Axle();
997 //AxleWasher();
998 //AxlePin();
999 //AxleFrictionWasher();
1000 //StorageArmLeft();
1001 //StorArmHoleTest();
1002 //FilamentGuideSpacer();
1003 //FilamentGuideArm();
1004 //FilamentGuideArmPrint();
1005 //Demo();