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