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