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 cupstrong_dx=selsz(0,-10);
  37
  38 propxshift = 0;
  39
  40 doveclipheight = 10;
  41
  42 teethh=3;
  43 teethgapx=4+fdia;
  44
  45 prongstalkxwidth=3;
  46
  47 stalklength=selsz(35,55);
  48 overclipcupgap=5;
  49 overclipdepth=15;
  50 overcliproundr=2.0;
  51 overclipthick=1.0;
  52 overclipcupnextgap=20;
  53
  54 hubaxlelen = selsz(25, cupwidth);
  55
  56 overclipsmaller=-2.5;
  57 overclipbigger=0.0;
  58
  59 wingspoke=3;
  60 wingsize=6;
  61 wingthick=3;
  62
  63 armendwallthick=2.5;
  64 armendbasethick=1.2;
  65
  66 axlehorizoffset = 12.5;
  67 axlevertheight = 100;
  68 towercliph = 16;
  69 towerclipcount = 3;
  70 towerpillarw = 5;
  71
  72 axlepinrad = 2;
  73 axlepintabrad = 5;
  74
  75 washerthick = 1.2;
  76 washerthinthick = 0.8;
  77 washerverythinthick = 0.4;
  78 washerrad = hubaxlerad + 7.5;
  79 frictionwasherarmwidth = 3;
  80 frictionwasherextrapush = 1.0;
  81
  82 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  83
  84 nondove_armbase = 100;
  85 nondove_armhole_x = 60;
  86 nondove_armhole_hole = 4;
  87 nondove_armhole_support = 7;
  88 nondove_armhole_wall = 4;
  89 nondove_armhole_slop = 0.5;
  90 nondove_armhole_slop_x = 0.5;
  91
  92 include <doveclip.scad>
  93 include <cliphook.scad>
  94 include <filamentteeth.scad>
  95 include <axlepin.scad>
  96
  97 channelwidth = prongthick + slop;
  98 channeldepth = prongwidth + ratchettoothheight;
  99 totalwidth = armendwallthick*2 + channelwidth;
 100 totalheight = channeldepth + armendbasethick;
 101 stalkwidth = prongwidth + prongstalkxwidth;
 102
 103 module ArmEnd(length=120){ ////toplevel
 104   if (usedove()) {
 105     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
 106       rotate([0,0,-90])
 107         DoveClipPairBase(h=doveclipheight);
 108     }
 109   } else {
 110     difference(){
 111       translate([1, -armendwallthick, -armendbasethick])
 112         mirror([1,0,0])
 113         cube([nondove_armbase+1, totalwidth, totalheight]);
 114       translate([-nondove_armbase + nondove_armhole_x,
 115                  -armendwallthick + totalwidth/2,
 116                  -armendbasethick -1])
 117         cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
 118     }
 119   }
 120
 121   difference(){
 122     translate([0, -armendwallthick, -armendbasethick])
 123       cube([length, totalwidth, totalheight]);
 124     translate([-1, 0, 0])
 125       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
 126     translate([-1, 0, ratchettoothheight])
 127       cube([length+2, channelwidth, channeldepth+1]);
 128   }
 129   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
 130     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
 131       rotate([90,0,0])
 132         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
 133       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
 134                         [       0,      1,      0,      0       ],
 135                         [       0,      0,      1,      0       ],
 136                         [       0,      0,      0,      1       ]])
 137         cube([ratchettooth - ratchettoothsmoothr*2,
 138               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 139     }
 140   }
 141 }
 142
 143 module FilamentCupHandle(){
 144   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 145   mirror([0,1,0]) {
 146     cube([stalklength, stalkwidth, prongthick]);
 147     translate([stalklength, stalkwidth/2, 0])
 148       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 149     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 150       minkowski(){
 151         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 152         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 153                         [       0,      1,      0,      0       ],
 154                         [       0,      0,      1,      0       ],
 155                         [       0,      0,      0,      1       ]])
 156           cube([pawlusewidth,
 157                 ratchettoothheight - ratchettoothsmoothr,
 158                 prongthick - 1]);
 159       }
 160     }
 161   }
 162 }
 163
 164 module FilamentCupCup(){
 165   for (my=[0,1]) mirror([0,my,0]) {
 166     translate([0, cupwidth/2, 0])
 167       cube([cupheight + prongwidth, prongwidth, prongthick]);
 168   }
 169 }
 170
 171 module FilamentCup() { ////toplevel
 172   FilamentCupHandle();
 173
 174   gapy = prongwidth;
 175   dy = cupwidth/2 + gapy + overclipcupgap;
 176   baselen = dy+cupwidth/2;
 177
 178   translate([0, dy, 0])
 179     FilamentCupCup();
 180   cube([prongwidth, baselen+1, prongthick]);
 181
 182   translate([cupstrong_dx, prongwidth, 0]) {
 183     cube([prongwidth, baselen-prongwidth, prongthick]);
 184     for (y = [0, .4, .7, 1])
 185       translate([0, (baselen - prongwidth*2) * y, 0])
 186         cube([-cupstrong_dx + 1, prongwidth, prongthick]);
 187   }
 188   if (cupstrong_dx != 0) {
 189     rotate([0,0,45])
 190       translate([-prongwidth*.55, -prongwidth*2.1, 0])
 191       cube([prongwidth*(2.65), prongwidth*4.2, prongthick]);
 192   }
 193
 194   midrad = cupwidth/2 + prongwidth/2;
 195
 196   propshift = stalklength - overclipdepth - prongthick + propxshift;
 197   proptaken = propshift;
 198   echo(midrad, propshift, proptaken);
 199
 200   translate([propshift, -1, 0]) {
 201     // something is wrong with the y calculation
 202     cube([prongwidth,
 203           gapy+2,
 204           prongthick]);
 205   }
 206   for (y = [overclipcupgap, overclipcupgap+overclipcupnextgap]) {
 207     translate([cupstrong_dx, y + prongwidth, 0])
 208       rotate([0,0, 102 + fdia])
 209       FilamentTeeth(fdia=fdia, h=teethh);
 210   }
 211   for (x = [-0.3, -1.3]) {
 212     translate([cupheight + overclipcupnextgap*x, baselen + prongthick, 0])
 213       rotate([0,0, 12 + fdia])
 214       FilamentTeeth(fdia=fdia, h=teethh);
 215   }
 216 }
 217
 218 module CupSecuringClipSolid(w,d,h1,h2){
 219   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 220     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 221   }
 222 }
 223
 224 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 225   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 226   minkowski(){
 227     CupSecuringClipSolid(w=totalwidth,
 228                          d=overclipdepth + xdepth,
 229                          h1=hbase - overclipsmaller,
 230                          h2=hbase + overclipbigger);
 231     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 232   }
 233 }
 234
 235 module CupSecuringClip(){ ////toplevel
 236   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 237   difference(){
 238     union(){
 239       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 240       translate([-wingswidth/2, -wingsize/2, 0])
 241         cube([wingswidth, wingsize, wingthick]);
 242       translate([-wingsize/2, -wingswidth/2, 0])
 243         cube([wingsize, wingswidth, wingthick]);
 244     }
 245     translate([0,0,-0.1])
 246       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 247   }
 248 }
 249
 250 module ArmDoveClipPin(){ ////toplevel
 251   DoveClipPin(h=doveclipheight);
 252 }
 253
 254 module TowerDoveClipPin(){ ////toplevel
 255   DoveClipPin(h=towercliph/2);
 256 }
 257
 258 module Hub(){ ////toplevel
 259   axlerad = hubaxlerad + slop;
 260   xmin = axlerad+hublwidth/2;
 261   xmax = hubbigrad-hublwidth/2;
 262   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 263   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 264   nondove_allwidth = nondove_armhole_wall*2 + totalwidth;
 265   difference(){
 266     union(){
 267       difference(){
 268         cylinder($fn=60, h=hublthick, r=hubbigrad);
 269         translate([0,0,-1])
 270           cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 271       }
 272       cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 273       for (ang=[0 : 360/num_arms : 359])
 274         rotate([0,0,ang]) {
 275           difference() {
 276             if (usedove()){
 277               translate([hubeffrad,0,0])
 278                 DoveClipPairSane(h=doveclipheight,
 279                                  baseextend = (hubeffrad - DoveClip_depth()
 280                                                - hubbigrad + hublwidth));
 281               if (hole>hublwidth && holewidth > 2) {
 282                 translate([hubbigrad + hublwidth, -holewidth/2, -1])
 283                   cube([hole, holewidth, hublthick+2]);
 284               }
 285             } else {
 286               difference(){
 287                 translate([0,
 288                            -nondove_allwidth/2,
 289                            0])
 290                   cube([hubeffrad + nondove_armhole_x
 291                         + nondove_armhole_hole/2 + nondove_armhole_support,
 292                         nondove_allwidth,
 293                         nondove_armhole_wall + totalheight]);
 294                 translate([hubeffrad - nondove_armhole_slop_x,
 295                            -nondove_allwidth/2
 296                            + nondove_armhole_wall - nondove_armhole_slop,
 297                            nondove_armhole_wall])
 298                   cube([nondove_armhole_x + 50,
 299                         totalwidth + nondove_armhole_slop*2,
 300                         totalheight + 1]);
 301                 translate([hubeffrad + nondove_armhole_x, 0, -20])
 302                    cylinder(r= nondove_armhole_hole/2, h=50, $fn=10);
 303               }
 304             }
 305           }
 306         }
 307       for (ang = [0 : 180/num_arms : 359])
 308         rotate([0,0,ang]) rotate([90,0,0]) {
 309           translate([0,0,-hublwidth/2])
 310             linear_extrude(height=hublwidth)
 311             polygon([[xmin,0.05], [xmax,0.05],
 312                      [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 313         }
 314     }
 315     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 316   }
 317 }
 318
 319 module ArmExtender(){ ////toplevel
 320   DoveClipExtender(length=exteffrad-hubeffrad,
 321                    ha=doveclipheight,
 322                    hb=doveclipheight);
 323 }
 324
 325 module FsAxlePin(){ ////toplevel
 326   AxlePin(hubaxlerad, washerrad*2, axlepinrad, axlepintabrad, slop);
 327 }
 328
 329 module Axle(){ ////toplevel
 330   pillarswidth = DoveClipPairSane_width(towerclipcount);
 331
 332   rotate([0,0, -( axleaxlefudgebend + atan(slop/hubaxlelen) ) ])
 333   translate([-axlehorizoffset, -axlevertheight, 0]) {
 334     rotate([0,0,-axletowerfudgebend])
 335     rotate([0,0,-90])
 336       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 337     translate([0, DoveClip_depth(), 0])
 338     rotate([0,0,90])
 339       ExtenderPillars(axlevertheight - DoveClip_depth(),
 340                       pillarswidth, towercliph,
 341                       pillarw=towerpillarw);
 342   }
 343
 344   axleclearlen = hubaxlelen + slop*4 + washerthick*2 + axlepadlen;
 345   axlerad = hubaxlerad-slop;
 346   bump = axlerad * 0.2;
 347   shift = axlerad-bump;
 348   joinbelowallow = 3;
 349
 350   intersection(){
 351     translate([0, 0, shift]) {
 352       difference() {
 353         union(){
 354           translate([-1, 0, 0])
 355             rotate([0,90,0])
 356             cylinder($fn=60,
 357                      r = axlerad,
 358                      h = 1 + axleclearlen + axlepinrad*2 + 2);
 359           mirror([1,0,0]) rotate([0,90,0])
 360             cylinder(r = axlerad*1.75, h = 3);
 361           intersection(){
 362             mirror([1,0,0])
 363               translate([axlehorizoffset - pillarswidth/2, 0, 0])
 364               rotate([0,90,0])
 365               cylinder($fn=60,
 366                        r = towercliph - shift,
 367                        h = pillarswidth);
 368             translate([-50, -joinbelowallow, -50])
 369               cube([100, joinbelowallow+50, 100]);
 370           }
 371         }
 372         rotate([90,0,0])
 373         translate([axleclearlen + axlepinrad/2, 0, -25])
 374           cylinder(r = axlepinrad + slop, h=50);
 375       }
 376     }
 377     translate([-50,-50,0]) cube([100,100,100]);
 378   }
 379 }
 380
 381 module washer(thick){
 382   Washer(hubaxlerad, washerrad, thick, slop);
 383 }
 384
 385 module AxleWasher(){ ////toplevel
 386   washer(thick=washerthick);
 387 }
 388
 389 module AxleThinWasher(){ ////toplevel
 390   washer(thick=washerthinthick);
 391 }
 392
 393 module AxleVeryThinWasher(){ ////toplevel
 394   washer(thick=washerverythinthick);
 395 }
 396
 397 module AxleFrictionWasher(){ ////toplevel
 398   difference(){
 399     cylinder(h=washerthick, r=washerrad);
 400     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 401   }
 402   frarmr = hubbigrad;
 403   frarmw = frictionwasherarmwidth;
 404   frarmpawlr = hublwidth;
 405   frarmpawlpush = slop*4 + frictionwasherextrapush;
 406   for (ang=[0,180]) rotate([0,0,ang]) {
 407     translate([washerrad-1, -frarmw/2, 0])
 408       cube([frarmr - washerrad + 1, frarmw, washerthick]);
 409     intersection(){
 410       translate([frarmr - frarmpawlr, -50, 0])
 411         cube([frarmpawlr, 100, 50]);
 412       rotate([0,90,0])
 413         cylinder(h = 50, r = frarmpawlpush, $fn=36);
 414     }
 415   }
 416 }
 417
 418 module TowerExtender(){ ////toplevel
 419   l = totalheightfromtower - axlevertheight;
 420   echo("TowerExtender",l);
 421   DoveClipExtender(length = l,
 422                    ha = towercliph, hb = towercliph,
 423                    counta = towerclipcount, countb = towerclipcount,
 424                    pillarw = towerpillarw);
 425 }
 426
 427 module FilamentCupPair(){ ////toplevel
 428   FilamentCup();
 429   translate([cupheight + prongthick*3,
 430              cupwidth/2*1.7,
 431              0])
 432     rotate([0,0,180]) FilamentCup();
 433 }
 434
 435 //ArmEnd();
 436 FilamentCup();
 437 //FilamentCupPair();
 438 //CupSecuringClip();
 439 //Hub();
 440 //ArmExtender();
 441 //Axle();
 442 //AxleWasher();
 443 //AxlePin();
 444 //AxleFrictionWasher();