chiark / gitweb /
bike-lipo-box: adjustments from #1306: overall thinner
[reprap-play.git] / filamentspool.scad
index 50f00a6..fe29eea 100644 (file)
 //
 // This file (and its includes) can generate:
 //
-//   - Heavy duty 4-armed spool suitable for holding a 100m
-//     Faberdashery coil on the spool arm of a Lulzbot TAZ-5.
+// ===== Heavy duty 4-armed spool for 3mm x 100m coil =====
+//
+// A heavy duty 4-armed spool suitable for holding a 100m
+// Faberdashery coil on the spool arm of a Lulzbot TAZ-5.
 //
 //     Set
 //           fdia=2.85
 //
 //     You will also need  4 x M4 machine screws and nuts.
 //
-//   - Light duty 3-armed spool suitable for up to around 30m
-//     of Faberdashery 2.85mm PLA.
+//     This is the default.
+//
+// ===== Light duty 3-armed spool for 3mm x <=30m coil =====
+//
+// A light duty 3-armed spool suitable for up to around 30m
+// of Faberdashery 2.85mm PLA.
 //
 //     Set
 //           fdia=2.85
 //           lightduty=true
+//     (or look in filamentspool-lt.scad).
+//
 //     And print following parts
 //           Hub
 //           ArmEnd x 3
@@ -64,6 +72,8 @@
 //     (note that the light duty and heavy duty CupSecuringClips
 //      are slightly different)
 //
+// ===== Notes regarding both the above spools =====
+//
 // When mounting either spool on the TAZ-5 spool arm, put the `pointy'
 // end of the hub towards the printer - ie, put put the spool on
 // `backwards'.  This ensures that the spool's arms will clear the
 //
 // For the above, I generally used the Cura `Standard' PLA profile.
 //
-//   - Storage arm suitable for screwing to walls, bookshelves,
-//     etc. (requires non-countersunk M4 screws); will hold two
-//     heavy duty spools each with a 100m coil.
+// ===== TAZ-5 feed tube adjustment kit =====
+//
+// With a TAZ-5 I recommend using this kit to improve the feed
+// reliability:
+//
+//       Set
+//           fdia=2.85
+//     And print following parts
+//           FilamentGuideSpacer (ideally, at `high detail')
+//           FilamentGuideArmPrint (optional; `high detail' or `standard')
+//
+//     And possibly also
+//           t-nut_jig_0.2.stl
+//     from Aleph Objects - look here:
+//           http://download.lulzbot.com/TAZ/accessories/tool_heads/version_2/Dual_Extruder_v2/production_parts/stl/
+//
+// The spacer clips onto the filament guide tube holder arm, on the
+// inside, with the pointy flanged end towards the filament guide
+// tube.  It stops the filament guide tube angle (and so the
+// filament's natural pickup location) changing as the print head moves.
+//
+// The FilamentGuideArm[Print] is a replacement for the arm supplied
+// with your TAZ-5.  It's longer, so that the filament pickup point is
+// closer to the middle of the coil.  Use the t-nut_jig to stop the
+// T-nuts in the aluminium channel from annoyingly sliding down to the
+// bottom while you swap out the arm.
+//
+// (Faberdashery coils, and therefore both the above spools, have a
+// larger diameter than the flat-walled spools often supplied by other
+// vendors.  And the spools above have individual arms rather than a
+// continuous disc.  If the filament `unhooks' from the arm, it can
+// pull taught around the hub and stop feeding properly.)
+//
+// ===== Spool storage arm, for mounting on walls =====
+//
+// A storage arm suitable for screwing to walls, bookshelves,
+// etc. (requires non-countersunk M4 screws); will hold two heavy duty
+// spools each with a 100m coil.
 //
 //     Set
 //           fdia=2.85
 //           lightduty=false
+//     (or look in filamentspool-sm.scad).
+//
 //     And print one of these, according to taste
 //            StorageArmLeft
 //            StorageArmRight
 // For the above, I used the Cura `High detail' PLA profile because
 // I wanted it pretty, but the `Standard' profile should do fine.
 //
-//   - Spool (in many parts) for handing 1.75mm filament, printable
-//     on, and with parts for mounting on, a Reprappro Huxley.
+// ===== Spools for 1.75mm filament =====
+//
+// Spool (in many parts) for handing 1.75mm filament, printable
+// on, and with parts for mounting on, a Reprappro Huxley.
 
 
 fdia=2.85; // or 1.75
@@ -109,7 +158,7 @@ channelslop=selsz(slop,0.75,slop);
 exteffrad = 70;
 hubeffrad = selsz(30, 82, 40);
 hubbigrad = selsz(20, 38, 38);
-hublwidth = selsz(3, 2.5, 4);
+hublwidth = selsz(3, 2.5, 3.0);
 hubstemwidth = 2;
 hublthick = 10;
 hubaxlerad = selsz(5, 28/2, 28/2);
@@ -164,6 +213,12 @@ wingthick=3;
 armendwallthick=selsz(2.5, 1.8, 2.5);
 armendbasethick=selsz(1.2, 1.2, 1.2);
 
+numbers_relief = 0.7;
+numbers_tick_len = 8;
+numbers_tick_width = 0.75;
+numbers_tick_linespc = 1.0;
+numbers_height_allow = 8;
+
 axlehorizoffset = 12.5;
 axlevertheight = 100;
 towercliph = 16;
@@ -197,6 +252,14 @@ include <doveclip.scad>
 include <cliphook.scad>
 include <filamentteeth.scad>
 include <axlepin.scad>
+include <commitid.scad>
+
+hub_clip_baseextend = (hubeffrad - DoveClip_depth()
+                      - hubbigrad + hublwidth);
+
+real_exteffrad = selsz(exteffrad + hub_clip_baseextend,
+                      hubeffrad + DoveClip_depth(),
+                      hubeffrad + nondove_armbase);
 
 channelwidth = prongthick + channelslop;
 channeldepth = prongwidth + ratchettoothheight;
@@ -204,6 +267,8 @@ totalwidth = armendwallthick*2 + channelwidth;
 totalheight = channeldepth + armendbasethick;
 stalkwidth = prongwidth + prongstalkxwidth;
 
+tau = PI*2;
+
 module ArmEnd(length=armend_length){ ////toplevel
   if (usedove()) {
     translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
@@ -219,27 +284,68 @@ module ArmEnd(length=armend_length){ ////toplevel
                 -armendwallthick + totalwidth/2,
                 -armendbasethick -1])
        cylinder(r= nondove_armhole_hole/2, h=totalheight+2, $fn=10);
+      translate([-nondove_armbase, -armendwallthick, -armendbasethick])
+        rotate([90,0,0])
+       Commitid_BestCount([nondove_armbase, totalwidth]);
     }
   }
 
   difference(){
-    translate([0, -armendwallthick, -armendbasethick])
-      cube([length, totalwidth, totalheight]);
-    translate([-1, 0, 0])
-      cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
-    translate([-1, 0, ratchettoothheight])
-      cube([length+2, channelwidth, channeldepth+1]);
-  }
-  for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
-    translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
-      rotate([90,0,0])
-       cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
-      multmatrix([     [       1, 0, ratchettoothslope, 0      ],
-                       [       0,      1,      0,      0       ],
-                       [       0,      0,      1,      0       ],
-                       [       0,      0,      0,      1       ]])
-       cube([ratchettooth - ratchettoothsmoothr*2,
-             channelwidth, ratchettoothheight - ratchettoothsmoothr]);
+    union(){
+      difference(){
+       translate([0, -armendwallthick, -armendbasethick])
+         cube([length, totalwidth, totalheight]);
+       translate([-1, 0, 0])
+         cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
+       translate([-1, 0, ratchettoothheight])
+         cube([length+2, channelwidth, channeldepth+1]);
+      }
+      for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
+       translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
+         rotate([90,0,0])
+           cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
+         multmatrix([  [       1, 0, ratchettoothslope, 0      ],
+                           [   0,      1,      0,      0       ],
+                           [   0,      0,      1,      0       ],
+                           [   0,      0,      0,      1       ]])
+           cube([ratchettooth - ratchettoothsmoothr*2,
+                 channelwidth, ratchettoothheight - ratchettoothsmoothr]);
+       }
+      }
+    }
+
+    for (otherside=[0,1]) {
+      for (circum = [300:100:1500]) {
+       assign(rad = circum / tau)
+         assign(fn = str("filamentspool-number-n",circum,".dxf"))
+         assign(rotateoffset = [0, totalwidth/2, 0])
+         assign(xlen = rad - real_exteffrad) {
+         if (xlen >= numbers_tick_width/2
+             + (otherside ? numbers_height_allow : 0) &&
+             xlen <= length - (otherside ? 0 : numbers_height_allow))
+           translate([xlen, -armendwallthick,
+                      -armendbasethick + (totalheight - numbers_tick_len)/2])
+           translate(rotateoffset)
+           rotate([0,0, otherside*180])
+           translate(-rotateoffset){
+             translate([-numbers_tick_width/2, -1, 0])
+               cube([numbers_tick_width, numbers_relief+1, numbers_tick_len]);
+             translate([numbers_tick_width/2 + numbers_tick_linespc,
+                        1,
+                        numbers_tick_len])
+               rotate([90,0,0])
+               rotate([0,0,-90])
+               linear_extrude(height= numbers_relief+1)
+               //    scale(templatescale)
+               import(file=fn, convexity=100);
+           }
+       }
+      }
+    }
+
+    if (usedove()){
+      translate([0, -armendwallthick, -armendbasethick])
+       Commitid_BestCount_M([length/3, totalwidth]);
     }
   }
 }
@@ -272,7 +378,7 @@ module FilamentCupCup(){
   }
 }
 
-module FilamentCup() { ////toplevel
+module FilamentCupPositive() {
   FilamentCupHandle();
 
   gapy = prongwidth;
@@ -327,6 +433,14 @@ module FilamentCup() { ////toplevel
   }      
 }
 
+module FilamentCup() { ////toplevel
+  difference(){
+    FilamentCupPositive();
+    translate([0, -stalkwidth, 0])
+      Commitid_BestCount_M([stalklength - stalkwidth, stalkwidth]);
+  }
+}
+
 module CupSecuringClipSolid(w,d,h1,h2){
   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
@@ -388,8 +502,7 @@ module Hub(){ ////toplevel
            difference() {
              translate([hubeffrad,0,0])
                DoveClipPairSane(h=doveclipheight,
-                                baseextend = (hubeffrad - DoveClip_depth()
-                                              - hubbigrad + hublwidth));
+                                baseextend = hub_clip_baseextend);
              if (hole>hublwidth && holewidth > 2) {
                translate([hubbigrad + hublwidth, -holewidth/2, -1])
                  cube([hole, holewidth, hublthick+2]);
@@ -425,6 +538,16 @@ module Hub(){ ////toplevel
        }
     }
     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
+
+    rotate([0,0, selsz(0,0,45)])
+      translate([axlerad+hublwidth,
+                -hublwidth/2,
+                0])
+      rotate([90,0,0])
+      Commitid_BestCount([(hubbigrad-hublwidth) - (axlerad+hublwidth),
+                         hublthick +
+                         hublwidth/2 * hubaxlelen/(hubbigrad-axlerad),
+                         ]);
   }
 }
 
@@ -680,12 +803,13 @@ module StorArmHoleTest(){ ////toplevel
 
 guide_armdia = 15.0;
 guide_armwidth = 10.2;
-guide_armcorelen = 15.3;
+guide_armcorelen = 25.0;
+guide_clipcirclethick = 10.0;
 
 guidefilclip_outerdia = 22.8;
 
 guidespacer_armslop = 0.75;
-guidespacer_armlenslop = 0.75;
+guidespacer_armlenslop = 1.05;
 
 guidespacer_prongprotrude = 4;
 guidespacer_thick = 1.6;
@@ -694,7 +818,8 @@ guidespacer_thick = 1.6;
 
 guidespacer_armdia = guide_armdia + guidespacer_armslop;
 guidespacer_armwidth = guide_armwidth + guidespacer_armslop;
-guidespacer_len = guide_armcorelen + guidespacer_armlenslop;
+guidespacer_len = guide_armcorelen - guide_clipcirclethick
+  + guidespacer_armlenslop;
 
 guidespacer_wingheight = (guidefilclip_outerdia - guidespacer_armdia)/2;
 
@@ -747,7 +872,7 @@ module FilamentGuideSpacer(){ ////toplevel
 guidearm_armslop = 0.25;
 guidearm_armlenslop = 0.25;
 
-guidearm_hookprotr = 4;
+guidearm_hookprotr = 3;
 guidearm_hookprotrflat = 1;
 guidearm_hookslope = 0.3;
 
@@ -755,10 +880,14 @@ guidearm_totallen = 60;
 
 guidearm_screwplatesz = 12;
 guidearm_screwplateth = 4;
-guidearm_screwhole = 4 + 0.5;
+guidearm_screwplatewd = 15;
+guidearm_screwhole = 5 + 0.5;
 
-guidearm_bendlen = 50;
-guidearm_bendslot = 5;
+guidearm_bendlen = 40;
+guidearm_bendslot = 4.5;
+
+guidearm_stopthick = 4;
+guidearm_protrslop = 1.0;
 
 // calculated
 
@@ -770,11 +899,12 @@ guidearm_base_z0 = -(guidearm_totallen - guidearm_armcorelen);
 
 guidearm_realbendlen = min(guidearm_bendlen,
                           guidearm_totallen - guidearm_screwplateth - 0.1);
+guidearm_slopelen = guidearm_hookprotr/guidearm_hookslope;
 
 module FilamentGuideArmStop(h){
   for (ts=[-1,+1]) {
     translate([ts * guidearm_hookprotr, 0,0])
-      cylinder(r=guidearm_armdia/2, h);
+      cylinder(r=guidearm_armdia/2, h, $fn=80);
   }
 }
 
@@ -782,29 +912,33 @@ module FilamentGuideArmShaftPositive(){
   r = guidearm_armdia/2;
 
   translate([0,0, guidearm_base_z0+1])
-    cylinder(r=r, h= guidearm_totallen);
+    cylinder(r=r, h= guidearm_totallen, $fn=80);
   translate([0,0, guidearm_armcorelen]){
     hull(){
       FilamentGuideArmStop(guidearm_hookprotrflat);
-      translate([0,0, guidearm_hookprotr/guidearm_hookslope])
-       cylinder(r=r, h=guidearm_hookprotrflat);
+      translate([0,0, guidearm_slopelen])
+       cylinder(r=r, h=guidearm_hookprotrflat, $fn=80);
     }
   }
+  mirror([0,0,1])
+    FilamentGuideArmStop(guidearm_stopthick);
 }
 
 module FilamentGuideArmBase(){
-  translate([0,0, guidearm_base_z0]){
+  translate([0,
+            (guidearm_screwplatewd - guidearm_armwidth)/2,
+            guidearm_base_z0]){
     difference(){
       translate([0,0, guidearm_screwplateth/2])
        cube(center=true,
             [guidearm_armdia + guidearm_screwplatesz*2,
-             guidearm_armwidth,
+             guidearm_screwplatewd,
              guidearm_screwplateth]);
       for (ts=[-1,+1]) {
        translate([ts * (guidearm_armdia/2 + guidearm_screwplatesz/2),
                   0,
                   -20])
-         cylinder(r= guidearm_screwhole/2, h=40);
+         cylinder(r= guidearm_screwhole/2, h=40, $fn=20);
       }
     }
   }
@@ -820,6 +954,15 @@ module FilamentGuideArm(){ ///toplevel
        cube([guidearm_bendslot,
              100,
              guidearm_realbendlen + 100]);
+      hull(){
+       for (zx=[ [ 0, guidearm_bendslot ],
+                 [ guidearm_armcorelen + guidearm_slopelen,
+                   guidearm_hookprotr*2 + guidearm_protrslop ]
+                 ]) {
+         translate([-zx[1]/2, -50, zx[0]])
+         cube([zx[1], 100, 1]);
+       }
+      }
     }
     cube(center=true,
         [guidearm_armdia*2,
@@ -829,11 +972,19 @@ module FilamentGuideArm(){ ///toplevel
   FilamentGuideArmBase();
 }
 
+module FilamentGuideArmPrint(){ ////toplevel
+  rotate([90,0,0])
+    FilamentGuideArm();
+}
 
-module Demo(){
-  translate([-hubeffrad-30,50,0]) Hub();
+module Demo(){ ////toplevel
+  translate([-real_exteffrad,-20,0]) Hub();
   ArmEnd();
-  translate([0,50,0]) FilamentCup();
+  translate([ratchettooth*2, 30, 0]) FilamentCup();
+  if (selsz(true,false,false)) {
+    translate([-exteffrad + hubeffrad - hub_clip_baseextend, -10, 0])
+      ArmExtender();
+  }
 }
 
 //ArmEnd();
@@ -850,4 +1001,5 @@ module Demo(){
 //StorArmHoleTest();
 //FilamentGuideSpacer();
 //FilamentGuideArm();
+//FilamentGuideArmPrint();
 //Demo();