filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=1.75;
   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
  17 prongthick=5;
  18 prongwidth=5;
  19 ratchetstep=15;
  20 ratchettooth=3;
  21 ratchettoothheight=5;
  22 ratchettoothsmoothr=1;
  23 ratchettoothslope=0.75;
  24 overlap=0.5;
  25 cupbigrad=20;
  26
  27 xstraightmul = 1.75;
  28
  29 propxshift = 0;
  30
  31 doveclipheight = 10;
  32
  33 teethh=3;
  34 teethgapx=4+fdia;
  35
  36 prongstalkxwidth=3;
  37
  38 stalklength=35;
  39 overclipcupgap=5;
  40 overclipdepth=15;
  41 overcliproundr=2.0;
  42 overclipthick=0.5;
  43
  44 overclipsmaller=-2.5;
  45 overclipbigger=0.0;
  46
  47 wingspoke=3;
  48 wingsize=6;
  49 wingthick=3;
  50
  51 armendwallthick=2.5;
  52 armendbasethick=1.2;
  53
  54 axlehorizoffset = 12.5;
  55 axlevertheight = 80;
  56 towercliph = 16;
  57 towerclipcount = 3;
  58 towerpillarw = 5;
  59
  60 axlepinrad = 2;
  61 axlepintabrad = 5;
  62
  63 washerthick = 1.2;
  64 washerrad = hubaxlerad + 7.5;
  65
  66 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  67
  68 include <doveclip.scad>
  69 include <cliphook.scad>
  70 include <filamentteeth.scad>
  71
  72 channelwidth = prongthick + slop;
  73 channeldepth = prongwidth + ratchettoothheight;
  74 totalwidth = armendwallthick*2 + channelwidth;
  75 totalheight = channeldepth + armendbasethick;
  76 stalkwidth = prongwidth + prongstalkxwidth;
  77
  78 module ArmEnd(length=120){ ////toplevel
  79   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  80     rotate([0,0,-90])
  81       DoveClipPairBase(h=doveclipheight);
  82   }
  83
  84   difference(){
  85     translate([0, -armendwallthick, -armendbasethick])
  86       cube([length, totalwidth, totalheight]);
  87     translate([-1, 0, 0])
  88       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  89     translate([-1, 0, ratchettoothheight])
  90       cube([length+2, channelwidth, channeldepth+1]);
  91   }
  92   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  93     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  94       rotate([90,0,0])
  95         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
  96       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
  97                         [       0,      1,      0,      0       ],
  98                         [       0,      0,      1,      0       ],
  99                         [       0,      0,      0,      1       ]])
 100         cube([ratchettooth - ratchettoothsmoothr*2,
 101               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
 102     }
 103   }
 104 }
 105
 106 module FilamentCupHandle(){
 107   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 108   mirror([0,1,0]) {
 109     cube([stalklength, stalkwidth, prongthick]);
 110     translate([stalklength, stalkwidth/2, 0])
 111       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 112     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 113       minkowski(){
 114         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 115         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 116                         [       0,      1,      0,      0       ],
 117                         [       0,      0,      1,      0       ],
 118                         [       0,      0,      0,      1       ]])
 119           cube([pawlusewidth,
 120                 ratchettoothheight - ratchettoothsmoothr,
 121                 prongthick - 1]);
 122       }
 123     }
 124   }
 125 }
 126
 127 module FilamentCupCup(){
 128   xstraight = cupbigrad * xstraightmul;
 129   linear_extrude(height=prongthick) {
 130     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 131   }
 132   for (my=[0,1]) mirror([0,my,0]) {
 133     translate([0,cupbigrad,0])
 134       cube([xstraight, prongwidth, prongthick]);
 135   }
 136 }
 137
 138 module FilamentCup() { ////toplevel
 139   FilamentCupHandle();
 140
 141   dx = cupbigrad + prongwidth;
 142   gapy = prongwidth;
 143   dy = cupbigrad + gapy + overclipcupgap;
 144
 145   translate([dx, dy, 0])
 146     FilamentCupCup();
 147   translate([0, -1, 0]);
 148   cube([prongwidth, dy+1, prongthick]);
 149
 150   midrad = cupbigrad + prongwidth/2;
 151
 152   propshift = stalklength - overclipdepth - prongthick + propxshift;
 153   proptaken = propshift;
 154   echo(cupbigrad, dx, midrad, propshift, proptaken);
 155
 156   translate([propshift, -1, 0]) {
 157     // something is wrong with the y calculation
 158     cube([prongwidth,
 159           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 160           prongthick]);
 161   }
 162   translate([0, overclipcupgap, 0])
 163     rotate([0,0, 102 + fdia])
 164     FilamentTeeth(fdia=fdia, h=teethh);
 165 }
 166
 167 module CupSecuringClipSolid(w,d,h1,h2){
 168   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 169     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 170   }
 171 }
 172
 173 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 174   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 175   minkowski(){
 176     CupSecuringClipSolid(w=totalwidth,
 177                          d=overclipdepth + xdepth,
 178                          h1=hbase - overclipsmaller,
 179                          h2=hbase + overclipbigger);
 180     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 181   }
 182 }
 183
 184 module CupSecuringClip(){ ////toplevel
 185   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 186   difference(){
 187     union(){
 188       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 189       translate([-wingswidth/2, -wingsize/2, 0])
 190         cube([wingswidth, wingsize, wingthick]);
 191     }
 192     translate([0,0,-0.1])
 193       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 194   }
 195 }
 196
 197 module ArmDoveClipPin(){ ////toplevel
 198   DoveClipPin(h=doveclipheight);
 199 }
 200
 201 module Hub(){ ////toplevel
 202   difference(){
 203     cylinder($fn=60, h=hublthick, r=hubbigrad);
 204     translate([0,0,-1])
 205       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 206   }
 207   axlerad = hubaxlerad + slop;
 208   difference(){
 209     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 210     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 211   }
 212   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 213   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 214   for (ang=[0,120,240])
 215     rotate([0,0,ang]) {
 216       difference() {
 217         translate([hubeffrad,0,0])
 218           DoveClipPairSane(h=doveclipheight,
 219                            baseextend = (hubeffrad - DoveClip_depth()
 220                                          - hubbigrad + hublwidth));
 221         if (hole>hublwidth && holewidth > 2) {
 222           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 223             cube([hole, holewidth, hublthick+2]);
 224         }
 225       }
 226     }
 227   xmin = axlerad+hublwidth/2;
 228   xmax = hubbigrad-hublwidth/2;
 229   for (ang = [0 : 60 : 359])
 230     rotate([0,0,ang]) rotate([90,0,0]) {
 231       translate([0,0,-hublwidth/2])
 232         linear_extrude(height=hublwidth)
 233         polygon([[xmin,0.05], [xmax,0.05],
 234                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 235     }
 236 }
 237
 238 module ArmExtender(){ ////toplevel
 239   DoveClipExtender(length=exteffrad-hubeffrad,
 240                    ha=doveclipheight,
 241                    hb=doveclipheight);
 242 }
 243
 244 module AxlePin(){ ////toplevel
 245   pinr = axlepinrad - slop;
 246   intersection(){
 247     translate([0, 0, pinr*0.7]) {
 248       translate([0, -washerrad, 0]) rotate([-90,0,0])
 249         cylinder(r=pinr, h=washerrad*2, $fn=10);
 250       translate([-axlepintabrad, hubaxlerad, -axlepinrad])
 251         cube([axlepintabrad*2, axlepinrad*2, axlepinrad*2]);
 252     }
 253     translate([-50,-50,0]) cube([100,100,50]);
 254   }
 255 }
 256
 257 module Axle(){ ////toplevel
 258   pillarswidth = DoveClipPairSane_width(towerclipcount);
 259
 260 if(0)
 261   translate([-axlehorizoffset, -axlevertheight, 0]) {
 262     rotate([0,0,-90])
 263       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 264     translate([0, DoveClip_depth(), 0])
 265     rotate([0,0,90])
 266       ExtenderPillars(axlevertheight - DoveClip_depth(),
 267                       pillarswidth, towercliph,
 268                       pillarw=towerpillarw);
 269   }
 270
 271   axleclearlen = hubaxlelen + slop*3 + washerthick*2;
 272   axlerad = hubaxlerad-slop;
 273   bump = axlerad * 0.2;
 274   shift = axlerad-bump;
 275   joinbelowallow = 3;
 276
 277   intersection(){
 278     translate([0, 0, shift]) {
 279       difference() {
 280         union(){
 281           translate([-1, 0, 0])
 282             rotate([0,90,0])
 283             cylinder(r = axlerad, h = 1 + axleclearlen + 3 + 2);
 284           mirror([1,0,0]) rotate([0,90,0])
 285             cylinder(r = washerrad, h = 3);
 286 if(0)
 287           intersection(){
 288             mirror([1,0,0]) rotate([0,90,0])
 289               cylinder(r = towercliph - shift,
 290                        h = pillarswidth/2 + axlehorizoffset);
 291             translate([-50, -joinbelowallow, -50])
 292               cube([100, joinbelowallow+50, 100]);
 293           }
 294         }
 295         rotate([90,0,0])
 296         translate([axleclearlen + axlepinrad/2, 0, -25])
 297           cylinder(r=axlepinrad, h=50);
 298       }
 299     }
 300     translate([-50,-50,0]) cube([100,100,100]);
 301   }
 302 }
 303
 304 module AxleWasher(){ ////toplevel
 305   difference(){
 306     cylinder(h=washerthick, r=washerrad);
 307     translate([0,0,-1]) cylinder(h=washerthick+2, r=hubaxlerad+slop);
 308   }
 309 }
 310
 311 //ArmEnd();
 312 //FilamentCup();
 313 //CupSecuringClip();
 314 //Hub();
 315 //ArmExtender();
 316 //Axle();
 317 //AxleWasher();
 318 //AxlePin();