filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=1.75;
   4
   5 slop=0.5;
   6 bigslop=slop*2;
   7
   8 hubeffrad = 30 + 55;
   9 hubbigrad = 20;
  10 hublwidth = 3;
  11 hubstemwidth = 2;
  12 hublthick = 10;
  13 hubaxlelen = 25;
  14 hubaxlerad = 5;
  15
  16 prongthick=5;
  17 prongwidth=5;
  18 ratchetstep=15;
  19 ratchettooth=3;
  20 ratchettoothheight=5;
  21 ratchettoothsmoothr=1;
  22 ratchettoothslope=0.75;
  23 overlap=0.5;
  24 cupbigrad=20;
  25
  26 xstraightmul = 1.75;
  27
  28 propxshift = 0;
  29
  30 doveclipheight = 10;
  31
  32 teethh=3;
  33 teethgapx=4+fdia;
  34
  35 prongstalkxwidth=3;
  36
  37 stalklength=35;
  38 overclipcupgap=5;
  39 overclipdepth=15;
  40 overcliproundr=2.0;
  41 overclipthick=0.5;
  42
  43 overclipsmaller=-2.5;
  44 overclipbigger=0.0;
  45
  46 wingspoke=3;
  47 wingsize=6;
  48 wingthick=3;
  49
  50 armendwallthick=2.5;
  51 armendbasethick=1.2;
  52
  53 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  54
  55 include <doveclip.scad>
  56 include <cliphook.scad>
  57 include <filamentteeth.scad>
  58
  59 channelwidth = prongthick + slop;
  60 channeldepth = prongwidth + ratchettoothheight;
  61 totalwidth = armendwallthick*2 + channelwidth;
  62 totalheight = channeldepth + armendbasethick;
  63 stalkwidth = prongwidth + prongstalkxwidth;
  64
  65 module ArmEnd(length=120){
  66   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  67     rotate([0,0,-90])
  68       DoveClipPairBase(h=doveclipheight);
  69   }
  70
  71   difference(){
  72     translate([0, -armendwallthick, -armendbasethick])
  73       cube([length, totalwidth, totalheight]);
  74     translate([-1, 0, 0])
  75       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  76     translate([-1, 0, ratchettoothheight])
  77       cube([length+2, channelwidth, channeldepth+1]);
  78   }
  79   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  80     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  81       rotate([90,0,0])
  82         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
  83       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
  84                         [       0,      1,      0,      0       ],
  85                         [       0,      0,      1,      0       ],
  86                         [       0,      0,      0,      1       ]])
  87         cube([ratchettooth - ratchettoothsmoothr*2,
  88               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
  89     }
  90   }
  91 }
  92
  93 module FilamentCupHandle(){
  94   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
  95   mirror([0,1,0]) {
  96     cube([stalklength, stalkwidth, prongthick]);
  97     translate([stalklength, stalkwidth/2, 0])
  98       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
  99     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 100       minkowski(){
 101         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 102         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 103                         [       0,      1,      0,      0       ],
 104                         [       0,      0,      1,      0       ],
 105                         [       0,      0,      0,      1       ]])
 106           cube([pawlusewidth,
 107                 ratchettoothheight - ratchettoothsmoothr,
 108                 prongthick - 1]);
 109       }
 110     }
 111   }
 112 }
 113
 114 module FilamentCupCup(){
 115   xstraight = cupbigrad * xstraightmul;
 116   linear_extrude(height=prongthick) {
 117     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 118   }
 119   for (my=[0,1]) mirror([0,my,0]) {
 120     translate([0,cupbigrad,0])
 121       cube([xstraight, prongwidth, prongthick]);
 122   }
 123 }
 124
 125 module FilamentCup() {
 126   FilamentCupHandle();
 127
 128   dx = cupbigrad + prongwidth;
 129   gapy = prongwidth;
 130   dy = cupbigrad + gapy + overclipcupgap;
 131
 132   translate([dx, dy, 0])
 133     FilamentCupCup();
 134   translate([0, -1, 0]);
 135   cube([prongwidth, dy+1, prongthick]);
 136
 137   midrad = cupbigrad + prongwidth/2;
 138
 139   propshift = stalklength - overclipdepth - prongthick + propxshift;
 140   proptaken = propshift;
 141   echo(cupbigrad, dx, midrad, propshift, proptaken);
 142
 143   translate([propshift, -1, 0]) {
 144     // something is wrong with the y calculation
 145     cube([prongwidth,
 146           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 147           prongthick]);
 148   }
 149   translate([0, overclipcupgap, 0])
 150     rotate([0,0, 102 + fdia])
 151     FilamentTeeth(fdia=fdia, h=teethh);
 152 }
 153
 154 module CupSecuringClipSolid(w,d,h1,h2){
 155   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 156     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 157   }
 158 }
 159
 160 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 161   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 162   minkowski(){
 163     CupSecuringClipSolid(w=totalwidth,
 164                          d=overclipdepth + xdepth,
 165                          h1=hbase - overclipsmaller,
 166                          h2=hbase + overclipbigger);
 167     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 168   }
 169 }
 170
 171 module CupSecuringClip(){
 172   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 173   difference(){
 174     union(){
 175       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 176       translate([-wingswidth/2, -wingsize/2, 0])
 177         cube([wingswidth, wingsize, wingthick]);
 178     }
 179     translate([0,0,-0.1])
 180       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 181   }
 182 }
 183
 184 module ArmDoveClipPin(){
 185   DoveClipPin(h=doveclipheight);
 186 }
 187
 188 module Hub(){
 189   difference(){
 190     cylinder(h=hublthick, r=hubbigrad);
 191     translate([0,0,-1]) cylinder(h=hublthick+2, r=(hubbigrad-hublwidth));
 192   }
 193   axlerad = hubaxlerad + bigslop;
 194   difference(){
 195     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 196     translate([0,0,-1]) cylinder(h=hubaxlelen+2, r=axlerad);
 197   }
 198   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 199   holewidth = DoveClip_width() - hubstemwidth*2;
 200   for (ang=[0,120,240])
 201     rotate([0,0,ang]) {
 202       difference() {
 203         translate([hubeffrad,0,0])
 204           DoveClipPairSane(h=doveclipheight,
 205                            baseextend = (hubeffrad - DoveClip_depth()
 206                                          - hubbigrad + hublwidth));
 207         if (hole>hublwidth && holewidth > 2) {
 208           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 209             cube([hole, holewidth, hublthick+2]);
 210         }
 211       }
 212     }
 213   xmin = axlerad+hublwidth/2;
 214   xmax = hubbigrad-hublwidth/2;
 215   for (ang = [0 : 60 : 359])
 216     rotate([0,0,ang]) rotate([90,0,0]) {
 217       translate([0,0,-hublwidth/2])
 218         linear_extrude(height=hublwidth)
 219         polygon([[xmin,0], [xmax,0], [xmax,hublthick], [xmin,hubaxlelen]]);
 220     }
 221 }
 222
 223 //ArmEnd();
 224 //FilamentCup();
 225 //CupSecuringClip();
 226
 227 Hub();