filamentspool.scad

   1 // -*- C -*-
   2
   3 fdia=1.75;
   4
   5 slop=0.5;
   6 bigslop=slop*2;
   7
   8 exteffrad = 85;
   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 washerthick = 1.2;
  61
  62 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  63
  64 include <doveclip.scad>
  65 include <cliphook.scad>
  66 include <filamentteeth.scad>
  67 include <splitpin.scad>
  68
  69 channelwidth = prongthick + slop;
  70 channeldepth = prongwidth + ratchettoothheight;
  71 totalwidth = armendwallthick*2 + channelwidth;
  72 totalheight = channeldepth + armendbasethick;
  73 stalkwidth = prongwidth + prongstalkxwidth;
  74
  75 module ArmEnd(length=120){ ////toplevel
  76   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  77     rotate([0,0,-90])
  78       DoveClipPairBase(h=doveclipheight);
  79   }
  80
  81   difference(){
  82     translate([0, -armendwallthick, -armendbasethick])
  83       cube([length, totalwidth, totalheight]);
  84     translate([-1, 0, 0])
  85       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  86     translate([-1, 0, ratchettoothheight])
  87       cube([length+2, channelwidth, channeldepth+1]);
  88   }
  89   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  90     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  91       rotate([90,0,0])
  92         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
  93       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
  94                         [       0,      1,      0,      0       ],
  95                         [       0,      0,      1,      0       ],
  96                         [       0,      0,      0,      1       ]])
  97         cube([ratchettooth - ratchettoothsmoothr*2,
  98               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
  99     }
 100   }
 101 }
 102
 103 module FilamentCupHandle(){
 104   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
 105   mirror([0,1,0]) {
 106     cube([stalklength, stalkwidth, prongthick]);
 107     translate([stalklength, stalkwidth/2, 0])
 108       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 109     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 110       minkowski(){
 111         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 112         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 113                         [       0,      1,      0,      0       ],
 114                         [       0,      0,      1,      0       ],
 115                         [       0,      0,      0,      1       ]])
 116           cube([pawlusewidth,
 117                 ratchettoothheight - ratchettoothsmoothr,
 118                 prongthick - 1]);
 119       }
 120     }
 121   }
 122 }
 123
 124 module FilamentCupCup(){
 125   xstraight = cupbigrad * xstraightmul;
 126   linear_extrude(height=prongthick) {
 127     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 128   }
 129   for (my=[0,1]) mirror([0,my,0]) {
 130     translate([0,cupbigrad,0])
 131       cube([xstraight, prongwidth, prongthick]);
 132   }
 133 }
 134
 135 module FilamentCup() { ////toplevel
 136   FilamentCupHandle();
 137
 138   dx = cupbigrad + prongwidth;
 139   gapy = prongwidth;
 140   dy = cupbigrad + gapy + overclipcupgap;
 141
 142   translate([dx, dy, 0])
 143     FilamentCupCup();
 144   translate([0, -1, 0]);
 145   cube([prongwidth, dy+1, prongthick]);
 146
 147   midrad = cupbigrad + prongwidth/2;
 148
 149   propshift = stalklength - overclipdepth - prongthick + propxshift;
 150   proptaken = propshift;
 151   echo(cupbigrad, dx, midrad, propshift, proptaken);
 152
 153   translate([propshift, -1, 0]) {
 154     // something is wrong with the y calculation
 155     cube([prongwidth,
 156           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 157           prongthick]);
 158   }
 159   translate([0, overclipcupgap, 0])
 160     rotate([0,0, 102 + fdia])
 161     FilamentTeeth(fdia=fdia, h=teethh);
 162 }
 163
 164 module CupSecuringClipSolid(w,d,h1,h2){
 165   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 166     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 167   }
 168 }
 169
 170 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 171   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 172   minkowski(){
 173     CupSecuringClipSolid(w=totalwidth,
 174                          d=overclipdepth + xdepth,
 175                          h1=hbase - overclipsmaller,
 176                          h2=hbase + overclipbigger);
 177     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 178   }
 179 }
 180
 181 module CupSecuringClip(){ ////toplevel
 182   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 183   difference(){
 184     union(){
 185       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 186       translate([-wingswidth/2, -wingsize/2, 0])
 187         cube([wingswidth, wingsize, wingthick]);
 188     }
 189     translate([0,0,-0.1])
 190       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 191   }
 192 }
 193
 194 module ArmDoveClipPin(){ ////toplevel
 195   DoveClipPin(h=doveclipheight);
 196 }
 197
 198 module Hub(){ ////toplevel
 199   difference(){
 200     cylinder($fn=60, h=hublthick, r=hubbigrad);
 201     translate([0,0,-1])
 202       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 203   }
 204   axlerad = hubaxlerad + slop;
 205   difference(){
 206     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 207     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 208   }
 209   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 210   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 211   for (ang=[0,120,240])
 212     rotate([0,0,ang]) {
 213       difference() {
 214         translate([hubeffrad,0,0])
 215           DoveClipPairSane(h=doveclipheight,
 216                            baseextend = (hubeffrad - DoveClip_depth()
 217                                          - hubbigrad + hublwidth));
 218         if (hole>hublwidth && holewidth > 2) {
 219           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 220             cube([hole, holewidth, hublthick+2]);
 221         }
 222       }
 223     }
 224   xmin = axlerad+hublwidth/2;
 225   xmax = hubbigrad-hublwidth/2;
 226   for (ang = [0 : 60 : 359])
 227     rotate([0,0,ang]) rotate([90,0,0]) {
 228       translate([0,0,-hublwidth/2])
 229         linear_extrude(height=hublwidth)
 230         polygon([[xmin,0.05], [xmax,0.05],
 231                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 232     }
 233 }
 234
 235 module ArmExtender(){ ////toplevel
 236   DoveClipExtender(length=exteffrad-hubeffrad,
 237                    ha=doveclipheight,
 238                    hb=doveclipheight);
 239 }
 240
 241 module Axle(){ ////toplevel
 242   pillarswidth = DoveClipPairSane_width(towerclipcount);
 243
 244   translate([-axlehorizoffset, -axlevertheight, 0]) {
 245     rotate([0,0,-90])
 246       DoveClipPairSane(h=towercliph, count=towerclipcount, baseextend=3);
 247     translate([0, DoveClip_depth(), 0])
 248     rotate([0,0,90])
 249       ExtenderPillars(axlevertheight - DoveClip_depth(),
 250                       pillarswidth, towercliph,
 251                       pillarw=towerpillarw);
 252   }
 253
 254   axleclearlen = hubaxlelen + slop*2 + washerthick;
 255   axlerad = hubaxlerad+slop;
 256   bump = axlerad * 0.2;
 257
 258   intersection(){
 259     difference() {
 260       translate([-1, 0, axlerad-bump])
 261         rotate([0,90,0])
 262         cylinder(r = axlerad, h = 1 + axleclearlen + 6);
 263       translate([axleclearlen, 0, 0])
 264         mirror([0,0,1])
 265         rotate([0,0,90])
 266         SplitPinCavity();
 267     }
 268     translate([-50,-50,0]) cube([100,100,100]);
 269   }
 270 }
 271
 272 //ArmEnd();
 273 //FilamentCup();
 274 //CupSecuringClip();
 275 //Hub();
 276 //ArmExtender();
 277 Axle();