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 ratchetpawl=ratchetstep-ratchettooth-bigslop*2;
  55
  56 include <doveclip.scad>
  57 include <cliphook.scad>
  58 include <filamentteeth.scad>
  59
  60 channelwidth = prongthick + slop;
  61 channeldepth = prongwidth + ratchettoothheight;
  62 totalwidth = armendwallthick*2 + channelwidth;
  63 totalheight = channeldepth + armendbasethick;
  64 stalkwidth = prongwidth + prongstalkxwidth;
  65
  66 module ArmEnd(length=120){ ////toplevel
  67   translate([ratchettoothsmoothr, channelwidth/2, -armendbasethick]) {
  68     rotate([0,0,-90])
  69       DoveClipPairBase(h=doveclipheight);
  70   }
  71
  72   difference(){
  73     translate([0, -armendwallthick, -armendbasethick])
  74       cube([length, totalwidth, totalheight]);
  75     translate([-1, 0, 0])
  76       cube([length+1 - ratchettooth, channelwidth, channeldepth+1]);
  77     translate([-1, 0, ratchettoothheight])
  78       cube([length+2, channelwidth, channeldepth+1]);
  79   }
  80   for (dx = [0 : ratchetstep : length - ratchetstep]) translate([dx,0,0]) {
  81     translate([ratchettoothsmoothr+0.5, armendwallthick/2, 0]) minkowski(){
  82       rotate([90,0,0])
  83         cylinder($fn=20, r=ratchettoothsmoothr, h=armendwallthick);
  84       multmatrix([      [       1, 0, ratchettoothslope, 0      ],
  85                         [       0,      1,      0,      0       ],
  86                         [       0,      0,      1,      0       ],
  87                         [       0,      0,      0,      1       ]])
  88         cube([ratchettooth - ratchettoothsmoothr*2,
  89               channelwidth, ratchettoothheight - ratchettoothsmoothr]);
  90     }
  91   }
  92 }
  93
  94 module FilamentCupHandle(){
  95   pawlusewidth = ratchetpawl-ratchettoothsmoothr*2;
  96   mirror([0,1,0]) {
  97     cube([stalklength, stalkwidth, prongthick]);
  98     translate([stalklength, stalkwidth/2, 0])
  99       cylinder(r=stalkwidth/2, h=prongthick, $fn=20);
 100     translate([ratchettoothsmoothr, stalkwidth, 0]) {
 101       minkowski(){
 102         cylinder($fn=20,r=ratchettoothsmoothr, h=1);
 103         multmatrix([    [       1, -ratchettoothslope, 0, 0     ],
 104                         [       0,      1,      0,      0       ],
 105                         [       0,      0,      1,      0       ],
 106                         [       0,      0,      0,      1       ]])
 107           cube([pawlusewidth,
 108                 ratchettoothheight - ratchettoothsmoothr,
 109                 prongthick - 1]);
 110       }
 111     }
 112   }
 113 }
 114
 115 module FilamentCupCup(){
 116   xstraight = cupbigrad * xstraightmul;
 117   linear_extrude(height=prongthick) {
 118     FlatArc(0,0, cupbigrad,cupbigrad+prongwidth, 89,271, $fn=80);
 119   }
 120   for (my=[0,1]) mirror([0,my,0]) {
 121     translate([0,cupbigrad,0])
 122       cube([xstraight, prongwidth, prongthick]);
 123   }
 124 }
 125
 126 module FilamentCup() { ////toplevel
 127   FilamentCupHandle();
 128
 129   dx = cupbigrad + prongwidth;
 130   gapy = prongwidth;
 131   dy = cupbigrad + gapy + overclipcupgap;
 132
 133   translate([dx, dy, 0])
 134     FilamentCupCup();
 135   translate([0, -1, 0]);
 136   cube([prongwidth, dy+1, prongthick]);
 137
 138   midrad = cupbigrad + prongwidth/2;
 139
 140   propshift = stalklength - overclipdepth - prongthick + propxshift;
 141   proptaken = propshift;
 142   echo(cupbigrad, dx, midrad, propshift, proptaken);
 143
 144   translate([propshift, -1, 0]) {
 145     // something is wrong with the y calculation
 146     cube([prongwidth,
 147           dy - sqrt(midrad*midrad - proptaken*proptaken) - prongwidth/2,
 148           prongthick]);
 149   }
 150   translate([0, overclipcupgap, 0])
 151     rotate([0,0, 102 + fdia])
 152     FilamentTeeth(fdia=fdia, h=teethh);
 153 }
 154
 155 module CupSecuringClipSolid(w,d,h1,h2){
 156   rotate([0,-90,0]) translate([0,-h1/2,-w/2]) linear_extrude(height=w) {
 157     polygon(points=[[0,0], [d,0], [d,h2], [0,h1]]);
 158   }
 159 }
 160
 161 module CupSecuringClipSolidSmooth(xrad=0, xdepth=0){
 162   hbase = totalheight + prongstalkxwidth - overcliproundr*2;
 163   minkowski(){
 164     CupSecuringClipSolid(w=totalwidth,
 165                          d=overclipdepth + xdepth,
 166                          h1=hbase - overclipsmaller,
 167                          h2=hbase + overclipbigger);
 168     cylinder($fn=20, h=0.01, r=overcliproundr+xrad);
 169   }
 170 }
 171
 172 module CupSecuringClip(){ ////toplevel
 173   wingswidth = wingspoke*2 + overclipthick*2 + overcliproundr*2 + totalwidth;
 174   difference(){
 175     union(){
 176       CupSecuringClipSolidSmooth(xrad=overclipthick, xdepth=0);
 177       translate([-wingswidth/2, -wingsize/2, 0])
 178         cube([wingswidth, wingsize, wingthick]);
 179     }
 180     translate([0,0,-0.1])
 181       CupSecuringClipSolidSmooth(xrad=0, xdepth=0.2);
 182   }
 183 }
 184
 185 module ArmDoveClipPin(){ ////toplevel
 186   DoveClipPin(h=doveclipheight);
 187 }
 188
 189 module Hub(){ ////toplevel
 190   difference(){
 191     cylinder($fn=60, h=hublthick, r=hubbigrad);
 192     translate([0,0,-1])
 193       cylinder($fn=30, h=hublthick+2, r=(hubbigrad-hublwidth));
 194   }
 195   axlerad = hubaxlerad + slop;
 196   difference(){
 197     cylinder(h=hubaxlelen, r=axlerad+hublwidth);
 198     translate([0,0,-1]) cylinder($fn=60, h=hubaxlelen+2, r=axlerad);
 199   }
 200   hole = hubeffrad - hubbigrad - DoveClip_depth() - hublwidth*2;
 201   holewidth = DoveClipPairSane_width() - hubstemwidth*2;
 202   for (ang=[0,120,240])
 203     rotate([0,0,ang]) {
 204       difference() {
 205         translate([hubeffrad,0,0])
 206           DoveClipPairSane(h=doveclipheight,
 207                            baseextend = (hubeffrad - DoveClip_depth()
 208                                          - hubbigrad + hublwidth));
 209         if (hole>hublwidth && holewidth > 2) {
 210           translate([hubbigrad + hublwidth, -holewidth/2, -1])
 211             cube([hole, holewidth, hublthick+2]);
 212         }
 213       }
 214     }
 215   xmin = axlerad+hublwidth/2;
 216   xmax = hubbigrad-hublwidth/2;
 217   for (ang = [0 : 60 : 359])
 218     rotate([0,0,ang]) rotate([90,0,0]) {
 219       translate([0,0,-hublwidth/2])
 220         linear_extrude(height=hublwidth)
 221         polygon([[xmin,0.05], [xmax,0.05],
 222                  [xmax,hublthick-0.2], [xmin, hubaxlelen-0.2]]);
 223     }
 224 }
 225
 226 module ArmExtender(){ ////toplevel
 227   DoveClipExtender(length=exteffrad-hubeffrad,
 228                    ha=doveclipheight,
 229                    hb=doveclipheight);
 230 }
 231
 232 //ArmEnd();
 233 //FilamentCup();
 234 //CupSecuringClip();
 235 //Hub();