don't support configuration without tensioning screw

1 files changed, 19 insertions, 30 deletions

diff --git a/another.scad b/another.scad
index 9ff7f6a..e6d9ca3 100644
--- a/another.scad
+++ b/another.scad
@@ -51,49 +51,48 @@ module the_extruder(
  // empty spaces
          idler_travel = 3,                      // how far should idler travel when pressed
  idler_clearance=1,
  pulley_d_clearance=2,
  pulley_small_d_clearance=0.5,
          lever_v_clearance=.7,                  // vertical clearance for the lever
  spring_d_clearance=1,
          protrusion_tolerance_h=.5,             // horizontal tolerance for the motor protrusion
          protrusion_tolerance_v=.5,             // vertical tolerance for the motor protrusion
  mount_screw_d_tolerance=.4,
  idler_v_tolerance=.5,
  knob_bore_d_tolerance=.6,
  st_nut_h_tolerance=.2,
  st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */
  st_screw_d_tolerance=.5,
  st_split_w_tolerance = .3,
 
  min_z_shell = 4*layer_height,                  // the very minimal shell thickness along z-axis.
  min_xy_shell = 2*extrusion_width,
 
  what="lever",  // lever|body|knob|springpad|*
  left=false,
  vitamins = true,
  bridges = true,
- tensioner = true,
  debug = false
 ) {
  fnd = 2*PI; fnr = 2*fnd;
 
  idler_filament_offset = filament_path_d/2; // -filament_offset;
  lever_shell = mount_screwhead_h+0.5;
  lever_thickness=max(spring_d+spring_d_clearance+layer_height*8,idler_h+idler_v_tolerance+2*lever_shell);
  lsd = idler_d-idler_clearance*2; // the diameter of lever thingie
  longwing=(mount_d+mount_screw_d+mount_screw_d_tolerance+spring_d+spring_d_clearance)/2+min_xy_shell;
  shortwing = let(a=mount_d/2,c=(pulley_d+idler_d)/2/sqrt(2))
              sqrt(c*c+pow(a-c,2));
  longwing_travel = idler_travel*longwing/shortwing;
  h_ = (pulley_d+idler_d)/(2*sqrt(2));
  ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) );
  spring_dl = idler_travel*longwing/ri;
  // finger and spring support
  fsw = gearbox_d-(gearbox_d-mount_d)/2-max(spring_lc,longwing_travel+(gearbox_d-mount_d)/2);
 
  mount_min_depth = mounthole_min_depth ? mounthole_min_depth : mounthole_depth-1;
  mount_max_depth = mounthole_max_depth ? mounthole_max_depth : mounthole_depth+1;
  filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
  ls_z = filament_elevation; // leverspace mid-z
  ls_h = lever_thickness+lever_v_clearance; // leverspace height
  mount_depth = mount_screw_l - (ls_z+ls_h/2+min_z_shell);
@@ -327,78 +326,68 @@ module the_extruder(
 
    // back side cutout
    // XXX: this is somewhat ugly and potentially bugged,
    //      but I want to sleep.
    a0_ = atan(
     (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2)
     /
     (
      pulley_d/2+filament_offset-
      (pf_d(pf)+2*pf_shell)/2/cos(30)
     )
    );
    a0 = -135 + ( (a0_>0) ? a0_ : 180+a0_ );
    a1 = atan((longwing-lever_thickness/2)/(gearbox_d/2));
    translate([0,0,ls_z]) difference() {
     rotate([0,0,-180+a0])
     rotate_extrude(angle=a1-a0)
     translate([0,-ls_h/2])
     square([sqrt(pow(gearbox_d/2,2)+pow(longwing-lever_thickness/2,2))+1,
            ls_h]);
     translate([-mount_d/2,0,0])
     cylinder(d=gearbox_d-mount_d,h=ls_h+2,center=true,$fn=fnd*(gearbox_d-mount_d));
    }//difference translate
    
-   //translate([-mount_d/2,-longwing,filament_elevation])
-   if(!tensioner) /* XXX: this seems to be bullshit, but it's so old, that it's historical bullshit */
-   translate([mount_d/2,-longwing,filament_elevation])
-   rotate([0,-90,0]) difference() {
-    cylinder(d=spring_d+spring_d_clearance,h=spring_lc+spring_dl,$fn=fnd*(spring_d+spring_d_clearance));
-    translate([0,0,spring_lc+spring_dl]) sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
-   }
-
    // spring tensioner
    translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) {
-    if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else {
-     mirror([0,0,1]) {
-      translate([0,0,st_thickshell])
-      hull() for(o=[0,spring_d]) translate([0,-o,0])
-      rotate([0,0,30])
-      cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
-      translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
-      bigd = spring_d+spring_d_clearance;
-      hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
-      translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) {
-       cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
-        h=hf+epsilon, $fn=fnd*bigd);
-       translate([0,-(st_thinshell+st_split_w_tolerance)/2,0])
-       cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]);
-      }
-      translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
-      cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
-     }
-    }
-   }
+    mirror([0,0,1]) {
+     translate([0,0,st_thickshell])
+     hull() for(o=[0,spring_d]) translate([0,-o,0])
+     rotate([0,0,30])
+     cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
+     translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
+     bigd = spring_d+spring_d_clearance;
+     hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
+     translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) {
+      cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
+       h=hf+epsilon, $fn=fnd*bigd);
+      translate([0,-(st_thinshell+st_split_w_tolerance)/2,0])
+      cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]);
+     }//translate
+     translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
+     cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
+    }//mirror
+   }//translate
 
   }//difference
 
  }//body module
 
  module springpad() {
   smalld=st_screw_d+st_screw_d_tolerance+min_xy_shell;
   bigd = spring_d+spring_d_clearance/2;
   hf = (bigd-smalld)/2;
   h = hf*3.5;
   translate([-gearbox_d/2+st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+1,-longwing,filament_elevation])
   rotate([0,90,0]) difference() {
    union() {
     cylinder(d1=smalld,d2=bigd,h=hf,$fn=fnd*bigd);
     translate([0,0,hf-epsilon])
     cylinder(d=bigd,h=h-hf,$fn=fnd*bigd);
     translate([0,0,h])
     sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
     l = body_h-ls_z;
     w = st_thinshell;
     hull() translate([0,-st_thinshell/2,0]) mirror([1,0,0]) {
      translate([0,0,w])
      cube(size=[l,st_thinshell,w]);
      cube(size=[l-w,st_thinshell,2*w]);
@@ -421,49 +410,49 @@ module the_extruder(
       cube([bore_d+2,bore_d/2,knob_bore_l+4]);
      }
     }
    }
    difference() {
     union() {
      cylinder(d1=gearbox_d-2*ch,d2=gearbox_d,h=ch+epsilon,$fn=fnd*gearbox_d);
      translate([0,0,ch])
      cylinder(d=gearbox_d,h=knob_h-2*ch+epsilon,$fn=fnd*gearbox_d);
      translate([0,0,knob_h-ch])
      cylinder(d1=gearbox_d,d2=gearbox_d-2*ch,h=ch,$fn=fnd*gearbox_d);
     }
     for(a=[0:360/knob_indents:359]) rotate([0,0,a])
      translate([0,gearbox_d/2,-1])
      cylinder(d=knob_indent_d,h=knob_h+2,$fn=fnd*knob_indent_d);
    }
   }
  }//knob module
 
  module debug() {
   difference() {
    children();
    if(debug) {
     // spring tensioner debug cutout
-    if(tensioner) // TODO: collapse copypasted transformations
+    // TODO: collapse copypasted transformations
     translate([-gearbox_d/2,0,0])
     translate([0,-longwing,ls_z]) rotate([0,-90,0])
     translate([0,-lever_thickness/2-1,-gearbox_d])
     cube(size=[body_h/2+1,lever_thickness/2+1,gearbox_d+2]);
     // lever axis debug cutout
     translate([mount_d/2,0,-1])
     rotate([0,0,-45])
     cube(size=[gearbox_d-mount_d,gearbox_d-mount_d,body_h+knob_h+2]);
     // idler debug cutout
     translate([0,0,ls_z])
     place_idler()
     rotate([0,0,-45])
     translate([0,0,-lever_thickness/2-epsilon])
     cube(size=[(idler_d+idler_clearance)/2,(idler_d+idler_clearance)/2,
                lever_thickness+2*epsilon]);
     // pushfit debug cutout
     place_idler()
     translate([-idler_d/2+filament_offset,0,ls_z])
     cube(size=[gearbox_d/2,gearbox_d/2+pf_h(pf),body_h-ls_z+1]);
    }//if debug
   }//difference
  }
 
  mirrorleft()