better indication of spring tensioner position

1 files changed, 15 insertions, 6 deletions

diff --git a/another.scad b/another.scad
index a25e047..fd73a61 100644
--- a/another.scad
+++ b/another.scad
@@ -298,212 +298,221 @@ module the_extruder(
     pushfit(pf);
     mirror([0,0,1]) {
      fh = 1.5* (filament_guide_d-filament_path_d)/2;
      fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh;
      translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,angle=225);
      translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225);
      translate([0,0,fo+epsilon])
      cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d);
     }//mirror
    }//rotate translate rotate translate rotate translate
    // pulley
    cylinder(d=pulley_d+pulley_small_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
    cylinder(d=pulley_d+pulley_d_clearance,ls_z-max(idler_h,filament_guide_d)/2,$fn=fnd*(pulley_d+pulley_d_clearance));
 
    translate([0,0,ls_z-ls_h/2]) {
     // idler travel
     translate([mount_d/2,0,0])
     rotate([0,0,45])
     rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2))
     square([shortwing+(idler_d+idler_clearance)/2,ls_h]);
     // idler itself
     place_idler()
     cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
     // lever space
     rotate([0,0,45])
     rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1)))
     square([gearbox_d/2+1,ls_h]);
    }
 
    // back side cutout
    // XXX: this is somewhat ugly and potentially bugged,
    //      but I want to sleep.
    a0_ = atan(
     (pf_offset+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
    
    // spring tensioner
    translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) {
     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, $fn=fnd*bigd);
       translate([0,-(st_split_w+st_split_w_tolerance)/2,0]) hull() {
        cube(size=[body_h-ls_z-sp_ch-st_split_w_tolerance,st_split_w+st_split_w_tolerance,fsw+1]);
        translate([0,0,sp_ch+st_split_w_tolerance+1])
        cube(size=[body_h-ls_z+1,st_split_w+st_split_w_tolerance,fsw+1]);
       }
      }//translate
      translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
      cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
     }//mirror
    }//translate
 
    // label
    body_label();
 
   }//difference
 
  }//body module
  module body_label() {
   if(body_label) {
    label=body_label;
    label_thickness=body_label_thickness;
    label_len = len(label);
    labelspace = [gearbox_d/2-mount_screwhead_d/2-min_xy_shell,longwing-(mount_screwhead_d-st_split_w-st_split_w_tolerance)/2-2*min_xy_shell];
    translate([0,0,body_h-label_thickness])
    linear_extrude(height=label_thickness+epsilon,convexity=64)
    translate([-mount_screwhead_d/2-min_xy_shell-labelspace.x/2,-longwing+(st_split_w+st_split_w_tolerance)/2+min_xy_shell+labelspace.y/2])
    mirror([left?0:1,0])
    text(text=label,size=labelspace.x/label_len,halign="center",valign="center",font="Arial Black");
   }else sphere(d=epsilon); // to avoid makefile breakage
  }
 
+ st_bump = 4*extrusion_width;
+ st_bump_tip = 2*extrusion_width;
  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 = max(hf*2,fsw-st_screw_l+hf);
+  h = max(hf*3,fsw-st_screw_l+hf);
   translate([-gearbox_d/2+fsw-h,-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,$fn=fnd*spring_d*3/4);
     l = body_h-ls_z;
     w = sp_ch;
-    hull() translate([0,-st_split_w/2,0]) mirror([1,0,0]) {
-     translate([0,0,w])
-     cube(size=[l,st_split_w,w]);
-     cube(size=[l-w,st_split_w,2*w]);
+    translate([0,-st_split_w/2,0]) mirror([1,0,0]) {
+     hull()  {
+      translate([0,0,w+st_bump])
+      cube(size=[l+st_bump,st_split_w,w]);
+      cube(size=[l-w,st_split_w,2*w]);
+     }
+     translate([l,0,w+st_bump]) hull() {
+      cube(size=[st_split_w,st_split_w,st_bump]);
+      translate([0,-st_bump+st_bump_tip,st_bump]) mirror([0,0,1])
+      cube(size=[st_split_w,st_split_w+2*(st_bump-st_bump_tip),st_bump_tip]);
+     }
     }
    }
    translate([0,0,-epsilon])
    cylinder(d=st_screw_d+st_screw_d_tolerance,
     h=min(st_screw_l,fsw-hf)-fsw+h+2*epsilon,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
   }
  }
 
  module knob() {
   ch = knob_indent_d/2;
   knob_bore_l = body_h-protrusion_h-pulley_elevation-pulley_h-knob_v_clearance;
   translate([0,0,body_h+epsilon]) {
    mirror([0,0,1]) translate([0,0,-epsilon]) {
     difference() {
      cylinder(d=pulley_d,h=knob_bore_l,$fn=fnd*pulley_d);
      translate([0,0,-1]) difference() {
       cylinder(d=bore_d+knob_bore_d_tolerance,h=knob_bore_l+2);
       translate([-bore_d/2-1,bore_dd-bore_d/2+knob_bore_d_tolerance/2,-1])
       cube([bore_d+2,bore_d/2,knob_bore_l+4]);
      }
     }
    }
    difference() {
     hull() {
      cylinder(d=gearbox_d-2*ch,h=knob_h,$fn=fnd*gearbox_d);
      translate([0,0,ch])
      cylinder(d=gearbox_d,h=knob_h-2*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);
     translate([0,0,-body_h-epsilon]) knob_label();
    }
   }
  }//knob module
  module knob_label() {
   if(knob_label) {
    ll = len(knob_label);
    lsl = gearbox_d-knob_indent_d;
    ts = knob_label_size?knob_label_size:min(lsl/ll,gearbox_d/4);
    translate([0,0,body_h+epsilon+knob_h-knob_label_thickness])
    linear_extrude(height=knob_label_thickness+epsilon,convexity=64)
    mirror([left?0:1,0])
    text(text=knob_label,size=ts,halign="center",valign="center",font="Arial Black");
   }else sphere(d=epsilon); // to avoid makefile breakage
  }
 
  module debug() {
   difference() {
    children();
    if(debug) {
     // spring tensioner debug cutout
     translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0])
     translate([0,-lever_thickness/2-1,-gearbox_d-1])
-    cube(size=[body_h/2+1,lever_thickness/2+1,gearbox_d+2]);
+    cube(size=[body_h-ls_z+st_bump+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=[lsd*sqrt(2)/2+1,lsd*sqrt(2)/2+1,
                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+knob_h+1]);
    }//if debug
   }//difference
  }
 
  mirrorleft()
  debug()
  if(what=="lever") color("green",0.7) lever();
  else if(what=="body") color("yellow",0.7) body();
  else if(what=="body.label") color("brown",0.7) body_label();
  else if(what=="knob") color("red",0.7) knob();
  else if(what=="knob.label") color("brown",0.7) knob_label();
  else if(what=="springpad") color("blue",0.7) springpad();
  else if(what=="both") {
   color("green",0.7) lever();
   color("yellow",0.7) body();
   color("brown",0.7) body_label();
  }else{
   color("green",0.7) lever();
   color("yellow",0.7) body();
   color("brown",0.7) body_label();
   color("red",0.7) knob();
   color("brown",0.7) knob_label();
   color("blue",0.7) springpad();
  }
 }
 
 the_extruder(what="*",left=false,debug=true);