another: work being done on spring tensioner

1 files changed, 50 insertions, 7 deletions

diff --git a/another.scad b/another.scad
index 2be24e4..844dc3b 100644
--- a/another.scad
+++ b/another.scad
@@ -1,104 +1,110 @@
 draft=true;
 layer_height=0.2; extrusion_width=0.4;
 epsilon=0.01;
 $fs=0.0125;
 
 use <pushfittery.scad>;
 include <pushfit_data.scad>;
 
 module the_extruder(
  // motor properties
  gearbox_d = 36,
          mount_d = 28,                          // the distance between opposite mounting holes
  mounthole_depth = 5,
          protrusion_d = 22, protrusion_h = 2.2,         // the dimensions of the protrusion on top of gearbox
  bore_d = 8, bore_l = 17.6,
  bore_dd = 7,
  // pulley properties
  pulley_d = 11.5, pulley_h=10,
          pulley_elevation = 1,                  // pulley elevation above the protrusion
          teeth_elevation = 7.5,                         // distance from the bottom of the pulley to its teeth
  // idler properties
          idler_d = 9.5, idler_h = 4, idler_id = 3,// idler dimensions: outer and inner diameters and height
  // spring properties
          spring_d = 10, spring_lc = 9.6,        // spring diameter and compressed length
  // filament path properties
  filament_d = 1.75,
  filament_path_d = 2,
          filament_guide_d = 4,                  // PTFE filament guide diameter
  // knob properties
  knob_h = 10,
  knob_bore_l = 4,
  knob_indent_d = 4,
  knob_indents = 12,
+ // spring tensioner
+ st_nut_d = 9, st_nut_h = 4,
+ st_screw_d = 5,
+ st_shell = 4*extrusion_width,
 
  // screw it
  mount_screw_d = 3.1, mount_screw_l = 20,
  mount_screwhead_d=6, mount_screwhead_h=3,
 
  pf = pushfit_embeddest,
 
  // empty spaces
          idler_travel = 3,                      // how far should idler travel when pressed
  idler_clearance=1,
  pulley_clearance=2,
          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,
 
- what="lever",
+ what="lever",  // lever|body|knob|springpad|*
  left=false,
  vitamins = true,
- supports = false
+ supports = false,
+ tensioner = true,
+ debug = false
 ) {
  lever_shell = mount_screwhead_h+0.5;
  lever_thickness=max(spring_d+layer_height*8,idler_h+idler_v_tolerance+2*lever_shell);
  lsd = idler_d-idler_clearance*2;
  longwing=gearbox_d/2+spring_d/2+lsd/2;
  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;
 
  filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
  ls_z = filament_elevation; // leverspace mid-z
  body_h = max(protrusion_h+bore_l,mount_screw_l-mounthole_depth/2+mount_screwhead_h,ls_z*2);
  ls_h = lever_thickness+lever_v_clearance; // leverspace height
 
  module mirrorleft() {
   mirror([left?0:1,0,0]) children();
  }
  module place_idler() {
   rotate([0,0,45])
   translate([(pulley_d+idler_d)/2,0,0])
   children();
  }
  module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) {
   if(depth) {
    hh = (-4*pow(depth,2)+pow(d,2))/(8*depth);
    rr = depth+hh;
    translate([0,0,hh]) sphere(r=rr,$fn=2*PI*rr);
   }else if(r) {
    hh=sqrt(pow(r,2)-pow(d,2)/4);
    translate([0,0,hh]) sphere(r=r,$fn=2*PI*r);
   }
  }
 
  % if(vitamins) mirrorleft() {
   translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60);
   for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0])
    cylinder(d=mount_screw_d,h=20,$fn=30);
   translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30);
   translate([0,0,protrusion_h]) {
    difference() {
     cylinder(d=bore_d,h=bore_l,$fn=30);
     translate([-bore_d/2-1,bore_dd-bore_d/2,-1])
     cube([bore_d+2,bore_d/2,bore_l+2]);
    }
    translate([0,0,pulley_elevation]) {
     cylinder(d=pulley_d,h=pulley_h,$fn=30);
     translate([0,0,teeth_elevation]) {
      place_idler() {
@@ -152,186 +158,223 @@ module the_extruder(
      }
      cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=30);
      translate([0,0,lever_thickness/2-mount_screwhead_h]) 
      cylinder(d=mount_screwhead_d,h=mount_screwhead_h+1,$fn=2*PI*mount_screwhead_d);
     }
     // mounting screw hole
     translate([mount_d/2,0,0])
     cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=2*PI*mount_screw_d);
     
     // lever end
     translate([mount_d/2,0,0]) rotate([0,90,0]) {
      translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15);
      translate([0,-longwing,0])
      mirror([0,0,1])
      difference() {
       cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=2*PI*spring_d);
       sphere(d=spring_d*3/4,$fn=PI*spring_d);
      }
     }//rotate-translate
    }//difference
    // bridging patch
    place_idler()
    translate([0,0,lever_thickness/2-mount_screwhead_h])
    mirror([0,0,1])
    cylinder(d=mount_screwhead_d,h=layer_height);
   }//translate
  }//lever module
  
  module body() {
   difference() {
    union() {
    cylinder(d=gearbox_d,h=body_h,$fn=2*PI*gearbox_d);
     // finger and spring support
     fsw = gearbox_d/2+mount_screwhead_d/2;
     translate([-gearbox_d/2,0,0]) difference() {
      union() {
       hull() {
        translate([0,-longwing,ls_z])
        rotate([0,90,0])
        cylinder(d=max(lever_thickness,spring_d+spring_d_clearance+2*extrusion_width),h=fsw,$fn=2*PI*lever_thickness);
        hh=body_h-ls_z;
        translate([0,0,ls_z-lever_thickness/2])
        mirror([0,1,0]) cube(size=[fsw,longwing-hh+lever_thickness/sqrt(2),hh+lever_thickness/2]);
        hhh=ls_z;
        translate([0,0,0])
        mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]);
       }
      }
-     translate([0,-longwing,ls_z]) rotate([0,-90,0])
-     finger_indent(d=lever_thickness-1,r=15);
+     translate([0,-longwing,ls_z]) rotate([0,-90,0]) {
+      if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else {
+       if(debug) translate([0,-gearbox_d,-gearbox_d]) cube(size=[body_h/2+1,gearbox_d,gearbox_d+2]);
+       mirror([0,0,1]) {
+        translate([0,0,st_shell])
+        hull() for(o=[0,spring_d]) translate([0,-o,0])
+        rotate([0,0,30])
+        cylinder(d=st_nut_d,h=st_nut_h,$fn=6);
+        translate([0,0,-1]) cylinder(d=st_screw_d,h=fsw+2,$fn=st_screw_d*PI*2);
+        bigd = spring_d+spring_d_clearance;
+        hf = (bigd-st_screw_d)/2;
+        translate([0,0,st_shell+st_nut_h+st_shell-epsilon])
+        cylinder(d1=st_screw_d,d2=bigd,
+         h=hf+epsilon, $fn=bigd*PI*2 );
+        translate([0,0,st_shell+st_nut_h+st_shell+hf-epsilon])
+        cylinder(d=bigd,h=fsw+1,$fn=bigd*PI*2);
+       }
+      }
+     }
     } // translate
     
     // pushfit bracket
     translate([0,0,filament_elevation])
     rotate([0,0,45]) translate([pulley_d/2,0,0])
     rotate([-90,0,0])
     translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/])
     cylinder(r=min(body_h-filament_elevation,filament_elevation)/sin(60)-epsilon,h=pf_h(pf)+gearbox_d/2/*TODO:*/,$fn=6);
    }//union (first child of difference)
    // protrusion
    translate([0,0,-1])
    cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=2*PI*protrusion_d);
    // mount screw holes
    for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) {
     translate([0,0,mount_screw_l-mounthole_depth/2-layer_height-1])
     mirror([0,0,1])
     cylinder(d=mount_screw_d+mount_screw_d_tolerance,
              h=mount_screw_l-mounthole_depth/2-layer_height+1,
              $fn=2*PI*mount_screw_d);
     translate([0,0,mount_screw_l-mounthole_depth/2])
     cylinder(d=mount_screwhead_d,h=body_h+1,$fn=2*PI*mount_screwhead_d);
    }//for
    // pushfit
    translate([0,0,filament_elevation])
    rotate([0,0,45]) translate([pulley_d/2,0,0])
    rotate([-90,0,0])
    translate([0,0,mount_d/sqrt(2)/2+mount_screw_d+epsilon])
    rotate([0,0,180]) {
     pushfit(pf);
     cylinder(d=filament_guide_d,h=gearbox_d,center=true,$fn=2*PI*filament_guide_d);
     translate([0,-filament_guide_d/2/sqrt(2),0])
     rotate([0,0,45])
     cube(size=[filament_guide_d/2,filament_guide_d/2,gearbox_d],center=true);
    }
    // pulley
    cylinder(d=pulley_d+pulley_clearance,h=body_h+1,$fn=2*PI*(pulley_d+pulley_clearance));
    // leverspace
    hull() for(x=[0,gearbox_d])
    rotate([0,0,45])
    translate([x,0,ls_z-ls_h/2])
    cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=2*PI*idler_d);
    
    a=cos(45)*(pulley_d+idler_d)/2;
    b=mount_d/2-a;
    x=sqrt(pow(a,2)+pow(b,2));
    translate([mount_d/2,0,ls_z])
    intersection() {
     r = x+idler_d/2+1;/* TODO: */
     cylinder(r=r,h=ls_h,center=true);
     translate([-r-1,0,-1]) cube(size=[2*r+2,r+1,ls_h+2]);
    }
    
    rotate([0,0,-45])
    translate([0,0,ls_z-ls_h/2])
    cube(size=[gearbox_d,gearbox_d,lever_thickness+lever_v_clearance]);
    translate([0,0,ls_z-ls_h/2]) {
     translate([mount_screwhead_d/2,0,0])
     mirror([0,1,0])
     cube(size=[gearbox_d,gearbox_d/2+1,lever_thickness+lever_v_clearance]);
    }
    //translate([-mount_d/2,-longwing,filament_elevation])
-   translate([mount_d/2,-longwing,filament_elevation])
+   if(!tensioner) translate([mount_d/2,-longwing,filament_elevation])
    rotate([0,-90,0]) difference() {
     cylinder(d=spring_d+spring_d_clearance,h=spring_lc+spring_dl,$fn=PI*spring_d);
     translate([0,0,spring_lc+spring_dl]) sphere(d=spring_d*3/4,$fn=PI*spring_d);
    }
    //sphere(d=spring_d*3/4,$fn=PI*spring_d);
    *difference() {
     // spring support
     translate([0,-longwing,filament_elevation])
     sphere(d=spring_d*3/4,$fn=PI*spring_d);
    }
     
   }//difference
 
   if(supports) intersection() {
    difference() {
     translate([0,0,ls_z-ls_h/2-epsilon])
     cylinder(d=gearbox_d,h=ls_h+2*epsilon,$fn=2*PI*gearbox_d);
     cylinder(d=pulley_d+pulley_clearance,h=body_h+1,$fn=2*PI*(pulley_d+pulley_clearance));
    }
    // supports
    // TODO: hardcoded stuff below…
    if(false) { // parallel
     for(y=[-gearbox_d:4:gearbox_d])
      translate([0,y-extrusion_width/2,0])
      cube(size=[gearbox_d,extrusion_width,body_h]);
    }else{ // radial
     for(zr=[-65:(65+50)/7:50])
      rotate([0,0,zr]) translate([0,-extrusion_width/2,0])
      cube(size=[gearbox_d,extrusion_width,body_h]);
    }
   }
 
  }//body module
 
+ module springpad() {
+  smalld=st_screw_d+extrusion_width;
+  bigd = spring_d+spring_d_clearance/2;
+  hf = (bigd-smalld)/2;
+  translate([-gearbox_d/2+st_shell+st_nut_h+st_shell+smalld,-longwing,filament_elevation])
+  rotate([0,90,0]) difference() {
+   union() {
+    cylinder(d1=smalld,d2=bigd,h=hf,$fn=bigd*PI*2);
+    translate([0,0,hf-epsilon])
+    cylinder(d=bigd,h=hf*2,$fn=bigd*PI*2);
+   }
+   cylinder(d=st_screw_d,h=2*hf,$fn=st_screw_d*PI*2);
+  }
+ }
+
  module knob() {
   ch = knob_indent_d/2;
   translate([0,0,body_h+epsilon]) {
    mirror([0,0,1]) translate([0,0,-epsilon]) {
     difference() {
      cylinder(d=pulley_d,h=knob_bore_l,$fn=pulley_d*PI*2);
      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() {
     union() {
      cylinder(d1=gearbox_d-2*ch,d2=gearbox_d,h=ch+epsilon,$fn=PI*gearbox_d*2);
      translate([0,0,ch])
      cylinder(d=gearbox_d,h=knob_h-2*ch+epsilon,$fn=PI*gearbox_d*2);
      translate([0,0,knob_h-ch])
      cylinder(d1=gearbox_d,d2=gearbox_d-2*ch,h=ch,$fn=PI*gearbox_d*2);
     }
     for(a=[0:360/knob_indents:359]) rotate([0,0,a])
      translate([0,gearbox_d/2,-1])
      cylinder(d=knob_indent_d,h=knob_h+2,$fn=knob_indent_d*PI*2);
    }
   }
  }//knob module
- 
+
  mirrorleft()
  if(what=="lever") color("green",0.7) lever();
  else if(what=="body") color("yellow",0.7) body();
  else if(what=="knob") color("red",0.7) knob();
- else if(what=="both" || what=="*") {
+ else if(what=="springpad") color("blue",0.7) springpad();
+ else if(what=="both") {
+  color("green",0.7) lever();
+  color("yellow",0.7) body();
+ }else{
   color("green",0.7) lever();
   color("yellow",0.7) body();
   color("red",0.7) knob();
+  color("blue",0.7) springpad();
  }
 }
 
 the_extruder(what="both",left=false);