Initial

1 files changed, 300 insertions, 0 deletions

diff --git a/another.scad b/another.scad
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+draft=true;
+layer_height=0.2; extrusion_width=0.4;
+epsilon=0.01;
+$fs=0.0125;
+
+use <threads.scad>;
+module pushfit_thread(h=10) {
+ thr = 3/8 + .5/25.4;
+ slit = 25.4*thr/2 + 0.4;
+ if(draft) cylinder(d=thr*25.4,h=h);
+ else english_thread(diameter=thr,threads_per_inch=28,length=h/25.4,internal=true);
+ translate([-2,-slit,0]) cube([4,2*slit,h]);
+}
+
+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,
+ // 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
+
+ // screw it
+ mount_screw_d = 3, mount_screw_l = 20,
+ mount_screwhead_d=6, mount_screwhead_h=3,
+
+ // 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=.5,
+ idler_v_tolerance=.5,
+
+ what="lever",
+ left=false,
+ vitamins = true
+) {
+ 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;
+
+ 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,$fn=2*PI*r);
+  }
+ }
+
+ // vitamins
+ % if(vitamins) mirrorleft() {
+  translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$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]) {
+   cylinder(d=bore_d,h=bore_l,$fn=30);
+   translate([0,0,pulley_elevation]) {
+    cylinder(d=pulley_d,h=pulley_h,$fn=30);
+    translate([0,0,teeth_elevation]) {
+     place_idler() {
+      cylinder(d=idler_d,h=idler_h,center=true,$fn=30);
+      cylinder(d=idler_id,h=lever_thickness+2,center=true,$fn=30);
+     }//place idler
+     // filament path
+     rotate([0,0,45]) translate([(pulley_d-filament_path_d)/2,0,0]) {
+      rotate([90,0,0]) cylinder(d=filament_d,h=gearbox_d*2,center=true,$fn=15);
+      rotate([-90,0,0])
+      translate([0,0,mount_d/sqrt(2)/2+mount_screw_d])
+      pushfit_thread();
+     }
+    }//translate teeth
+   }//translate pulley
+  }//translate protrusion
+ }// vitamins to let
+
+ module lever() {
+  translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) {
+   difference() {
+    union() {
+     hull() {
+      place_idler()
+      cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
+      translate([mount_d/2,0,0])
+      cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
+     }//hull
+     hull() {
+      translate([mount_d/2,0,0])
+      cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
+      translate([mount_d/2,-longwing,0]) rotate([0,90,0])
+      cylinder(d=lever_thickness,h=lsd,center=true,$fn=60);
+     }//hull
+    }//union
+ 
+    // filament path
+    place_idler() translate([-(idler_d+filament_path_d)/2,0,0]) rotate([90,0,0]) {
+     cylinder(d=filament_path_d,h=3*gearbox_d,center=true,$fn=30);
+     translate([0,-filament_path_d/2/sqrt(2),0]) rotate([0,0,45])
+     cube(size=[filament_path_d/2,filament_path_d/2,3*gearbox_d],center=true);
+    }
+    
+    // idler space and mounting hole
+    place_idler() {
+     difference() {
+      cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60);
+      // supports
+      for(y=[-lsd/2+extrusion_width:(lsd-2*extrusion_width)/3:lsd/2-extrusion_width])
+       translate([-lsd/2-1,y-extrusion_width/2,-idler_h/2-idler_v_tolerance/2-1])
+       cube(size=[lsd+2,extrusion_width,idler_h+idler_v_tolerance+2]);
+     }
+     cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$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() {
+  filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
+  ls_z = filament_elevation;
+  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;
+  difference() {
+   union() {
+   cylinder(d=gearbox_d,h=body_h,$fn=2*PI*gearbox_d);
+    // finger and spring support
+    fsw = gearbox_d/2+mount_screwhead_d/2;
+    translate([-gearbox_d/2,0,0]) difference() {
+     union() {
+      hull() {
+       translate([0,-longwing,ls_z])
+       rotate([0,90,0])
+       cylinder(d=lever_thickness,h=fsw,$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
+    
+    // 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=10+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 threads
+   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_thread(h=10);
+    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,$fn=2*PI*idler_d);
+   
+   a=cos(45)*(pulley_d+idler_d)/2;
+   b=mount_d/2-a;
+   x=sqrt(pow(a,2)+pow(b,2));
+   translate([mount_d/2,0,ls_z])
+   intersection() {
+    r = x+idler_d/2+1;/* TODO: */
+    cylinder(r=r,h=ls_h,center=true);
+    translate([-r-1,0,-1]) cube(size=[2*r+2,r+1,ls_h+2]);
+   }
+   
+   rotate([0,0,-45])
+   translate([0,0,ls_z-ls_h/2])
+   cube(size=[gearbox_d,gearbox_d,lever_thickness+lever_v_clearance]);
+   translate([0,0,ls_z-ls_h/2]) {
+    translate([mount_screwhead_d/2,0,0])
+    mirror([0,1,0])
+    cube(size=[gearbox_d,gearbox_d/2+1,lever_thickness+lever_v_clearance]);
+   }
+   //translate([-mount_d/2,-longwing,filament_elevation])
+   translate([mount_d/2,-longwing,filament_elevation])
+   rotate([0,-90,0]) difference() {
+    cylinder(d=spring_d+spring_d_clearance,h=spring_lc+spring_dl,$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,$fn=PI*spring_d);
+   }
+    
+  }//difference
+
+  intersection() {
+   difference() {
+    translate([0,0,ls_z-ls_h/2-epsilon])
+    cylinder(d=gearbox_d,h=ls_h+2*epsilon,$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
+ 
+ mirrorleft()
+ if(what=="lever") color("green",0.7) lever();
+ else if(what=="body") color("yellow",0.7) body();
+ else if(what=="both") {
+  color("green",0.7) lever();
+  color("yellow",0.7) body();
+ }
+}
+
+the_extruder(what="both",left=false);