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-rw-r--r--another.scad2
1 files changed, 1 insertions, 1 deletions
diff --git a/another.scad b/another.scad
index 20ac37a..bb67dea 100644
--- a/another.scad
+++ b/another.scad
@@ -1,473 +1,473 @@
1draft=true; 1draft=true;
2layer_height=0.2; extrusion_width=0.4; 2layer_height=0.2; extrusion_width=0.4;
3epsilon=0.01; 3epsilon=0.01;
4$fs=0.0125; 4$fs=0.0125;
5 5
6use <pushfittery.scad>; 6use <pushfittery.scad>;
7include <pushfit_data.scad>; 7include <pushfit_data.scad>;
8 8
9module the_extruder( 9module the_extruder(
10 // motor properties 10 // motor properties
11 gearbox_d = 36, 11 gearbox_d = 36,
12 mount_d = 28, // the distance between opposite mounting holes 12 mount_d = 28, // the distance between opposite mounting holes
13 mounthole_depth = 5, 13 mounthole_depth = 5,
14 mounthole_min_depth = 3, mounthole_max_depth = 4, 14 mounthole_min_depth = 3, mounthole_max_depth = 4,
15 protrusion_d = 22, protrusion_h = 2.2, // the dimensions of the protrusion on top of gearbox 15 protrusion_d = 22, protrusion_h = 2.2, // the dimensions of the protrusion on top of gearbox
16 bore_d = 8, bore_l = 17.6, 16 bore_d = 8, bore_l = 17.6,
17 bore_dd = 7, 17 bore_dd = 7,
18 // pulley properties 18 // pulley properties
19 pulley_d = 11.5, pulley_h=10, 19 pulley_d = 11.5, pulley_h=10,
20 pulley_elevation = 1, // pulley elevation above the protrusion 20 pulley_elevation = 1, // pulley elevation above the protrusion
21 teeth_elevation = 7.5, // distance from the bottom of the pulley to its teeth 21 teeth_elevation = 7.5, // distance from the bottom of the pulley to its teeth
22 filament_offset = (8.25-(3.0+3.5)/2) - 11.5/2 + 1.75/2, 22 filament_offset = (8.25-(3.0+3.5)/2) - 11.5/2 + 1.75/2,
23 // idler properties 23 // idler properties
24 idler_d = 9.5, idler_h = 4, idler_id = 3,// idler dimensions: outer and inner diameters and height 24 idler_d = 9.5, idler_h = 4, idler_id = 3,// idler dimensions: outer and inner diameters and height
25 // spring properties 25 // spring properties
26 spring_d = 10, spring_lc = 9.6, // spring diameter and compressed length 26 spring_d = 10, spring_lc = 9.6, // spring diameter and compressed length
27 // filament path properties 27 // filament path properties
28 filament_d = 1.75, 28 filament_d = 1.75,
29 filament_path_d = 2, 29 filament_path_d = 2,
30 filament_guide_d = 4, // PTFE filament guide diameter 30 filament_guide_d = 4, // PTFE filament guide diameter
31 // knob properties 31 // knob properties
32 knob_h = 10, 32 knob_h = 10,
33 knob_bore_l = 4, 33 knob_bore_l = 4,
34 knob_indent_d = 4, 34 knob_indent_d = 4,
35 knob_indents = 12, 35 knob_indents = 12,
36 // spring tensioner 36 // spring tensioner
37 st_nut_d = 9, st_nut_h = 4, 37 st_nut_d = 9, st_nut_h = 4,
38 st_screw_d = 5, 38 st_screw_d = 5,
39 st_thickshell = 8*extrusion_width, st_thinshell = 4*extrusion_width, 39 st_thickshell = 8*extrusion_width, st_thinshell = 2*extrusion_width,
40 40
41 // screw it 41 // screw it
42 mount_screw_d = 3.1, mount_screw_l = 20, 42 mount_screw_d = 3.1, mount_screw_l = 20,
43 mount_screwhead_d=6, mount_screwhead_h=3, 43 mount_screwhead_d=6, mount_screwhead_h=3,
44 idler_screw_d = 3, 44 idler_screw_d = 3,
45 idler_screwhead_d=6, idler_screwhead_h=3, 45 idler_screwhead_d=6, idler_screwhead_h=3,
46 46
47 pf = pushfit_embeddest, 47 pf = pushfit_embeddest,
48 pf_shell = max(3*layer_height,3*extrusion_width), 48 pf_shell = max(3*layer_height,3*extrusion_width),
49 pf_smooth = true, 49 pf_smooth = true,
50 50
51 // empty spaces 51 // empty spaces
52 idler_travel = 3, // how far should idler travel when pressed 52 idler_travel = 3, // how far should idler travel when pressed
53 idler_clearance=1, 53 idler_clearance=1,
54 pulley_d_clearance=2, 54 pulley_d_clearance=2,
55 pulley_small_d_clearance=0.5, 55 pulley_small_d_clearance=0.5,
56 lever_v_clearance=.7, // vertical clearance for the lever 56 lever_v_clearance=.7, // vertical clearance for the lever
57 spring_d_clearance=1, 57 spring_d_clearance=1,
58 protrusion_tolerance_h=.5, // horizontal tolerance for the motor protrusion 58 protrusion_tolerance_h=.5, // horizontal tolerance for the motor protrusion
59 protrusion_tolerance_v=.5, // vertical tolerance for the motor protrusion 59 protrusion_tolerance_v=.5, // vertical tolerance for the motor protrusion
60 mount_screw_d_tolerance=.4, 60 mount_screw_d_tolerance=.4,
61 idler_v_tolerance=.5, 61 idler_v_tolerance=.5,
62 knob_bore_d_tolerance=.6, 62 knob_bore_d_tolerance=.6,
63 st_nut_h_tolerance=.2, 63 st_nut_h_tolerance=.2,
64 st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */ 64 st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */
65 st_screw_d_tolerance=.5, 65 st_screw_d_tolerance=.5,
66 st_split_w_tolerance = .3, 66 st_split_w_tolerance = .3,
67 67
68 min_z_shell = 4*layer_height, // the very minimal shell thickness along z-axis. 68 min_z_shell = 4*layer_height, // the very minimal shell thickness along z-axis.
69 min_xy_shell = 2*extrusion_width, 69 min_xy_shell = 2*extrusion_width,
70 70
71 what="lever", // lever|body|knob|springpad|* 71 what="lever", // lever|body|knob|springpad|*
72 left=false, 72 left=false,
73 vitamins = true, 73 vitamins = true,
74 bridges = true, 74 bridges = true,
75 debug = false 75 debug = false
76) { 76) {
77 fnd = 2*PI; fnr = 2*fnd; 77 fnd = 2*PI; fnr = 2*fnd;
78 78
79 idler_filament_offset = filament_path_d/2; // -filament_offset; 79 idler_filament_offset = filament_path_d/2; // -filament_offset;
80 lever_shell = mount_screwhead_h+0.5; 80 lever_shell = mount_screwhead_h+0.5;
81 lever_thickness=max(spring_d+spring_d_clearance+layer_height*8,idler_h+idler_v_tolerance+2*lever_shell); 81 lever_thickness=max(spring_d+spring_d_clearance+layer_height*8,idler_h+idler_v_tolerance+2*lever_shell);
82 lsd = idler_d-idler_clearance*2; // the diameter of lever thingie 82 lsd = idler_d-idler_clearance*2; // the diameter of lever thingie
83 longwing=(mount_d+mount_screw_d+mount_screw_d_tolerance+spring_d+spring_d_clearance)/2+min_xy_shell; 83 longwing=(mount_d+mount_screw_d+mount_screw_d_tolerance+spring_d+spring_d_clearance)/2+min_xy_shell;
84 shortwing = let(a=mount_d/2,c=(pulley_d+idler_d)/2/sqrt(2)) 84 shortwing = let(a=mount_d/2,c=(pulley_d+idler_d)/2/sqrt(2))
85 sqrt(c*c+pow(a-c,2)); 85 sqrt(c*c+pow(a-c,2));
86 longwing_travel = idler_travel*longwing/shortwing; 86 longwing_travel = idler_travel*longwing/shortwing;
87 h_ = (pulley_d+idler_d)/(2*sqrt(2)); 87 h_ = (pulley_d+idler_d)/(2*sqrt(2));
88 ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) ); 88 ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) );
89 spring_dl = idler_travel*longwing/ri; 89 spring_dl = idler_travel*longwing/ri;
90 // finger and spring support 90 // finger and spring support
91 fsw = gearbox_d-(gearbox_d-mount_d)/2-max(spring_lc,longwing_travel+(gearbox_d-mount_d)/2); 91 fsw = gearbox_d-(gearbox_d-mount_d)/2-max(spring_lc,longwing_travel+(gearbox_d-mount_d)/2);
92 92
93 mount_min_depth = mounthole_min_depth ? mounthole_min_depth : mounthole_depth-1; 93 mount_min_depth = mounthole_min_depth ? mounthole_min_depth : mounthole_depth-1;
94 mount_max_depth = mounthole_max_depth ? mounthole_max_depth : mounthole_depth+1; 94 mount_max_depth = mounthole_max_depth ? mounthole_max_depth : mounthole_depth+1;
95 filament_elevation=protrusion_h+pulley_elevation+teeth_elevation; 95 filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
96 ls_z = filament_elevation; // leverspace mid-z 96 ls_z = filament_elevation; // leverspace mid-z
97 ls_h = lever_thickness+lever_v_clearance; // leverspace height 97 ls_h = lever_thickness+lever_v_clearance; // leverspace height
98 mount_depth = mount_screw_l - (ls_z+ls_h/2+min_z_shell); 98 mount_depth = mount_screw_l - (ls_z+ls_h/2+min_z_shell);
99 body_h = max(protrusion_h+bore_l,mount_screw_l-mount_depth+mount_screwhead_h+min_z_shell,ls_z*2); 99 body_h = max(protrusion_h+bore_l,mount_screw_l-mount_depth+mount_screwhead_h+min_z_shell,ls_z*2);
100 echo("mount depth",mount_depth); 100 echo("mount depth",mount_depth);
101 101
102 module teardrop(r,d,h,center=false,angle=45) { 102 module teardrop(r,d,h,center=false,angle=45) {
103 dd = d ? d : (2*r); 103 dd = d ? d : (2*r);
104 $fn = dd*fnd; 104 $fn = dd*fnd;
105 cylinder(d=dd,h=h,center=center); 105 cylinder(d=dd,h=h,center=center);
106 if(angle>0) translate([0,0,center?-h/2:0]) 106 if(angle>0) translate([0,0,center?-h/2:0])
107 rotate([0,0,angle]) 107 rotate([0,0,angle])
108 cube(size=[d/2,d/2,h]); 108 cube(size=[d/2,d/2,h]);
109 } 109 }
110 110
111 module mirrorleft() { 111 module mirrorleft() {
112 mirror([left?0:1,0,0]) children(); 112 mirror([left?0:1,0,0]) children();
113 } 113 }
114 module place_idler() { 114 module place_idler() {
115 rotate([0,0,45]) 115 rotate([0,0,45])
116 translate([(pulley_d+idler_d)/2,0,0]) 116 translate([(pulley_d+idler_d)/2,0,0])
117 children(); 117 children();
118 } 118 }
119 module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) { 119 module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) {
120 if(depth) { 120 if(depth) {
121 hh = (-4*pow(depth,2)+pow(d,2))/(8*depth); 121 hh = (-4*pow(depth,2)+pow(d,2))/(8*depth);
122 rr = depth+hh; 122 rr = depth+hh;
123 translate([0,0,hh]) sphere(r=rr,$fn=fnr*rr); 123 translate([0,0,hh]) sphere(r=rr,$fn=fnr*rr);
124 }else if(r) { 124 }else if(r) {
125 hh=sqrt(pow(r,2)-pow(d,2)/4); 125 hh=sqrt(pow(r,2)-pow(d,2)/4);
126 translate([0,0,hh]) sphere(r=r,$fn=fnr*r); 126 translate([0,0,hh]) sphere(r=r,$fn=fnr*r);
127 } 127 }
128 } 128 }
129 129
130 % if(vitamins) mirrorleft() { 130 % if(vitamins) mirrorleft() {
131 translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60); 131 translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60);
132 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) 132 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0])
133 cylinder(d=mount_screw_d,h=20,$fn=30); 133 cylinder(d=mount_screw_d,h=20,$fn=30);
134 translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30); 134 translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30);
135 translate([0,0,protrusion_h]) { 135 translate([0,0,protrusion_h]) {
136 difference() { 136 difference() {
137 cylinder(d=bore_d,h=bore_l,$fn=30); 137 cylinder(d=bore_d,h=bore_l,$fn=30);
138 translate([-bore_d/2-1,bore_dd-bore_d/2,-1]) 138 translate([-bore_d/2-1,bore_dd-bore_d/2,-1])
139 cube([bore_d+2,bore_d/2,bore_l+2]); 139 cube([bore_d+2,bore_d/2,bore_l+2]);
140 } 140 }
141 translate([0,0,pulley_elevation]) { 141 translate([0,0,pulley_elevation]) {
142 cylinder(d=pulley_d,h=pulley_h,$fn=30); 142 cylinder(d=pulley_d,h=pulley_h,$fn=30);
143 translate([0,0,teeth_elevation]) { 143 translate([0,0,teeth_elevation]) {
144 place_idler() { 144 place_idler() {
145 cylinder(d=idler_d,h=idler_h,center=true,$fn=30); 145 cylinder(d=idler_d,h=idler_h,center=true,$fn=30);
146 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30); 146 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
147 }//place idler 147 }//place idler
148 // filament path 148 // filament path
149 rotate([0,0,45]) { 149 rotate([0,0,45]) {
150 translate([pulley_d/2-idler_filament_offset,0,0]) rotate([90,0,0]) { 150 translate([pulley_d/2-idler_filament_offset,0,0]) rotate([90,0,0]) {
151 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15); 151 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15);
152 }//rotate translate 152 }//rotate translate
153 translate([pulley_d/2+filament_offset,0,0]) rotate([-90,0,0]) { 153 translate([pulley_d/2+filament_offset,0,0]) rotate([-90,0,0]) {
154 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15); 154 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15);
155 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d]) 155 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d])
156 pushfit(pf); 156 pushfit(pf);
157 }//rotate translate 157 }//rotate translate
158 }//rotate 158 }//rotate
159 }//translate teeth 159 }//translate teeth
160 }//translate pulley 160 }//translate pulley
161 }//translate protrusion 161 }//translate protrusion
162 }//vitamins 162 }//vitamins
163 163
164 module lever() { 164 module lever() {
165 translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) { 165 translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) {
166 difference() { 166 difference() {
167 union() { 167 union() {
168 hull() { 168 hull() {
169 place_idler() 169 place_idler()
170 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 170 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
171 translate([mount_d/2,0,0]) 171 translate([mount_d/2,0,0])
172 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 172 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
173 }//hull 173 }//hull
174 hull() { 174 hull() {
175 translate([mount_d/2,0,0]) 175 translate([mount_d/2,0,0])
176 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 176 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
177 translate([mount_d/2,-longwing,0]) rotate([0,90,0]) 177 translate([mount_d/2,-longwing,0]) rotate([0,90,0])
178 cylinder(d=lever_thickness,h=lsd,center=true,$fn=60); 178 cylinder(d=lever_thickness,h=lsd,center=true,$fn=60);
179 }//hull 179 }//hull
180 }//union 180 }//union
181 181
182 // filament path 182 // filament path
183 place_idler() 183 place_idler()
184 translate([-idler_d/2-idler_filament_offset,0,0]) 184 translate([-idler_d/2-idler_filament_offset,0,0])
185 rotate([90,0,0]) { 185 rotate([90,0,0]) {
186 mirror([0,1,0]) 186 mirror([0,1,0])
187 teardrop(d=filament_path_d,h=3*gearbox_d,center=true); 187 teardrop(d=filament_path_d,h=3*gearbox_d,center=true);
188 translate([0,0, 188 translate([0,0,
189 sqrt(2)*(mount_d-pulley_d+lsd)/2 189 sqrt(2)*(mount_d-pulley_d+lsd)/2
190 ]) { 190 ]) {
191 cylinder(d1=filament_path_d,d2=2*filament_path_d, 191 cylinder(d1=filament_path_d,d2=2*filament_path_d,
192 h=filament_path_d,$fn=2*filament_path_d*fnd); 192 h=filament_path_d,$fn=2*filament_path_d*fnd);
193 translate([0,0,filament_path_d-epsilon]) 193 translate([0,0,filament_path_d-epsilon])
194 cylinder(d=2*filament_path_d,h=lsd*sqrt(2),$fn=2*filament_path_d*fnd); 194 cylinder(d=2*filament_path_d,h=lsd*sqrt(2),$fn=2*filament_path_d*fnd);
195 }//translate 195 }//translate
196 }//rotate translate place_idler 196 }//rotate translate place_idler
197 197
198 // idler space and mounting hole 198 // idler space and mounting hole
199 place_idler() { 199 place_idler() {
200 cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60); 200 cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60);
201 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30); 201 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
202 translate([0,0,lever_thickness/2-idler_screwhead_h]) 202 translate([0,0,lever_thickness/2-idler_screwhead_h])
203 cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d); 203 cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d);
204 } 204 }
205 // mounting screw hole 205 // mounting screw hole
206 translate([mount_d/2,0,0]) 206 translate([mount_d/2,0,0])
207 cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d); 207 cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d);
208 208
209 // lever end 209 // lever end
210 translate([mount_d/2,0,0]) rotate([0,90,0]) { 210 translate([mount_d/2,0,0]) rotate([0,90,0]) {
211 translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15); 211 translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15);
212 translate([0,-longwing,0]) 212 translate([0,-longwing,0])
213 mirror([0,0,1]) 213 mirror([0,0,1])
214 difference() { 214 difference() {
215 cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=fnd*(spring_d+spring_d_clearance)); 215 cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=fnd*(spring_d+spring_d_clearance));
216 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4); 216 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
217 } 217 }
218 }//rotate-translate 218 }//rotate-translate
219 }//difference 219 }//difference
220 // bridging patch 220 // bridging patch
221 if(bridges) place_idler() 221 if(bridges) place_idler()
222 translate([0,0,lever_thickness/2-mount_screwhead_h]) 222 translate([0,0,lever_thickness/2-mount_screwhead_h])
223 mirror([0,0,1]) 223 mirror([0,0,1])
224 cylinder(d=mount_screwhead_d,h=layer_height); 224 cylinder(d=mount_screwhead_d,h=layer_height);
225 }//translate 225 }//translate
226 }//lever module 226 }//lever module
227 227
228 module body() { 228 module body() {
229 difference() { 229 difference() {
230 union() { 230 union() {
231 cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d); 231 cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d);
232 // spring tensioner part 232 // spring tensioner part
233 translate([-gearbox_d/2,0,0]) hull() { 233 translate([-gearbox_d/2,0,0]) hull() {
234 translate([0,-longwing,ls_z]) 234 translate([0,-longwing,ls_z])
235 rotate([0,90,0]) 235 rotate([0,90,0])
236 cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness); 236 cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness);
237 hh=body_h-ls_z; 237 hh=body_h-ls_z;
238 translate([0,0,ls_z]) 238 translate([0,0,ls_z])
239 mirror([0,1,0]) cube(size=[fsw,longwing+(st_thinshell+st_split_w_tolerance)/2+st_thickshell,body_h-ls_z]); 239 mirror([0,1,0]) cube(size=[fsw,longwing+(st_thinshell+st_split_w_tolerance)/2+st_thickshell,body_h-ls_z]);
240 hhh=ls_z; 240 hhh=ls_z;
241 translate([0,0,0]) 241 translate([0,0,0])
242 mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]); 242 mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]);
243 }//hull translate 243 }//hull translate
244 244
245 // pushfit bracket 245 // pushfit bracket
246 translate([0,0,filament_elevation]) 246 translate([0,0,filament_elevation])
247 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0]) 247 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0])
248 rotate([-90,0,0]) 248 rotate([-90,0,0])
249 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) { 249 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) {
250 pfbl = pf_h(pf)+gearbox_d/2; //TODO: 250 pfbl = pf_h(pf)+gearbox_d/2; //TODO:
251 if(pf_smooth) { 251 if(pf_smooth) {
252 pfbd = pf_d(pf)+2*pf_shell; 252 pfbd = pf_d(pf)+2*pf_shell;
253 hull() { 253 hull() {
254 cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd); 254 cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd);
255 translate([-epsilon/2,0,0]) { 255 translate([-epsilon/2,0,0]) {
256 cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]); 256 cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]);
257 mirror([0,1,0]) 257 mirror([0,1,0])
258 cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]); 258 cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]);
259 }//translate 259 }//translate
260 }//hull 260 }//hull
261 }else{ 261 }else{
262 pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2; 262 pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2;
263 pfbd = pfb2a/cos(30); 263 pfbd = pfb2a/cos(30);
264 pfbs = pfb2a*tan(30); 264 pfbs = pfb2a*tan(30);
265 cylinder(d=pfbd,h=pfbl,$fn=6); 265 cylinder(d=pfbd,h=pfbl,$fn=6);
266 translate([-pfbs/2,0,0]) { 266 translate([-pfbs/2,0,0]) {
267 hull() { 267 hull() {
268 translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]); 268 translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]);
269 cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]); 269 cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]);
270 mirror([0,1,0]) 270 mirror([0,1,0])
271 cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]); 271 cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]);
272 }//hull 272 }//hull
273 }//translate*/ 273 }//translate*/
274 }//if(pf_smooth) 274 }//if(pf_smooth)
275 }//translate rotate translate rotate translate 275 }//translate rotate translate rotate translate
276 }//union (first child of difference) 276 }//union (first child of difference)
277 277
278 // protrusion 278 // protrusion
279 translate([0,0,-1]) 279 translate([0,0,-1])
280 cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=fnd*(protrusion_d+protrusion_tolerance_h)); 280 cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=fnd*(protrusion_d+protrusion_tolerance_h));
281 // mount screw holes 281 // mount screw holes
282 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) { 282 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) {
283 translate([0,0,mount_screw_l-mount_depth-(bridges?layer_height:-epsilon)]) 283 translate([0,0,mount_screw_l-mount_depth-(bridges?layer_height:-epsilon)])
284 mirror([0,0,1]) 284 mirror([0,0,1])
285 cylinder(d=mount_screw_d+mount_screw_d_tolerance, 285 cylinder(d=mount_screw_d+mount_screw_d_tolerance,
286 h=mount_screw_l-mount_depth+1, 286 h=mount_screw_l-mount_depth+1,
287 $fn=fnd*(mount_screw_d+mount_screw_d_tolerance)); 287 $fn=fnd*(mount_screw_d+mount_screw_d_tolerance));
288 translate([0,0,mount_screw_l-mount_depth]) 288 translate([0,0,mount_screw_l-mount_depth])
289 cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d); 289 cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d);
290 }//for 290 }//for
291 // pushfit 291 // pushfit
292 pf_offset = mount_d/sqrt(2)/2+mount_screw_d; 292 pf_offset = mount_d/sqrt(2)/2+mount_screw_d;
293 translate([0,0,filament_elevation]) 293 translate([0,0,filament_elevation])
294 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0]) 294 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0])
295 rotate([-90,0,0]) 295 rotate([-90,0,0])
296 translate([0,0,pf_offset]) 296 translate([0,0,pf_offset])
297 rotate([0,0,180]) { 297 rotate([0,0,180]) {
298 pushfit(pf); 298 pushfit(pf);
299 mirror([0,0,1]) { 299 mirror([0,0,1]) {
300 fh = 1.5* (filament_guide_d-filament_path_d)/2; 300 fh = 1.5* (filament_guide_d-filament_path_d)/2;
301 fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh; 301 fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh;
302 translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,angle=225); 302 translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,angle=225);
303 translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225); 303 translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225);
304 translate([0,0,fo+epsilon]) 304 translate([0,0,fo+epsilon])
305 cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d); 305 cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d);
306 }//mirror 306 }//mirror
307 }//rotate translate rotate translate rotate translate 307 }//rotate translate rotate translate rotate translate
308 // pulley 308 // pulley
309 cylinder(d=pulley_d+pulley_small_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance)); 309 cylinder(d=pulley_d+pulley_small_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
310 cylinder(d=pulley_d+pulley_d_clearance,ls_z-max(idler_h,filament_guide_d)/2,$fn=fnd*(pulley_d+pulley_d_clearance)); 310 cylinder(d=pulley_d+pulley_d_clearance,ls_z-max(idler_h,filament_guide_d)/2,$fn=fnd*(pulley_d+pulley_d_clearance));
311 311
312 translate([0,0,ls_z-ls_h/2]) { 312 translate([0,0,ls_z-ls_h/2]) {
313 // idler travel 313 // idler travel
314 translate([mount_d/2,0,0]) 314 translate([mount_d/2,0,0])
315 rotate([0,0,45]) 315 rotate([0,0,45])
316 rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2)) 316 rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2))
317 square([shortwing+(idler_d+idler_clearance)/2,ls_h]); 317 square([shortwing+(idler_d+idler_clearance)/2,ls_h]);
318 // idler itself 318 // idler itself
319 place_idler() 319 place_idler()
320 cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance)); 320 cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
321 // lever space 321 // lever space
322 rotate([0,0,45]) 322 rotate([0,0,45])
323 rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1))) 323 rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1)))
324 square([gearbox_d/2+1,ls_h]); 324 square([gearbox_d/2+1,ls_h]);
325 } 325 }
326 326
327 // back side cutout 327 // back side cutout
328 // XXX: this is somewhat ugly and potentially bugged, 328 // XXX: this is somewhat ugly and potentially bugged,
329 // but I want to sleep. 329 // but I want to sleep.
330 a0_ = atan( 330 a0_ = atan(
331 (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2) 331 (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2)
332 / 332 /
333 ( 333 (
334 pulley_d/2+filament_offset- 334 pulley_d/2+filament_offset-
335 (pf_d(pf)+2*pf_shell)/2/cos(30) 335 (pf_d(pf)+2*pf_shell)/2/cos(30)
336 ) 336 )
337 ); 337 );
338 a0 = -135 + ( (a0_>0) ? a0_ : 180+a0_ ); 338 a0 = -135 + ( (a0_>0) ? a0_ : 180+a0_ );
339 a1 = atan((longwing-lever_thickness/2)/(gearbox_d/2)); 339 a1 = atan((longwing-lever_thickness/2)/(gearbox_d/2));
340 translate([0,0,ls_z]) difference() { 340 translate([0,0,ls_z]) difference() {
341 rotate([0,0,-180+a0]) 341 rotate([0,0,-180+a0])
342 rotate_extrude(angle=a1-a0) 342 rotate_extrude(angle=a1-a0)
343 translate([0,-ls_h/2]) 343 translate([0,-ls_h/2])
344 square([sqrt(pow(gearbox_d/2,2)+pow(longwing-lever_thickness/2,2))+1, 344 square([sqrt(pow(gearbox_d/2,2)+pow(longwing-lever_thickness/2,2))+1,
345 ls_h]); 345 ls_h]);
346 translate([-mount_d/2,0,0]) 346 translate([-mount_d/2,0,0])
347 cylinder(d=gearbox_d-mount_d,h=ls_h+2,center=true,$fn=fnd*(gearbox_d-mount_d)); 347 cylinder(d=gearbox_d-mount_d,h=ls_h+2,center=true,$fn=fnd*(gearbox_d-mount_d));
348 }//difference translate 348 }//difference translate
349 349
350 // spring tensioner 350 // spring tensioner
351 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) { 351 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) {
352 mirror([0,0,1]) { 352 mirror([0,0,1]) {
353 translate([0,0,st_thickshell]) 353 translate([0,0,st_thickshell])
354 hull() for(o=[0,spring_d]) translate([0,-o,0]) 354 hull() for(o=[0,spring_d]) translate([0,-o,0])
355 rotate([0,0,30]) 355 rotate([0,0,30])
356 cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6); 356 cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
357 translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance)); 357 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));
358 bigd = spring_d+spring_d_clearance; 358 bigd = spring_d+spring_d_clearance;
359 hf = (bigd-st_screw_d-st_screw_d_tolerance)/2; 359 hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
360 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) { 360 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) {
361 cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd, 361 cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
362 h=hf+epsilon, $fn=fnd*bigd); 362 h=hf+epsilon, $fn=fnd*bigd);
363 translate([0,-(st_thinshell+st_split_w_tolerance)/2,0]) 363 translate([0,-(st_thinshell+st_split_w_tolerance)/2,0])
364 cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]); 364 cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]);
365 }//translate 365 }//translate
366 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon]) 366 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
367 cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd); 367 cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
368 }//mirror 368 }//mirror
369 }//translate 369 }//translate
370 370
371 }//difference 371 }//difference
372 372
373 }//body module 373 }//body module
374 374
375 module springpad() { 375 module springpad() {
376 smalld=st_screw_d+st_screw_d_tolerance+min_xy_shell; 376 smalld=st_screw_d+st_screw_d_tolerance+min_xy_shell;
377 bigd = spring_d+spring_d_clearance/2; 377 bigd = spring_d+spring_d_clearance/2;
378 hf = (bigd-smalld)/2; 378 hf = (bigd-smalld)/2;
379 h = hf*3.5; 379 h = hf*3.5;
380 translate([-gearbox_d/2+st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+1,-longwing,filament_elevation]) 380 translate([-gearbox_d/2+st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+1,-longwing,filament_elevation])
381 rotate([0,90,0]) difference() { 381 rotate([0,90,0]) difference() {
382 union() { 382 union() {
383 cylinder(d1=smalld,d2=bigd,h=hf,$fn=fnd*bigd); 383 cylinder(d1=smalld,d2=bigd,h=hf,$fn=fnd*bigd);
384 translate([0,0,hf-epsilon]) 384 translate([0,0,hf-epsilon])
385 cylinder(d=bigd,h=h-hf,$fn=fnd*bigd); 385 cylinder(d=bigd,h=h-hf,$fn=fnd*bigd);
386 translate([0,0,h]) 386 translate([0,0,h])
387 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4); 387 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
388 l = body_h-ls_z; 388 l = body_h-ls_z;
389 w = st_thinshell; 389 w = st_thinshell;
390 hull() translate([0,-st_thinshell/2,0]) mirror([1,0,0]) { 390 hull() translate([0,-st_thinshell/2,0]) mirror([1,0,0]) {
391 translate([0,0,w]) 391 translate([0,0,w])
392 cube(size=[l,st_thinshell,w]); 392 cube(size=[l,st_thinshell,w]);
393 cube(size=[l-w,st_thinshell,2*w]); 393 cube(size=[l-w,st_thinshell,2*w]);
394 } 394 }
395 } 395 }
396 translate([0,0,-epsilon]) 396 translate([0,0,-epsilon])
397 cylinder(d=st_screw_d+st_screw_d_tolerance,h=2*hf+epsilon,$fn=fnd*(st_screw_d+st_screw_d_tolerance)); 397 cylinder(d=st_screw_d+st_screw_d_tolerance,h=2*hf+epsilon,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
398 } 398 }
399 } 399 }
400 400
401 module knob() { 401 module knob() {
402 ch = knob_indent_d/2; 402 ch = knob_indent_d/2;
403 translate([0,0,body_h+epsilon]) { 403 translate([0,0,body_h+epsilon]) {
404 mirror([0,0,1]) translate([0,0,-epsilon]) { 404 mirror([0,0,1]) translate([0,0,-epsilon]) {
405 difference() { 405 difference() {
406 cylinder(d=pulley_d,h=knob_bore_l,$fn=fnd*pulley_d); 406 cylinder(d=pulley_d,h=knob_bore_l,$fn=fnd*pulley_d);
407 translate([0,0,-1]) difference() { 407 translate([0,0,-1]) difference() {
408 cylinder(d=bore_d+knob_bore_d_tolerance,h=knob_bore_l+2); 408 cylinder(d=bore_d+knob_bore_d_tolerance,h=knob_bore_l+2);
409 translate([-bore_d/2-1,bore_dd-bore_d/2+knob_bore_d_tolerance/2,-1]) 409 translate([-bore_d/2-1,bore_dd-bore_d/2+knob_bore_d_tolerance/2,-1])
410 cube([bore_d+2,bore_d/2,knob_bore_l+4]); 410 cube([bore_d+2,bore_d/2,knob_bore_l+4]);
411 } 411 }
412 } 412 }
413 } 413 }
414 difference() { 414 difference() {
415 union() { 415 union() {
416 cylinder(d1=gearbox_d-2*ch,d2=gearbox_d,h=ch+epsilon,$fn=fnd*gearbox_d); 416 cylinder(d1=gearbox_d-2*ch,d2=gearbox_d,h=ch+epsilon,$fn=fnd*gearbox_d);
417 translate([0,0,ch]) 417 translate([0,0,ch])
418 cylinder(d=gearbox_d,h=knob_h-2*ch+epsilon,$fn=fnd*gearbox_d); 418 cylinder(d=gearbox_d,h=knob_h-2*ch+epsilon,$fn=fnd*gearbox_d);
419 translate([0,0,knob_h-ch]) 419 translate([0,0,knob_h-ch])
420 cylinder(d1=gearbox_d,d2=gearbox_d-2*ch,h=ch,$fn=fnd*gearbox_d); 420 cylinder(d1=gearbox_d,d2=gearbox_d-2*ch,h=ch,$fn=fnd*gearbox_d);
421 } 421 }
422 for(a=[0:360/knob_indents:359]) rotate([0,0,a]) 422 for(a=[0:360/knob_indents:359]) rotate([0,0,a])
423 translate([0,gearbox_d/2,-1]) 423 translate([0,gearbox_d/2,-1])
424 cylinder(d=knob_indent_d,h=knob_h+2,$fn=fnd*knob_indent_d); 424 cylinder(d=knob_indent_d,h=knob_h+2,$fn=fnd*knob_indent_d);
425 } 425 }
426 } 426 }
427 }//knob module 427 }//knob module
428 428
429 module debug() { 429 module debug() {
430 difference() { 430 difference() {
431 children(); 431 children();
432 if(debug) { 432 if(debug) {
433 // spring tensioner debug cutout 433 // spring tensioner debug cutout
434 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) 434 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0])
435 translate([0,-lever_thickness/2-1,-gearbox_d]) 435 translate([0,-lever_thickness/2-1,-gearbox_d])
436 cube(size=[body_h/2+1,lever_thickness/2+1,gearbox_d+2]); 436 cube(size=[body_h/2+1,lever_thickness/2+1,gearbox_d+2]);
437 // lever axis debug cutout 437 // lever axis debug cutout
438 translate([mount_d/2,0,-1]) 438 translate([mount_d/2,0,-1])
439 rotate([0,0,-45]) 439 rotate([0,0,-45])
440 cube(size=[gearbox_d-mount_d,gearbox_d-mount_d,body_h+knob_h+2]); 440 cube(size=[gearbox_d-mount_d,gearbox_d-mount_d,body_h+knob_h+2]);
441 // idler debug cutout 441 // idler debug cutout
442 translate([0,0,ls_z]) 442 translate([0,0,ls_z])
443 place_idler() 443 place_idler()
444 rotate([0,0,-45]) 444 rotate([0,0,-45])
445 translate([0,0,-lever_thickness/2-epsilon]) 445 translate([0,0,-lever_thickness/2-epsilon])
446 cube(size=[(idler_d+idler_clearance)/2,(idler_d+idler_clearance)/2, 446 cube(size=[(idler_d+idler_clearance)/2,(idler_d+idler_clearance)/2,
447 lever_thickness+2*epsilon]); 447 lever_thickness+2*epsilon]);
448 // pushfit debug cutout 448 // pushfit debug cutout
449 place_idler() 449 place_idler()
450 translate([-idler_d/2+filament_offset,0,ls_z]) 450 translate([-idler_d/2+filament_offset,0,ls_z])
451 cube(size=[gearbox_d/2,gearbox_d/2+pf_h(pf),body_h-ls_z+1]); 451 cube(size=[gearbox_d/2,gearbox_d/2+pf_h(pf),body_h-ls_z+1]);
452 }//if debug 452 }//if debug
453 }//difference 453 }//difference
454 } 454 }
455 455
456 mirrorleft() 456 mirrorleft()
457 debug() 457 debug()
458 if(what=="lever") color("green",0.7) lever(); 458 if(what=="lever") color("green",0.7) lever();
459 else if(what=="body") color("yellow",0.7) body(); 459 else if(what=="body") color("yellow",0.7) body();
460 else if(what=="knob") color("red",0.7) knob(); 460 else if(what=="knob") color("red",0.7) knob();
461 else if(what=="springpad") color("blue",0.7) springpad(); 461 else if(what=="springpad") color("blue",0.7) springpad();
462 else if(what=="both") { 462 else if(what=="both") {
463 color("green",0.7) lever(); 463 color("green",0.7) lever();
464 color("yellow",0.7) body(); 464 color("yellow",0.7) body();
465 }else{ 465 }else{
466 color("green",0.7) lever(); 466 color("green",0.7) lever();
467 color("yellow",0.7) body(); 467 color("yellow",0.7) body();
468 color("red",0.7) knob(); 468 color("red",0.7) knob();
469 color("blue",0.7) springpad(); 469 color("blue",0.7) springpad();
470 } 470 }
471} 471}
472 472
473the_extruder(what="*",left=false,debug=true); 473the_extruder(what="*",left=false,debug=true);