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1 files changed, 12 insertions, 1 deletions
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@@ -1,473 +1,484 @@
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 = 2*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 label = "another"
76) { 77) {
77 fnd = 2*PI; fnr = 2*fnd; 78 fnd = 2*PI; fnr = 2*fnd;
78 79
79 idler_filament_offset = filament_path_d/2; // -filament_offset; 80 idler_filament_offset = filament_path_d/2; // -filament_offset;
80 lever_shell = mount_screwhead_h+0.5; 81 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); 82 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 83 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; 84 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)) 85 shortwing = let(a=mount_d/2,c=(pulley_d+idler_d)/2/sqrt(2))
85 sqrt(c*c+pow(a-c,2)); 86 sqrt(c*c+pow(a-c,2));
86 longwing_travel = idler_travel*longwing/shortwing; 87 longwing_travel = idler_travel*longwing/shortwing;
87 h_ = (pulley_d+idler_d)/(2*sqrt(2)); 88 h_ = (pulley_d+idler_d)/(2*sqrt(2));
88 ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) ); 89 ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) );
89 spring_dl = idler_travel*longwing/ri; 90 spring_dl = idler_travel*longwing/ri;
90 // finger and spring support 91 // finger and spring support
91 fsw = gearbox_d-(gearbox_d-mount_d)/2-max(spring_lc,longwing_travel+(gearbox_d-mount_d)/2); 92 fsw = gearbox_d-(gearbox_d-mount_d)/2-max(spring_lc,longwing_travel+(gearbox_d-mount_d)/2);
92 93
93 mount_min_depth = mounthole_min_depth ? mounthole_min_depth : mounthole_depth-1; 94 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; 95 mount_max_depth = mounthole_max_depth ? mounthole_max_depth : mounthole_depth+1;
95 filament_elevation=protrusion_h+pulley_elevation+teeth_elevation; 96 filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
96 ls_z = filament_elevation; // leverspace mid-z 97 ls_z = filament_elevation; // leverspace mid-z
97 ls_h = lever_thickness+lever_v_clearance; // leverspace height 98 ls_h = lever_thickness+lever_v_clearance; // leverspace height
98 mount_depth = mount_screw_l - (ls_z+ls_h/2+min_z_shell); 99 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); 100 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); 101 echo("mount depth",mount_depth);
101 102
102 module teardrop(r,d,h,center=false,angle=45) { 103 module teardrop(r,d,h,center=false,angle=45) {
103 dd = d ? d : (2*r); 104 dd = d ? d : (2*r);
104 $fn = dd*fnd; 105 $fn = dd*fnd;
105 cylinder(d=dd,h=h,center=center); 106 cylinder(d=dd,h=h,center=center);
106 if(angle>0) translate([0,0,center?-h/2:0]) 107 if(angle>0) translate([0,0,center?-h/2:0])
107 rotate([0,0,angle]) 108 rotate([0,0,angle])
108 cube(size=[d/2,d/2,h]); 109 cube(size=[d/2,d/2,h]);
109 } 110 }
110 111
111 module mirrorleft() { 112 module mirrorleft() {
112 mirror([left?0:1,0,0]) children(); 113 mirror([left?0:1,0,0]) children();
113 } 114 }
114 module place_idler() { 115 module place_idler() {
115 rotate([0,0,45]) 116 rotate([0,0,45])
116 translate([(pulley_d+idler_d)/2,0,0]) 117 translate([(pulley_d+idler_d)/2,0,0])
117 children(); 118 children();
118 } 119 }
119 module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) { 120 module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) {
120 if(depth) { 121 if(depth) {
121 hh = (-4*pow(depth,2)+pow(d,2))/(8*depth); 122 hh = (-4*pow(depth,2)+pow(d,2))/(8*depth);
122 rr = depth+hh; 123 rr = depth+hh;
123 translate([0,0,hh]) sphere(r=rr,$fn=fnr*rr); 124 translate([0,0,hh]) sphere(r=rr,$fn=fnr*rr);
124 }else if(r) { 125 }else if(r) {
125 hh=sqrt(pow(r,2)-pow(d,2)/4); 126 hh=sqrt(pow(r,2)-pow(d,2)/4);
126 translate([0,0,hh]) sphere(r=r,$fn=fnr*r); 127 translate([0,0,hh]) sphere(r=r,$fn=fnr*r);
127 } 128 }
128 } 129 }
129 130
130 % if(vitamins) mirrorleft() { 131 % if(vitamins) mirrorleft() {
131 translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60); 132 translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60);
132 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) 133 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0])
133 cylinder(d=mount_screw_d,h=20,$fn=30); 134 cylinder(d=mount_screw_d,h=20,$fn=30);
134 translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30); 135 translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30);
135 translate([0,0,protrusion_h]) { 136 translate([0,0,protrusion_h]) {
136 difference() { 137 difference() {
137 cylinder(d=bore_d,h=bore_l,$fn=30); 138 cylinder(d=bore_d,h=bore_l,$fn=30);
138 translate([-bore_d/2-1,bore_dd-bore_d/2,-1]) 139 translate([-bore_d/2-1,bore_dd-bore_d/2,-1])
139 cube([bore_d+2,bore_d/2,bore_l+2]); 140 cube([bore_d+2,bore_d/2,bore_l+2]);
140 } 141 }
141 translate([0,0,pulley_elevation]) { 142 translate([0,0,pulley_elevation]) {
142 cylinder(d=pulley_d,h=pulley_h,$fn=30); 143 cylinder(d=pulley_d,h=pulley_h,$fn=30);
143 translate([0,0,teeth_elevation]) { 144 translate([0,0,teeth_elevation]) {
144 place_idler() { 145 place_idler() {
145 cylinder(d=idler_d,h=idler_h,center=true,$fn=30); 146 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); 147 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
147 }//place idler 148 }//place idler
148 // filament path 149 // filament path
149 rotate([0,0,45]) { 150 rotate([0,0,45]) {
150 translate([pulley_d/2-idler_filament_offset,0,0]) rotate([90,0,0]) { 151 translate([pulley_d/2-idler_filament_offset,0,0]) rotate([90,0,0]) {
151 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15); 152 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15);
152 }//rotate translate 153 }//rotate translate
153 translate([pulley_d/2+filament_offset,0,0]) rotate([-90,0,0]) { 154 translate([pulley_d/2+filament_offset,0,0]) rotate([-90,0,0]) {
154 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15); 155 cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15);
155 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d]) 156 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d])
156 pushfit(pf); 157 pushfit(pf);
157 }//rotate translate 158 }//rotate translate
158 }//rotate 159 }//rotate
159 }//translate teeth 160 }//translate teeth
160 }//translate pulley 161 }//translate pulley
161 }//translate protrusion 162 }//translate protrusion
162 }//vitamins 163 }//vitamins
163 164
164 module lever() { 165 module lever() {
165 translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) { 166 translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) {
166 difference() { 167 difference() {
167 union() { 168 union() {
168 hull() { 169 hull() {
169 place_idler() 170 place_idler()
170 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 171 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
171 translate([mount_d/2,0,0]) 172 translate([mount_d/2,0,0])
172 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 173 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
173 }//hull 174 }//hull
174 hull() { 175 hull() {
175 translate([mount_d/2,0,0]) 176 translate([mount_d/2,0,0])
176 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 177 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
177 translate([mount_d/2,-longwing,0]) rotate([0,90,0]) 178 translate([mount_d/2,-longwing,0]) rotate([0,90,0])
178 cylinder(d=lever_thickness,h=lsd,center=true,$fn=60); 179 cylinder(d=lever_thickness,h=lsd,center=true,$fn=60);
179 }//hull 180 }//hull
180 }//union 181 }//union
181 182
182 // filament path 183 // filament path
183 place_idler() 184 place_idler()
184 translate([-idler_d/2-idler_filament_offset,0,0]) 185 translate([-idler_d/2-idler_filament_offset,0,0])
185 rotate([90,0,0]) { 186 rotate([90,0,0]) {
186 mirror([0,1,0]) 187 mirror([0,1,0])
187 teardrop(d=filament_path_d,h=3*gearbox_d,center=true); 188 teardrop(d=filament_path_d,h=3*gearbox_d,center=true);
188 translate([0,0, 189 translate([0,0,
189 sqrt(2)*(mount_d-pulley_d+lsd)/2 190 sqrt(2)*(mount_d-pulley_d+lsd)/2
190 ]) { 191 ]) {
191 cylinder(d1=filament_path_d,d2=2*filament_path_d, 192 cylinder(d1=filament_path_d,d2=2*filament_path_d,
192 h=filament_path_d,$fn=2*filament_path_d*fnd); 193 h=filament_path_d,$fn=2*filament_path_d*fnd);
193 translate([0,0,filament_path_d-epsilon]) 194 translate([0,0,filament_path_d-epsilon])
194 cylinder(d=2*filament_path_d,h=lsd*sqrt(2),$fn=2*filament_path_d*fnd); 195 cylinder(d=2*filament_path_d,h=lsd*sqrt(2),$fn=2*filament_path_d*fnd);
195 }//translate 196 }//translate
196 }//rotate translate place_idler 197 }//rotate translate place_idler
197 198
198 // idler space and mounting hole 199 // idler space and mounting hole
199 place_idler() { 200 place_idler() {
200 cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60); 201 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); 202 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
202 translate([0,0,lever_thickness/2-idler_screwhead_h]) 203 translate([0,0,lever_thickness/2-idler_screwhead_h])
203 cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d); 204 cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d);
204 } 205 }
205 // mounting screw hole 206 // mounting screw hole
206 translate([mount_d/2,0,0]) 207 translate([mount_d/2,0,0])
207 cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d); 208 cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d);
208 209
209 // lever end 210 // lever end
210 translate([mount_d/2,0,0]) rotate([0,90,0]) { 211 translate([mount_d/2,0,0]) rotate([0,90,0]) {
211 translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15); 212 translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15);
212 translate([0,-longwing,0]) 213 translate([0,-longwing,0])
213 mirror([0,0,1]) 214 mirror([0,0,1])
214 difference() { 215 difference() {
215 cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=fnd*(spring_d+spring_d_clearance)); 216 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); 217 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
217 } 218 }
218 }//rotate-translate 219 }//rotate-translate
219 }//difference 220 }//difference
220 // bridging patch 221 // bridging patch
221 if(bridges) place_idler() 222 if(bridges) place_idler()
222 translate([0,0,lever_thickness/2-mount_screwhead_h]) 223 translate([0,0,lever_thickness/2-mount_screwhead_h])
223 mirror([0,0,1]) 224 mirror([0,0,1])
224 cylinder(d=mount_screwhead_d,h=layer_height); 225 cylinder(d=mount_screwhead_d,h=layer_height);
225 }//translate 226 }//translate
226 }//lever module 227 }//lever module
227 228
228 module body() { 229 module body() {
229 difference() { 230 difference() {
230 union() { 231 union() {
231 cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d); 232 cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d);
232 // spring tensioner part 233 // spring tensioner part
233 translate([-gearbox_d/2,0,0]) hull() { 234 translate([-gearbox_d/2,0,0]) hull() {
234 translate([0,-longwing,ls_z]) 235 translate([0,-longwing,ls_z])
235 rotate([0,90,0]) 236 rotate([0,90,0])
236 cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness); 237 cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness);
237 hh=body_h-ls_z; 238 hh=body_h-ls_z;
238 translate([0,0,ls_z]) 239 translate([0,0,ls_z])
239 mirror([0,1,0]) cube(size=[fsw,longwing+(st_thinshell+st_split_w_tolerance)/2+st_thickshell,body_h-ls_z]); 240 mirror([0,1,0]) cube(size=[fsw,longwing+(st_thinshell+st_split_w_tolerance)/2+st_thickshell,body_h-ls_z]);
240 hhh=ls_z; 241 hhh=ls_z;
241 translate([0,0,0]) 242 translate([0,0,0])
242 mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]); 243 mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]);
243 }//hull translate 244 }//hull translate
244 245
245 // pushfit bracket 246 // pushfit bracket
246 translate([0,0,filament_elevation]) 247 translate([0,0,filament_elevation])
247 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0]) 248 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0])
248 rotate([-90,0,0]) 249 rotate([-90,0,0])
249 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) { 250 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) {
250 pfbl = pf_h(pf)+gearbox_d/2; //TODO: 251 pfbl = pf_h(pf)+gearbox_d/2; //TODO:
251 if(pf_smooth) { 252 if(pf_smooth) {
252 pfbd = pf_d(pf)+2*pf_shell; 253 pfbd = pf_d(pf)+2*pf_shell;
253 hull() { 254 hull() {
254 cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd); 255 cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd);
255 translate([-epsilon/2,0,0]) { 256 translate([-epsilon/2,0,0]) {
256 cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]); 257 cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]);
257 mirror([0,1,0]) 258 mirror([0,1,0])
258 cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]); 259 cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]);
259 }//translate 260 }//translate
260 }//hull 261 }//hull
261 }else{ 262 }else{
262 pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2; 263 pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2;
263 pfbd = pfb2a/cos(30); 264 pfbd = pfb2a/cos(30);
264 pfbs = pfb2a*tan(30); 265 pfbs = pfb2a*tan(30);
265 cylinder(d=pfbd,h=pfbl,$fn=6); 266 cylinder(d=pfbd,h=pfbl,$fn=6);
266 translate([-pfbs/2,0,0]) { 267 translate([-pfbs/2,0,0]) {
267 hull() { 268 hull() {
268 translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]); 269 translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]);
269 cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]); 270 cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]);
270 mirror([0,1,0]) 271 mirror([0,1,0])
271 cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]); 272 cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]);
272 }//hull 273 }//hull
273 }//translate*/ 274 }//translate*/
274 }//if(pf_smooth) 275 }//if(pf_smooth)
275 }//translate rotate translate rotate translate 276 }//translate rotate translate rotate translate
276 }//union (first child of difference) 277 }//union (first child of difference)
277 278
278 // protrusion 279 // protrusion
279 translate([0,0,-1]) 280 translate([0,0,-1])
280 cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=fnd*(protrusion_d+protrusion_tolerance_h)); 281 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 282 // mount screw holes
282 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) { 283 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)]) 284 translate([0,0,mount_screw_l-mount_depth-(bridges?layer_height:-epsilon)])
284 mirror([0,0,1]) 285 mirror([0,0,1])
285 cylinder(d=mount_screw_d+mount_screw_d_tolerance, 286 cylinder(d=mount_screw_d+mount_screw_d_tolerance,
286 h=mount_screw_l-mount_depth+1, 287 h=mount_screw_l-mount_depth+1,
287 $fn=fnd*(mount_screw_d+mount_screw_d_tolerance)); 288 $fn=fnd*(mount_screw_d+mount_screw_d_tolerance));
288 translate([0,0,mount_screw_l-mount_depth]) 289 translate([0,0,mount_screw_l-mount_depth])
289 cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d); 290 cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d);
290 }//for 291 }//for
291 // pushfit 292 // pushfit
292 pf_offset = mount_d/sqrt(2)/2+mount_screw_d; 293 pf_offset = mount_d/sqrt(2)/2+mount_screw_d;
293 translate([0,0,filament_elevation]) 294 translate([0,0,filament_elevation])
294 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0]) 295 rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0])
295 rotate([-90,0,0]) 296 rotate([-90,0,0])
296 translate([0,0,pf_offset]) 297 translate([0,0,pf_offset])
297 rotate([0,0,180]) { 298 rotate([0,0,180]) {
298 pushfit(pf); 299 pushfit(pf);
299 mirror([0,0,1]) { 300 mirror([0,0,1]) {
300 fh = 1.5* (filament_guide_d-filament_path_d)/2; 301 fh = 1.5* (filament_guide_d-filament_path_d)/2;
301 fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh; 302 fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh;
302 translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,angle=225); 303 translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,angle=225);
303 translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225); 304 translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225);
304 translate([0,0,fo+epsilon]) 305 translate([0,0,fo+epsilon])
305 cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d); 306 cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d);
306 }//mirror 307 }//mirror
307 }//rotate translate rotate translate rotate translate 308 }//rotate translate rotate translate rotate translate
308 // pulley 309 // pulley
309 cylinder(d=pulley_d+pulley_small_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance)); 310 cylinder(d=pulley_d+pulley_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)); 311 cylinder(d=pulley_d+pulley_d_clearance,ls_z-max(idler_h,filament_guide_d)/2,$fn=fnd*(pulley_d+pulley_d_clearance));
311 312
312 translate([0,0,ls_z-ls_h/2]) { 313 translate([0,0,ls_z-ls_h/2]) {
313 // idler travel 314 // idler travel
314 translate([mount_d/2,0,0]) 315 translate([mount_d/2,0,0])
315 rotate([0,0,45]) 316 rotate([0,0,45])
316 rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2)) 317 rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2))
317 square([shortwing+(idler_d+idler_clearance)/2,ls_h]); 318 square([shortwing+(idler_d+idler_clearance)/2,ls_h]);
318 // idler itself 319 // idler itself
319 place_idler() 320 place_idler()
320 cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance)); 321 cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
321 // lever space 322 // lever space
322 rotate([0,0,45]) 323 rotate([0,0,45])
323 rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1))) 324 rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1)))
324 square([gearbox_d/2+1,ls_h]); 325 square([gearbox_d/2+1,ls_h]);
325 } 326 }
326 327
327 // back side cutout 328 // back side cutout
328 // XXX: this is somewhat ugly and potentially bugged, 329 // XXX: this is somewhat ugly and potentially bugged,
329 // but I want to sleep. 330 // but I want to sleep.
330 a0_ = atan( 331 a0_ = atan(
331 (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2) 332 (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2)
332 / 333 /
333 ( 334 (
334 pulley_d/2+filament_offset- 335 pulley_d/2+filament_offset-
335 (pf_d(pf)+2*pf_shell)/2/cos(30) 336 (pf_d(pf)+2*pf_shell)/2/cos(30)
336 ) 337 )
337 ); 338 );
338 a0 = -135 + ( (a0_>0) ? a0_ : 180+a0_ ); 339 a0 = -135 + ( (a0_>0) ? a0_ : 180+a0_ );
339 a1 = atan((longwing-lever_thickness/2)/(gearbox_d/2)); 340 a1 = atan((longwing-lever_thickness/2)/(gearbox_d/2));
340 translate([0,0,ls_z]) difference() { 341 translate([0,0,ls_z]) difference() {
341 rotate([0,0,-180+a0]) 342 rotate([0,0,-180+a0])
342 rotate_extrude(angle=a1-a0) 343 rotate_extrude(angle=a1-a0)
343 translate([0,-ls_h/2]) 344 translate([0,-ls_h/2])
344 square([sqrt(pow(gearbox_d/2,2)+pow(longwing-lever_thickness/2,2))+1, 345 square([sqrt(pow(gearbox_d/2,2)+pow(longwing-lever_thickness/2,2))+1,
345 ls_h]); 346 ls_h]);
346 translate([-mount_d/2,0,0]) 347 translate([-mount_d/2,0,0])
347 cylinder(d=gearbox_d-mount_d,h=ls_h+2,center=true,$fn=fnd*(gearbox_d-mount_d)); 348 cylinder(d=gearbox_d-mount_d,h=ls_h+2,center=true,$fn=fnd*(gearbox_d-mount_d));
348 }//difference translate 349 }//difference translate
349 350
350 // spring tensioner 351 // spring tensioner
351 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) { 352 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) {
352 mirror([0,0,1]) { 353 mirror([0,0,1]) {
353 translate([0,0,st_thickshell]) 354 translate([0,0,st_thickshell])
354 hull() for(o=[0,spring_d]) translate([0,-o,0]) 355 hull() for(o=[0,spring_d]) translate([0,-o,0])
355 rotate([0,0,30]) 356 rotate([0,0,30])
356 cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6); 357 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)); 358 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; 359 bigd = spring_d+spring_d_clearance;
359 hf = (bigd-st_screw_d-st_screw_d_tolerance)/2; 360 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]) { 361 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, 362 cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
362 h=hf+epsilon, $fn=fnd*bigd); 363 h=hf+epsilon, $fn=fnd*bigd);
363 translate([0,-(st_thinshell+st_split_w_tolerance)/2,0]) 364 translate([0,-(st_thinshell+st_split_w_tolerance)/2,0])
364 cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]); 365 cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]);
365 }//translate 366 }//translate
366 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon]) 367 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
367 cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd); 368 cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
368 }//mirror 369 }//mirror
369 }//translate 370 }//translate
370 371
372 // label
373 label_thickness = 2*layer_height;
374 label_len = len(label);
375 labelspace = [gearbox_d/2-mount_screwhead_d/2-min_xy_shell,longwing-(mount_screwhead_d-st_thinshell-st_split_w_tolerance)/2-2*min_xy_shell-mount_d/2];
376 translate([0,0,body_h-label_thickness])
377 linear_extrude(height=label_thickness+epsilon,convexity=64)
378 translate([-mount_screwhead_d/2-min_xy_shell-labelspace.x/2,-longwing+(st_thinshell+st_split_w_tolerance)/2+min_xy_shell+labelspace.y/2])
379 mirror([left?0:1,0])
380 text(text=label,size=labelspace.x/label_len,halign="center",valign="center",font="Arial Black");
381
371 }//difference 382 }//difference
372 383
373 }//body module 384 }//body module
374 385
375 module springpad() { 386 module springpad() {
376 smalld=st_screw_d+st_screw_d_tolerance+min_xy_shell; 387 smalld=st_screw_d+st_screw_d_tolerance+min_xy_shell;
377 bigd = spring_d+spring_d_clearance/2; 388 bigd = spring_d+spring_d_clearance/2;
378 hf = (bigd-smalld)/2; 389 hf = (bigd-smalld)/2;
379 h = hf*3.5; 390 h = hf*3.5;
380 translate([-gearbox_d/2+st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+1,-longwing,filament_elevation]) 391 translate([-gearbox_d/2+st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+1,-longwing,filament_elevation])
381 rotate([0,90,0]) difference() { 392 rotate([0,90,0]) difference() {
382 union() { 393 union() {
383 cylinder(d1=smalld,d2=bigd,h=hf,$fn=fnd*bigd); 394 cylinder(d1=smalld,d2=bigd,h=hf,$fn=fnd*bigd);
384 translate([0,0,hf-epsilon]) 395 translate([0,0,hf-epsilon])
385 cylinder(d=bigd,h=h-hf,$fn=fnd*bigd); 396 cylinder(d=bigd,h=h-hf,$fn=fnd*bigd);
386 translate([0,0,h]) 397 translate([0,0,h])
387 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4); 398 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
388 l = body_h-ls_z; 399 l = body_h-ls_z;
389 w = st_thinshell; 400 w = st_thinshell;
390 hull() translate([0,-st_thinshell/2,0]) mirror([1,0,0]) { 401 hull() translate([0,-st_thinshell/2,0]) mirror([1,0,0]) {
391 translate([0,0,w]) 402 translate([0,0,w])
392 cube(size=[l,st_thinshell,w]); 403 cube(size=[l,st_thinshell,w]);
393 cube(size=[l-w,st_thinshell,2*w]); 404 cube(size=[l-w,st_thinshell,2*w]);
394 } 405 }
395 } 406 }
396 translate([0,0,-epsilon]) 407 translate([0,0,-epsilon])
397 cylinder(d=st_screw_d+st_screw_d_tolerance,h=2*hf+epsilon,$fn=fnd*(st_screw_d+st_screw_d_tolerance)); 408 cylinder(d=st_screw_d+st_screw_d_tolerance,h=2*hf+epsilon,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
398 } 409 }
399 } 410 }
400 411
401 module knob() { 412 module knob() {
402 ch = knob_indent_d/2; 413 ch = knob_indent_d/2;
403 translate([0,0,body_h+epsilon]) { 414 translate([0,0,body_h+epsilon]) {
404 mirror([0,0,1]) translate([0,0,-epsilon]) { 415 mirror([0,0,1]) translate([0,0,-epsilon]) {
405 difference() { 416 difference() {
406 cylinder(d=pulley_d,h=knob_bore_l,$fn=fnd*pulley_d); 417 cylinder(d=pulley_d,h=knob_bore_l,$fn=fnd*pulley_d);
407 translate([0,0,-1]) difference() { 418 translate([0,0,-1]) difference() {
408 cylinder(d=bore_d+knob_bore_d_tolerance,h=knob_bore_l+2); 419 cylinder(d=bore_d+knob_bore_d_tolerance,h=knob_bore_l+2);
409 translate([-bore_d/2-1,bore_dd-bore_d/2+knob_bore_d_tolerance/2,-1]) 420 translate([-bore_d/2-1,bore_dd-bore_d/2+knob_bore_d_tolerance/2,-1])
410 cube([bore_d+2,bore_d/2,knob_bore_l+4]); 421 cube([bore_d+2,bore_d/2,knob_bore_l+4]);
411 } 422 }
412 } 423 }
413 } 424 }
414 difference() { 425 difference() {
415 union() { 426 union() {
416 cylinder(d1=gearbox_d-2*ch,d2=gearbox_d,h=ch+epsilon,$fn=fnd*gearbox_d); 427 cylinder(d1=gearbox_d-2*ch,d2=gearbox_d,h=ch+epsilon,$fn=fnd*gearbox_d);
417 translate([0,0,ch]) 428 translate([0,0,ch])
418 cylinder(d=gearbox_d,h=knob_h-2*ch+epsilon,$fn=fnd*gearbox_d); 429 cylinder(d=gearbox_d,h=knob_h-2*ch+epsilon,$fn=fnd*gearbox_d);
419 translate([0,0,knob_h-ch]) 430 translate([0,0,knob_h-ch])
420 cylinder(d1=gearbox_d,d2=gearbox_d-2*ch,h=ch,$fn=fnd*gearbox_d); 431 cylinder(d1=gearbox_d,d2=gearbox_d-2*ch,h=ch,$fn=fnd*gearbox_d);
421 } 432 }
422 for(a=[0:360/knob_indents:359]) rotate([0,0,a]) 433 for(a=[0:360/knob_indents:359]) rotate([0,0,a])
423 translate([0,gearbox_d/2,-1]) 434 translate([0,gearbox_d/2,-1])
424 cylinder(d=knob_indent_d,h=knob_h+2,$fn=fnd*knob_indent_d); 435 cylinder(d=knob_indent_d,h=knob_h+2,$fn=fnd*knob_indent_d);
425 } 436 }
426 } 437 }
427 }//knob module 438 }//knob module
428 439
429 module debug() { 440 module debug() {
430 difference() { 441 difference() {
431 children(); 442 children();
432 if(debug) { 443 if(debug) {
433 // spring tensioner debug cutout 444 // spring tensioner debug cutout
434 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) 445 translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0])
435 translate([0,-lever_thickness/2-1,-gearbox_d]) 446 translate([0,-lever_thickness/2-1,-gearbox_d])
436 cube(size=[body_h/2+1,lever_thickness/2+1,gearbox_d+2]); 447 cube(size=[body_h/2+1,lever_thickness/2+1,gearbox_d+2]);
437 // lever axis debug cutout 448 // lever axis debug cutout
438 translate([mount_d/2,0,-1]) 449 translate([mount_d/2,0,-1])
439 rotate([0,0,-45]) 450 rotate([0,0,-45])
440 cube(size=[gearbox_d-mount_d,gearbox_d-mount_d,body_h+knob_h+2]); 451 cube(size=[gearbox_d-mount_d,gearbox_d-mount_d,body_h+knob_h+2]);
441 // idler debug cutout 452 // idler debug cutout
442 translate([0,0,ls_z]) 453 translate([0,0,ls_z])
443 place_idler() 454 place_idler()
444 rotate([0,0,-45]) 455 rotate([0,0,-45])
445 translate([0,0,-lever_thickness/2-epsilon]) 456 translate([0,0,-lever_thickness/2-epsilon])
446 cube(size=[(idler_d+idler_clearance)/2,(idler_d+idler_clearance)/2, 457 cube(size=[(idler_d+idler_clearance)/2,(idler_d+idler_clearance)/2,
447 lever_thickness+2*epsilon]); 458 lever_thickness+2*epsilon]);
448 // pushfit debug cutout 459 // pushfit debug cutout
449 place_idler() 460 place_idler()
450 translate([-idler_d/2+filament_offset,0,ls_z]) 461 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]); 462 cube(size=[gearbox_d/2,gearbox_d/2+pf_h(pf),body_h-ls_z+1]);
452 }//if debug 463 }//if debug
453 }//difference 464 }//difference
454 } 465 }
455 466
456 mirrorleft() 467 mirrorleft()
457 debug() 468 debug()
458 if(what=="lever") color("green",0.7) lever(); 469 if(what=="lever") color("green",0.7) lever();
459 else if(what=="body") color("yellow",0.7) body(); 470 else if(what=="body") color("yellow",0.7) body();
460 else if(what=="knob") color("red",0.7) knob(); 471 else if(what=="knob") color("red",0.7) knob();
461 else if(what=="springpad") color("blue",0.7) springpad(); 472 else if(what=="springpad") color("blue",0.7) springpad();
462 else if(what=="both") { 473 else if(what=="both") {
463 color("green",0.7) lever(); 474 color("green",0.7) lever();
464 color("yellow",0.7) body(); 475 color("yellow",0.7) body();
465 }else{ 476 }else{
466 color("green",0.7) lever(); 477 color("green",0.7) lever();
467 color("yellow",0.7) body(); 478 color("yellow",0.7) body();
468 color("red",0.7) knob(); 479 color("red",0.7) knob();
469 color("blue",0.7) springpad(); 480 color("blue",0.7) springpad();
470 } 481 }
471} 482}
472 483
473the_extruder(what="*",left=false,debug=true); 484the_extruder(what="*",left=false,debug=true);