initial implementation

3 files changed, 169 insertions, 0 deletions

diff --git a/.gitignore b/.gitignore
new file mode 100644
index 0000000..c25a6bd
--- a/dev/null
+++ b/.gitignore
@@ -0,0 +1,3 @@
+/Makefile.local
+/*.stl
+/*.gcode
diff --git a/Makefile b/Makefile
new file mode 100644
index 0000000..d04b0c3
--- a/dev/null
+++ b/Makefile
@@ -0,0 +1,21 @@
+-include Makefile.local
+
+OPENSCAD_APP?=/Applications/OpenSCAD.app
+OPENSCAD_BIN?=${OPENSCAD_APP}/Contents/MacOS/OpenSCAD
+OPENSCAD_FLAGS?=-D draft=false
+
+RENDERVIEWS=holder base
+STLS=$(addsuffix .stl,$(addprefix adapter-,${RENDERVIEWS}))
+
+default: all
+
+all: ${STLS}
+clean:
+        rm -f ${STLS}
+
+adapter-%.stl: x-carriage-adapter.scad
+        ${OPENSCAD_BIN} ${OPENSCAD_FLAGS} -D draft=false -D 'view="$*"' -o "$@" "$<"
+
+
+%.stl: %.scad
+        ${OPENSCAD_BIN} ${OPENSCAD_FLAGS} -o "$@" "$<"
diff --git a/x-carriage-adapter.scad b/x-carriage-adapter.scad
new file mode 100644
index 0000000..af91d52
--- a/dev/null
+++ b/x-carriage-adapter.scad
@@ -0,0 +1,145 @@
+screw_tolerance=0.1; slide_tolerance=.3; play_tolerance=.8;
+draft=true;
+use <e3dchimera.scad>;
+
+        assembly_height = 49.5;         // the height of e3d chimera assembly in e3dchimera.scad
+        hs_nozzles_from_back = 6;// the distance from nozzles from the back of the heatsink
+        hs_size = [30,18,30];   // the heatsink size
+        mounting_holes_from_top = [// the offsets of mounting holes on the back
+ [0, 20], [-4.5,10], [4.5,10]
+];
+        mounting_holes_on_top = [// the offsets of mounting holes on the top
+ [0,-3], [-17/2,9], [17/2,9]
+];
+        feeds_apart = 18;       // the distance between nozzles (and, therefore filament feeds)
+
+        feed_shell_d = 17;      // the shell diameter around filament feed, pushfit's diameter
+        screw_shell_d = 8;      // the shell diameter around screws
+        thread_h = 10.5;        // the height of the pushfit's thread
+        hinge_s = 6;            // hinges thickness
+
+        screwhead_d = 5.5;      // the diameter of the screw head
+        screwhead_h = 3;        // the height of the screw head
+
+        ms_size = [19.8,6,10];  // microswitch dimensions
+        ms_screws_apart = 9.5;  // distance between microswitch mounting screws
+        ms_switch_offset = 2.5;         // the offset of the switch from the center
+        ms_bump = ms_size[1];   // how far from hinge microswitch is mounted
+
+        lower_by = 15;          // lower hotend from the original intention by this long
+        gap = 5;                // gap between microswitch and heatsink
+
+        ps_offset = 3+3;        // pushscrew offset from the hinge
+
+        back_thickness = 8;     // thickness of the part behind the hinge
+        nut_thickness = 2.5;    // intelligent guess should suffice
+        nut_width = 5.5;        // intelligent guess should suffice
+
+use <threads.scad>;
+/* the internal thread for e3d bowden coupling: http://e3d-online.com/E3D-v6/Spares/Threaded-Bowden-Coupling-1.75mm-Filament */
+module pushfit_thread(h=thread_h) {
+ thr = 3/8 + .5/25.4;
+ slit = 25.4*thr/2 + 0.4;
+ translate([0,0,-1]) if(draft) cylinder(d=thr*25.4,h=h+2);
+ else english_thread(diameter=thr,threads_per_inch=28,length=(h+2)/25.4,internal=true);
+ translate([-2,-slit,-1]) cube([4,slit,h+2]);
+}
+
+
+        sff = hs_nozzles_from_back+gap;                 // switch from feeds
+        hff = sff+ms_size[1]+ms_bump+thread_h/2;// hinges from feeds
+
+module holder() {
+ translate([0,0,0]) difference() {
+  union() {
+   hull() {
+    rs = 3; drs = screw_shell_d/2-rs;
+    rf = 6; drf = feed_shell_d/2-rf;
+    for(sx=[-1,1]) translate([sx*feeds_apart/2,0,0]) {
+     translate([0,0,drf])
+     cylinder(d=feed_shell_d,h=thread_h-drf,$fn=60);
+     cylinder(r=rf,h=thread_h,$fn=30);
+    }
+    for(mhot = mounting_holes_on_top) translate([mhot[0],mhot[1],0]) {
+     translate([0,0,drs])
+     cylinder(d=screw_shell_d,h=thread_h-drs,$fn=30);
+     cylinder(r=rs,h=thread_h,$fn=30);
+    }
+   }
+   hull() {
+    translate([0,0,thread_h/2]) cube(size=[hs_size[0]-2*hinge_s-2*slide_tolerance,feed_shell_d,thread_h],center=true);
+    translate([0,-hff,thread_h/2])
+    rotate([0,90,0])
+    cylinder(d=thread_h,h=hs_size[0]-2*hinge_s-2*slide_tolerance,center=true,$fn=60);
+   }
+  }//union
+  for(sx=[-1,1]) translate([sx*feeds_apart/2,0,0])
+   pushfit_thread();
+  for(mhot = mounting_holes_on_top) translate([mhot[0],mhot[1],0]) {
+   translate([0,0,-1]) cylinder(d=3,h=thread_h+2,$fn=12); // TODO: sink heads
+   translate([0,0,thread_h/2]) cylinder(d=screwhead_d+slide_tolerance,h=thread_h/2+1,$fn=30);
+  }
+  // hinge
+  translate([0,-hff,thread_h/2])
+  rotate([0,90,0]) cylinder(d=3+slide_tolerance,h=hs_size[0],center=true,$fn=12);
+  // push screw
+  hull() for(oy=[-1,1]) translate([0,-hff+ps_offset+oy,-1]) cylinder(d=3+play_tolerance,h=thread_h+2,$fn=30);
+  // tune screw
+  translate([0,-sff-ms_size[1]/2,-1]) cylinder(d=3,h=thread_h+2);
+ }//difference
+}
+
+
+module base() {
+ us = 2*ms_size[2];
+ translate([0,-hff,0]) difference() {
+  union() {
+   for(sx=[-1,1]) translate([sx*(hs_size[0]-hinge_s)/2,0,0]) hull() {
+    translate([0,0,thread_h/2])
+    rotate([0,90,0]) cylinder(d=thread_h,h=hinge_s,center=true,$fn=60);
+    cube(size=[hinge_s,thread_h,thread_h],center=true);
+    translate([-hinge_s/2,0,-1]) mirror([0,1,0]) cube(size=[hinge_s,thread_h/2+back_thickness,thread_h+1]);
+   } // hull for
+   hull() {
+    translate([0,0,-us/2-slide_tolerance]) cube(size=[hs_size[0],thread_h+1,us],center=true);
+    for(sx=[-1,1]) translate([sx*(hs_size[0]/2-ms_bump),thread_h/2,-us-slide_tolerance])
+    cylinder(r=ms_bump,h=us+slide_tolerance,$fn=30);
+   }
+   translate([-hs_size[0]/2,-thread_h/2-slide_tolerance,-us-slide_tolerance])
+   mirror([0,1,0]) cube(size=[hs_size[0],back_thickness,us+slide_tolerance+thread_h]);
+  } // union
+  translate([0,0,thread_h/2])
+  rotate([0,90,0]) cylinder(d=3+screw_tolerance,h=hs_size[0]+2,center=true,$fn=12);
+  for(smx=[0,1]) mirror([smx,0,0])
+   translate([hs_size[0]/2+1,0,thread_h/2]) rotate([0,-90,0]) cylinder(d=screwhead_d+slide_tolerance,h=screwhead_h+1,$fn=30);
+  /* changed my mind; for(srx=[-1,1]) rotate([srx*15,0,0])
+   translate([0,0,thread_h/2-slide_tolerance])
+   cube(size=[hs_size[0]-2*hinge_s,thread_h*sqrt(2)+2,thread_h],center=true); */
+  // switch mount
+  for(sx=[-1,1]) translate([sx*ms_screws_apart/2+ms_switch_offset,thread_h/2,-ms_size[2]])
+   rotate([90,0,0])
+   cylinder(d=2.5,h=ms_size[1]*2,center=true,$fn=12);
+  // thing mount
+  translate([0,-thread_h/2-back_thickness,lower_by])
+  for(mhft = mounting_holes_from_top) translate([mhft[0],0,-mhft[1]]) {
+   rotate([-90,0,0])
+   translate([0,0,-1])
+   cylinder(d=3,h=back_thickness+1);
+   translate([0,back_thickness/2,0])
+   cube(size=[2*hs_size[0],nut_thickness+slide_tolerance,nut_width+slide_tolerance],center=true);
+  } // translate for
+  mirror([0,0,1]) translate([0,ps_offset,-1]) cylinder(d=3,h=hs_size[2]+1);
+ } // difference
+}
+
+view="*";
+
+if(view=="holder") {
+ holder();
+}else if(view=="base") {
+ base();
+}else {
+ % translate([0,0,-assembly_height]) chimera_assembly();
+ color("lightgreen",0.7) holder();
+ color("darkgreen",0.7) base();
+}