somewhat finalized output funnel

1 files changed, 9 insertions, 14 deletions

diff --git a/another.scad b/another.scad
index 4a9fc01..8fd9356 100644
--- a/another.scad
+++ b/another.scad
@@ -26,66 +26,66 @@ module the_extruder(
          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_thickshell = 8*extrusion_width, st_thinshell = 4*extrusion_width,
 
  // screw it
  mount_screw_d = 3.1, mount_screw_l = 20,
  mount_screwhead_d=6, mount_screwhead_h=3,
  idler_screw_d = 3,
  idler_screwhead_d=6, idler_screwhead_h=3,
 
  pf = pushfit_embeddest,
  pf_shell = max(3*layer_height,3*extrusion_width),
  pf_smooth = true,
-         pf_guidelen = 3,                       // the length of ptfe guide before pushfit
 
  // empty spaces
          idler_travel = 3,                      // how far should idler travel when pressed
  idler_clearance=1,
  pulley_d_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,
  st_nut_h_tolerance=.2,
  st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */
  st_screw_d_tolerance=.5,
 
  min_z_shell = 4*layer_height,                  // the very minimal shell thickness along z-axis.
+ min_xy_shell = 2*extrusion_width,
 
  what="lever",  // lever|body|knob|springpad|*
  left=false,
  vitamins = true,
  supports = false, bridges = true,
  tensioner = true,
  debug = false
 ) {
  fnd = 2*PI; fnr = 2*fnd;
 
  idler_filament_offset = filament_path_d/2; // -filament_offset;
  lever_shell = mount_screwhead_h+0.5;
  lever_thickness=max(spring_d+spring_d_clearance+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;
 
  mount_min_depth = mounthole_min_depth ? mounthole_min_depth : mounthole_depth-1;
  mount_max_depth = mounthole_max_depth ? mounthole_max_depth : mounthole_depth+1;
  filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
  ls_z = filament_elevation; // leverspace mid-z
  ls_h = lever_thickness+lever_v_clearance; // leverspace height
@@ -290,68 +290,63 @@ module the_extruder(
         translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]);
         cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]);
         mirror([0,1,0])
         cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]);
        }//hull
       }//translate*/
      }//if(pf_smooth)
     }//translate rotate translate rotate translate
    }//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=fnd*(protrusion_d+protrusion_tolerance_h));
    // mount screw holes
    for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) {
     translate([0,0,mount_screw_l-mount_depth-(bridges?layer_height:-epsilon)])
     mirror([0,0,1])
     cylinder(d=mount_screw_d+mount_screw_d_tolerance,
              h=mount_screw_l-mount_depth+1,
              $fn=fnd*(mount_screw_d+mount_screw_d_tolerance));
     translate([0,0,mount_screw_l-mount_depth])
     cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d);
    }//for
    // pushfit
+   pf_offset = mount_d/sqrt(2)/2+mount_screw_d;
    translate([0,0,filament_elevation])
    rotate([0,0,45]) translate([pulley_d/2+filament_offset,0,0])
    rotate([-90,0,0])
-   translate([0,0,mount_d/sqrt(2)/2+mount_screw_d+epsilon])
+   translate([0,0,pf_offset])
    rotate([0,0,180]) {
     pushfit(pf);
     mirror([0,0,1]) {
-     translate([0,0,-epsilon])
-     teardrop(d=filament_guide_d,h=pf_guidelen+epsilon,angle=225);
-     nl = 3.5; /* TODO: */
-     translate([0,0,pf_guidelen-1])
-     teardrop(d=filament_path_d,h=nl+2,angle=-225);
      fh = (filament_guide_d-filament_path_d)/2;
-     union() {
-      translate([0,0,pf_guidelen+nl])
-      cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d);
-      translate([0,0,pf_guidelen+nl+fh-epsilon])
-      teardrop(d=filament_guide_d,h=gearbox_d/2,angle=225);
-     }
-    }
+     fo = pf_offset-(idler_d+idler_clearance)/2-fh;
+     translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo-extrusion_width+1,angle=225);
+     translate([0,0,-1]) teardrop(d=filament_path_d,h=gearbox_d/2+1,angle=-225);
+     translate([0,0,fo+epsilon])
+     cylinder(d1=filament_path_d,d2=filament_guide_d,h=fh,$fn=fnd*filament_guide_d);
+    }//mirror
    }//rotate translate rotate translate rotate translate
    // pulley
    cylinder(d=pulley_d+pulley_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
    // leverspace
    hull() for(x=[0,gearbox_d])
    rotate([0,0,45])
    translate([x,0,ls_z-ls_h/2])
    cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
 
    // idler clearance
    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+idler_clearance;
     cylinder(r=r,h=ls_h,center=true);
     translate([-r-1,0,-ls_h/2-1]) cube(size=[2*r+2,r+1,ls_h+2]);
    }
 
    // back side cutout
    // XXX: this is somewhat ugly and potentially bugged,
    //      but I want to sleep.
    a0_ = atan(