move pushfit a tiny bit closer

1 files changed, 5 insertions, 4 deletions

diff --git a/another.scad b/another.scad
index 0d67286..8334b11 100644
--- a/another.scad
+++ b/another.scad
@@ -86,48 +86,50 @@ module the_extruder(
 
  idler_filament_offset = filament_path_d/2;
  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; // the diameter of lever thingie
  longwing=(mount_d+mount_screw_d+mount_screw_d_tolerance+spring_d+spring_d_clearance)/2+min_xy_shell;
  shortwing = let(a=mount_d/2,c=(pulley_d+idler_d)/2/sqrt(2))
              sqrt(c*c+pow(a-c,2));
  longwing_travel = idler_travel*longwing/shortwing;
  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;
  // finger and spring support
  fsw = gearbox_d-(gearbox_d-mount_d)/2-max(spring_lc,longwing_travel+(gearbox_d-mount_d)/2);
 
  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
  mount_depth = mount_screw_l - (ls_z+ls_h/2+min_z_shell);
  body_h = max(protrusion_h+bore_l,mount_screw_l-mount_depth+mount_screwhead_h+min_z_shell,ls_z*2);
  echo("mount depth",mount_depth);
 
+ pf_offset = mount_d/sqrt(2)/2+mount_screw_d/2+min_xy_shell;
+
  module teardrop(r,d,h,center=false,angle=45) {
   dd = d ? d : (2*r);
   $fn = dd*fnd;
   cylinder(d=dd,h=h,center=center);
   if(angle>0) translate([0,0,center?-h/2:0])
    rotate([0,0,angle])
    cube(size=[d/2,d/2,h]);
  }
 
  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,$fn=fnr*rr);
   }else if(r) {
    hh=sqrt(pow(r,2)-pow(d,2)/4);
@@ -139,49 +141,49 @@ module the_extruder(
   translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$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]) {
    difference() {
     cylinder(d=bore_d,h=bore_l,$fn=30);
     translate([-bore_d/2-1,bore_dd-bore_d/2,-1])
     cube([bore_d+2,bore_d/2,bore_l+2]);
    }
    translate([0,0,pulley_elevation]) {
     cylinder(d=pulley_d,h=pulley_h,$fn=30);
     translate([0,0,teeth_elevation]) {
      place_idler() {
       cylinder(d=idler_d,h=idler_h,center=true,$fn=30);
       cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
      }//place idler
      // filament path
      rotate([0,0,45]) {
       translate([pulley_d/2-idler_filament_offset,0,0]) rotate([90,0,0]) {
        cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15);
       }//rotate translate
       translate([pulley_d/2+filament_offset,0,0]) rotate([-90,0,0]) {
        cylinder(d=filament_d,h=gearbox_d,center=false,$fn=15);
-       translate([0,0,mount_d/sqrt(2)/2+mount_screw_d])
+       translate([0,0,pf_offset])
        pushfit(pf);
       }//rotate translate
      }//rotate
     }//translate teeth
    }//translate pulley
   }//translate protrusion
  }//vitamins
 
  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
@@ -233,116 +235,115 @@ module the_extruder(
   }//translate
  }//lever module
  
  module body() {
   difference() {
    union() {
     cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d);
     // spring tensioner part
     translate([-gearbox_d/2,0,0]) hull() {
      translate([0,-longwing,ls_z])
      rotate([0,90,0])
      cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness);
      hh=body_h-ls_z;
      translate([0,0,ls_z])
      mirror([0,1,0]) cube(size=[fsw,longwing+(st_split_w+st_split_w_tolerance)/2+st_thickshell,body_h-ls_z]);
      hhh=ls_z;
      translate([0,0,0])
      mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]);
     }//hull translate
     
     // pushfit bracket
     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-gearbox_d/2/*TODO:*/]) {
+    translate([0,0,pf_offset-gearbox_d/2/*TODO:*/]) {
      pfbl = pf_h(pf)+gearbox_d/2; //TODO:
      pfbd = pf_d(pf)+2*pf_shell;
      hull() {
       cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd);
       translate([-epsilon/2,0,0]) {
        cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]);
        mirror([0,1,0])
        cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]);
       }//translate
      }//hull
     }//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,pf_offset])
    rotate([0,0,180]) {
     pushfit(pf);
     mirror([0,0,1]) {
      fh = 1.5* (filament_guide_d-filament_path_d)/2;
      fo = pf_offset -filament_path_d /*(idler_d+idler_clearance)/2*/-fh;
      translate([0,0,-1]) teardrop(d=filament_guide_d,h=fo/2,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,$fn=fnd*filament_guide_d);
     }//mirror
    }//rotate translate rotate translate rotate translate
    // pulley
    cylinder(d=pulley_d+pulley_small_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
    cylinder(d=pulley_d+pulley_d_clearance,ls_z-max(idler_h,filament_guide_d)/2,$fn=fnd*(pulley_d+pulley_d_clearance));
 
    translate([0,0,ls_z-ls_h/2]) {
     // idler travel
     translate([mount_d/2,0,0])
     rotate([0,0,45])
     rotate_extrude(angle=90,$fn=fnr*(shortwing+(idler_d+idler_clearance)/2))
     square([shortwing+(idler_d+idler_clearance)/2,ls_h]);
     // idler itself
     place_idler()
     cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
     // lever space
     rotate([0,0,45])
     rotate_extrude(angle=-135+max(atan(2*fsw/gearbox_d-1),atan(gearbox_d/mount_d-1)))
     square([gearbox_d/2+1,ls_h]);
    }
 
    // back side cutout
    // XXX: this is somewhat ugly and potentially bugged,
    //      but I want to sleep.
    a0_ = atan(
-    (mount_d/sqrt(2)/2+mount_screw_d+pf_h(pf)+gearbox_d/2)
+    (pf_offset+pf_h(pf)+gearbox_d/2)
     /
     (
      pulley_d/2+filament_offset-
      (pf_d(pf)+2*pf_shell)/2/cos(30)
     )
    );
    a0 = -135 + ( (a0_>0) ? a0_ : 180+a0_ );
    a1 = atan((longwing-lever_thickness/2)/(gearbox_d/2));
    translate([0,0,ls_z]) difference() {
     rotate([0,0,-180+a0])
     rotate_extrude(angle=a1-a0)
     translate([0,-ls_h/2])
     square([sqrt(pow(gearbox_d/2,2)+pow(longwing-lever_thickness/2,2))+1,
            ls_h]);
     translate([-mount_d/2,0,0])
     cylinder(d=gearbox_d-mount_d,h=ls_h+2,center=true,$fn=fnd*(gearbox_d-mount_d));
    }//difference translate
    
    // spring tensioner
    translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) {
     mirror([0,0,1]) {
      translate([0,0,st_thickshell])
      hull() for(o=[0,spring_d]) translate([0,-o,0])
      rotate([0,0,30])