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authorMichael Krelin <hacker@klever.net>2018-08-12 00:52:29 (UTC)
committer Michael Krelin <hacker@klever.net>2018-08-12 00:52:29 (UTC)
commit84832958278728643334a327bc3a2783ad354d72 (patch) (unidiff)
treeded21c16730d38a19cd8e89f3e52314018e7eeb3
parent60f188ff063a4c6f7e5d4a1078fd520a84f829c4 (diff)
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increase spring tensioner screw tolerance
Diffstat (more/less context) (ignore whitespace changes)
-rw-r--r--another.scad2
1 files changed, 1 insertions, 1 deletions
diff --git a/another.scad b/another.scad
index 4c4af5c..f54c5cd 100644
--- a/another.scad
+++ b/another.scad
@@ -1,318 +1,318 @@
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 protrusion_d = 22, protrusion_h = 2.2, // the dimensions of the protrusion on top of gearbox 14 protrusion_d = 22, protrusion_h = 2.2, // the dimensions of the protrusion on top of gearbox
15 bore_d = 8, bore_l = 17.6, 15 bore_d = 8, bore_l = 17.6,
16 bore_dd = 7, 16 bore_dd = 7,
17 // pulley properties 17 // pulley properties
18 pulley_d = 11.5, pulley_h=10, 18 pulley_d = 11.5, pulley_h=10,
19 pulley_elevation = 1, // pulley elevation above the protrusion 19 pulley_elevation = 1, // pulley elevation above the protrusion
20 teeth_elevation = 7.5, // distance from the bottom of the pulley to its teeth 20 teeth_elevation = 7.5, // distance from the bottom of the pulley to its teeth
21 // idler properties 21 // idler properties
22 idler_d = 9.5, idler_h = 4, idler_id = 3,// idler dimensions: outer and inner diameters and height 22 idler_d = 9.5, idler_h = 4, idler_id = 3,// idler dimensions: outer and inner diameters and height
23 // spring properties 23 // spring properties
24 spring_d = 10, spring_lc = 9.6, // spring diameter and compressed length 24 spring_d = 10, spring_lc = 9.6, // spring diameter and compressed length
25 // filament path properties 25 // filament path properties
26 filament_d = 1.75, 26 filament_d = 1.75,
27 filament_path_d = 2, 27 filament_path_d = 2,
28 filament_guide_d = 4, // PTFE filament guide diameter 28 filament_guide_d = 4, // PTFE filament guide diameter
29 // knob properties 29 // knob properties
30 knob_h = 10, 30 knob_h = 10,
31 knob_bore_l = 4, 31 knob_bore_l = 4,
32 knob_indent_d = 4, 32 knob_indent_d = 4,
33 knob_indents = 12, 33 knob_indents = 12,
34 // spring tensioner 34 // spring tensioner
35 st_nut_d = 9, st_nut_h = 4, 35 st_nut_d = 9, st_nut_h = 4,
36 st_screw_d = 5, 36 st_screw_d = 5,
37 st_thickshell = 8*extrusion_width, st_thinshell = 4*extrusion_width, 37 st_thickshell = 8*extrusion_width, st_thinshell = 4*extrusion_width,
38 38
39 // screw it 39 // screw it
40 mount_screw_d = 3.1, mount_screw_l = 20, 40 mount_screw_d = 3.1, mount_screw_l = 20,
41 mount_screwhead_d=6, mount_screwhead_h=3, 41 mount_screwhead_d=6, mount_screwhead_h=3,
42 idler_screw_d = 3, 42 idler_screw_d = 3,
43 idler_screwhead_d=6, idler_screwhead_h=3, 43 idler_screwhead_d=6, idler_screwhead_h=3,
44 44
45 pf = pushfit_embeddest, 45 pf = pushfit_embeddest,
46 pf_shell = max(3*layer_height,3*extrusion_width), 46 pf_shell = max(3*layer_height,3*extrusion_width),
47 pf_smooth = true, 47 pf_smooth = true,
48 48
49 // empty spaces 49 // empty spaces
50 idler_travel = 3, // how far should idler travel when pressed 50 idler_travel = 3, // how far should idler travel when pressed
51 idler_clearance=1, 51 idler_clearance=1,
52 pulley_clearance=2, 52 pulley_clearance=2,
53 lever_v_clearance=.7, // vertical clearance for the lever 53 lever_v_clearance=.7, // vertical clearance for the lever
54 spring_d_clearance=1, 54 spring_d_clearance=1,
55 protrusion_tolerance_h=.5, // horizontal tolerance for the motor protrusion 55 protrusion_tolerance_h=.5, // horizontal tolerance for the motor protrusion
56 protrusion_tolerance_v=.5, // vertical tolerance for the motor protrusion 56 protrusion_tolerance_v=.5, // vertical tolerance for the motor protrusion
57 mount_screw_d_tolerance=.4, 57 mount_screw_d_tolerance=.4,
58 idler_v_tolerance=.5, 58 idler_v_tolerance=.5,
59 knob_bore_d_tolerance=.6, 59 knob_bore_d_tolerance=.6,
60 st_nut_h_tolerance=.2, 60 st_nut_h_tolerance=.2,
61 st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */ 61 st_nut_d_tolerance=.2,/* TODO: make it st_nut_w_tolerance */
62 st_screw_d_tolerance=.3, 62 st_screw_d_tolerance=.5,
63 63
64 what="lever", // lever|body|knob|springpad|* 64 what="lever", // lever|body|knob|springpad|*
65 left=false, 65 left=false,
66 vitamins = true, 66 vitamins = true,
67 supports = false, bridges = true, 67 supports = false, bridges = true,
68 tensioner = true, 68 tensioner = true,
69 debug = false 69 debug = false
70) { 70) {
71 fnd = 2*PI; fnr = 2*fnd; 71 fnd = 2*PI; fnr = 2*fnd;
72 72
73 lever_shell = mount_screwhead_h+0.5; 73 lever_shell = mount_screwhead_h+0.5;
74 lever_thickness=max(spring_d+spring_d_clearance+layer_height*8,idler_h+idler_v_tolerance+2*lever_shell); 74 lever_thickness=max(spring_d+spring_d_clearance+layer_height*8,idler_h+idler_v_tolerance+2*lever_shell);
75 lsd = idler_d-idler_clearance*2; 75 lsd = idler_d-idler_clearance*2;
76 longwing=gearbox_d/2+spring_d/2+lsd/2; 76 longwing=gearbox_d/2+spring_d/2+lsd/2;
77 h_ = (pulley_d+idler_d)/(2*sqrt(2)); 77 h_ = (pulley_d+idler_d)/(2*sqrt(2));
78 ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) ); 78 ri = sqrt( pow(h_,2) + pow(mount_d/2-h_,2) );
79 spring_dl = idler_travel*longwing/ri; 79 spring_dl = idler_travel*longwing/ri;
80 80
81 filament_elevation=protrusion_h+pulley_elevation+teeth_elevation; 81 filament_elevation=protrusion_h+pulley_elevation+teeth_elevation;
82 ls_z = filament_elevation; // leverspace mid-z 82 ls_z = filament_elevation; // leverspace mid-z
83 body_h = max(protrusion_h+bore_l,mount_screw_l-mounthole_depth/2+mount_screwhead_h,ls_z*2); 83 body_h = max(protrusion_h+bore_l,mount_screw_l-mounthole_depth/2+mount_screwhead_h,ls_z*2);
84 ls_h = lever_thickness+lever_v_clearance; // leverspace height 84 ls_h = lever_thickness+lever_v_clearance; // leverspace height
85 85
86 module mirrorleft() { 86 module mirrorleft() {
87 mirror([left?0:1,0,0]) children(); 87 mirror([left?0:1,0,0]) children();
88 } 88 }
89 module place_idler() { 89 module place_idler() {
90 rotate([0,0,45]) 90 rotate([0,0,45])
91 translate([(pulley_d+idler_d)/2,0,0]) 91 translate([(pulley_d+idler_d)/2,0,0])
92 children(); 92 children();
93 } 93 }
94 module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) { 94 module finger_indent(d=lever_thickness,depth/*=1*/,r/*=15*/) {
95 if(depth) { 95 if(depth) {
96 hh = (-4*pow(depth,2)+pow(d,2))/(8*depth); 96 hh = (-4*pow(depth,2)+pow(d,2))/(8*depth);
97 rr = depth+hh; 97 rr = depth+hh;
98 translate([0,0,hh]) sphere(r=rr,$fn=fnr*rr); 98 translate([0,0,hh]) sphere(r=rr,$fn=fnr*rr);
99 }else if(r) { 99 }else if(r) {
100 hh=sqrt(pow(r,2)-pow(d,2)/4); 100 hh=sqrt(pow(r,2)-pow(d,2)/4);
101 translate([0,0,hh]) sphere(r=r,$fn=fnr*r); 101 translate([0,0,hh]) sphere(r=r,$fn=fnr*r);
102 } 102 }
103 } 103 }
104 104
105 % if(vitamins) mirrorleft() { 105 % if(vitamins) mirrorleft() {
106 translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60); 106 translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60);
107 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) 107 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0])
108 cylinder(d=mount_screw_d,h=20,$fn=30); 108 cylinder(d=mount_screw_d,h=20,$fn=30);
109 translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30); 109 translate([0,0,-epsilon]) cylinder(d=protrusion_d,h=protrusion_h,$fn=30);
110 translate([0,0,protrusion_h]) { 110 translate([0,0,protrusion_h]) {
111 difference() { 111 difference() {
112 cylinder(d=bore_d,h=bore_l,$fn=30); 112 cylinder(d=bore_d,h=bore_l,$fn=30);
113 translate([-bore_d/2-1,bore_dd-bore_d/2,-1]) 113 translate([-bore_d/2-1,bore_dd-bore_d/2,-1])
114 cube([bore_d+2,bore_d/2,bore_l+2]); 114 cube([bore_d+2,bore_d/2,bore_l+2]);
115 } 115 }
116 translate([0,0,pulley_elevation]) { 116 translate([0,0,pulley_elevation]) {
117 cylinder(d=pulley_d,h=pulley_h,$fn=30); 117 cylinder(d=pulley_d,h=pulley_h,$fn=30);
118 translate([0,0,teeth_elevation]) { 118 translate([0,0,teeth_elevation]) {
119 place_idler() { 119 place_idler() {
120 cylinder(d=idler_d,h=idler_h,center=true,$fn=30); 120 cylinder(d=idler_d,h=idler_h,center=true,$fn=30);
121 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30); 121 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
122 }//place idler 122 }//place idler
123 // filament path 123 // filament path
124 rotate([0,0,45]) translate([pulley_d/2,0,0]) { 124 rotate([0,0,45]) translate([pulley_d/2,0,0]) {
125 rotate([90,0,0]) cylinder(d=filament_d,h=gearbox_d*2,center=true,$fn=15); 125 rotate([90,0,0]) cylinder(d=filament_d,h=gearbox_d*2,center=true,$fn=15);
126 rotate([-90,0,0]) 126 rotate([-90,0,0])
127 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d]) 127 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d])
128 pushfit(pf); 128 pushfit(pf);
129 } 129 }
130 }//translate teeth 130 }//translate teeth
131 }//translate pulley 131 }//translate pulley
132 }//translate protrusion 132 }//translate protrusion
133 }//vitamins 133 }//vitamins
134 134
135 module lever() { 135 module lever() {
136 translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) { 136 translate([0,0,protrusion_h+pulley_elevation+teeth_elevation]) {
137 difference() { 137 difference() {
138 union() { 138 union() {
139 hull() { 139 hull() {
140 place_idler() 140 place_idler()
141 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 141 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
142 translate([mount_d/2,0,0]) 142 translate([mount_d/2,0,0])
143 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 143 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
144 }//hull 144 }//hull
145 hull() { 145 hull() {
146 translate([mount_d/2,0,0]) 146 translate([mount_d/2,0,0])
147 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60); 147 cylinder(d=lsd,h=lever_thickness,center=true,$fn=60);
148 translate([mount_d/2,-longwing,0]) rotate([0,90,0]) 148 translate([mount_d/2,-longwing,0]) rotate([0,90,0])
149 cylinder(d=lever_thickness,h=lsd,center=true,$fn=60); 149 cylinder(d=lever_thickness,h=lsd,center=true,$fn=60);
150 }//hull 150 }//hull
151 }//union 151 }//union
152 152
153 // filament path 153 // filament path
154 place_idler() { 154 place_idler() {
155 translate([-idler_d/2,0,0]) rotate([90,0,0]) { 155 translate([-idler_d/2,0,0]) rotate([90,0,0]) {
156 cylinder(d=filament_path_d,h=3*gearbox_d,center=true,$fn=30); 156 cylinder(d=filament_path_d,h=3*gearbox_d,center=true,$fn=30);
157 translate([0,-filament_path_d/2/sqrt(2),0]) rotate([0,0,45]) 157 translate([0,-filament_path_d/2/sqrt(2),0]) rotate([0,0,45])
158 cube(size=[filament_path_d/2,filament_path_d/2,3*gearbox_d],center=true); 158 cube(size=[filament_path_d/2,filament_path_d/2,3*gearbox_d],center=true);
159 }//rotate translate 159 }//rotate translate
160 translate([-idler_d/2,0,0]) 160 translate([-idler_d/2,0,0])
161 rotate([90,0,0]) 161 rotate([90,0,0])
162 translate([0,0, 162 translate([0,0,
163 sqrt(2)*(mount_d-pulley_d+lsd)/2 163 sqrt(2)*(mount_d-pulley_d+lsd)/2
164 ]) { 164 ]) {
165 cylinder(d1=filament_path_d,d2=2*filament_path_d, 165 cylinder(d1=filament_path_d,d2=2*filament_path_d,
166 h=filament_path_d,$fn=2*filament_path_d*fnd); 166 h=filament_path_d,$fn=2*filament_path_d*fnd);
167 translate([0,0,filament_path_d-epsilon]) 167 translate([0,0,filament_path_d-epsilon])
168 cylinder(d=2*filament_path_d,h=lsd,$fn=2*filament_path_d*fnd); 168 cylinder(d=2*filament_path_d,h=lsd,$fn=2*filament_path_d*fnd);
169 } 169 }
170 }//place_idler 170 }//place_idler
171 171
172 // idler space and mounting hole 172 // idler space and mounting hole
173 place_idler() { 173 place_idler() {
174 difference() { 174 difference() {
175 cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60); 175 cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60);
176 if(supports) for(y=[-lsd/2+extrusion_width:(lsd-2*extrusion_width)/3:lsd/2-extrusion_width]) 176 if(supports) for(y=[-lsd/2+extrusion_width:(lsd-2*extrusion_width)/3:lsd/2-extrusion_width])
177 translate([-lsd/2-1,y-extrusion_width/2,-idler_h/2-idler_v_tolerance/2-1]) 177 translate([-lsd/2-1,y-extrusion_width/2,-idler_h/2-idler_v_tolerance/2-1])
178 cube(size=[lsd+2,extrusion_width,idler_h+idler_v_tolerance+2]); 178 cube(size=[lsd+2,extrusion_width,idler_h+idler_v_tolerance+2]);
179 } 179 }
180 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30); 180 cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
181 translate([0,0,lever_thickness/2-idler_screwhead_h]) 181 translate([0,0,lever_thickness/2-idler_screwhead_h])
182 cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d); 182 cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d);
183 } 183 }
184 // mounting screw hole 184 // mounting screw hole
185 translate([mount_d/2,0,0]) 185 translate([mount_d/2,0,0])
186 cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d); 186 cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d);
187 187
188 // lever end 188 // lever end
189 translate([mount_d/2,0,0]) rotate([0,90,0]) { 189 translate([mount_d/2,0,0]) rotate([0,90,0]) {
190 translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15); 190 translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15);
191 translate([0,-longwing,0]) 191 translate([0,-longwing,0])
192 mirror([0,0,1]) 192 mirror([0,0,1])
193 difference() { 193 difference() {
194 cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=fnd*(spring_d+spring_d_clearance)); 194 cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=fnd*(spring_d+spring_d_clearance));
195 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4); 195 sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
196 } 196 }
197 }//rotate-translate 197 }//rotate-translate
198 }//difference 198 }//difference
199 // bridging patch 199 // bridging patch
200 if(bridges) place_idler() 200 if(bridges) place_idler()
201 translate([0,0,lever_thickness/2-mount_screwhead_h]) 201 translate([0,0,lever_thickness/2-mount_screwhead_h])
202 mirror([0,0,1]) 202 mirror([0,0,1])
203 cylinder(d=mount_screwhead_d,h=layer_height); 203 cylinder(d=mount_screwhead_d,h=layer_height);
204 }//translate 204 }//translate
205 }//lever module 205 }//lever module
206 206
207 module body() { 207 module body() {
208 difference() { 208 difference() {
209 union() { 209 union() {
210 cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d); 210 cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d);
211 // finger and spring support 211 // finger and spring support
212 fsw = gearbox_d-(gearbox_d-mount_d)/2-spring_lc; 212 fsw = gearbox_d-(gearbox_d-mount_d)/2-spring_lc;
213 translate([-gearbox_d/2,0,0]) difference() { 213 translate([-gearbox_d/2,0,0]) difference() {
214 union() { 214 union() {
215 hull() { 215 hull() {
216 translate([0,-longwing,ls_z]) 216 translate([0,-longwing,ls_z])
217 rotate([0,90,0]) 217 rotate([0,90,0])
218 cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness); 218 cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness);
219 hh=body_h-ls_z; 219 hh=body_h-ls_z;
220 translate([0,0,ls_z-lever_thickness/2]) 220 translate([0,0,ls_z-lever_thickness/2])
221 mirror([0,1,0]) cube(size=[fsw,longwing-hh+lever_thickness/sqrt(2),hh+lever_thickness/2]); 221 mirror([0,1,0]) cube(size=[fsw,longwing-hh+lever_thickness/sqrt(2),hh+lever_thickness/2]);
222 hhh=ls_z; 222 hhh=ls_z;
223 translate([0,0,0]) 223 translate([0,0,0])
224 mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]); 224 mirror([0,1,0]) cube(size=[fsw,longwing-hhh+lever_thickness/sqrt(2),hhh+lever_thickness/2]);
225 } 225 }
226 } 226 }
227 translate([0,-longwing,ls_z]) rotate([0,-90,0]) { 227 translate([0,-longwing,ls_z]) rotate([0,-90,0]) {
228 if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else { 228 if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else {
229 mirror([0,0,1]) { 229 mirror([0,0,1]) {
230 translate([0,0,st_thickshell]) 230 translate([0,0,st_thickshell])
231 hull() for(o=[0,spring_d]) translate([0,-o,0]) 231 hull() for(o=[0,spring_d]) translate([0,-o,0])
232 rotate([0,0,30]) 232 rotate([0,0,30])
233 cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6); 233 cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
234 translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance)); 234 translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
235 bigd = spring_d+spring_d_clearance; 235 bigd = spring_d+spring_d_clearance;
236 hf = (bigd-st_screw_d-st_screw_d_tolerance)/2; 236 hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
237 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) 237 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon])
238 cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd, 238 cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
239 h=hf+epsilon, $fn=fnd*bigd); 239 h=hf+epsilon, $fn=fnd*bigd);
240 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon]) 240 translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
241 cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd); 241 cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
242 } 242 }
243 } 243 }
244 } 244 }
245 } // translate 245 } // translate
246 246
247 // pushfit bracket 247 // pushfit bracket
248 translate([0,0,filament_elevation]) 248 translate([0,0,filament_elevation])
249 rotate([0,0,45]) translate([pulley_d/2,0,0]) 249 rotate([0,0,45]) translate([pulley_d/2,0,0])
250 rotate([-90,0,0]) 250 rotate([-90,0,0])
251 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) { 251 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d-gearbox_d/2/*TODO:*/]) {
252 pfbl = pf_h(pf)+gearbox_d/2; //TODO: 252 pfbl = pf_h(pf)+gearbox_d/2; //TODO:
253 if(pf_smooth) { 253 if(pf_smooth) {
254 pfbd = pf_d(pf)+2*pf_shell; 254 pfbd = pf_d(pf)+2*pf_shell;
255 hull() { 255 hull() {
256 cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd); 256 cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd);
257 translate([-epsilon/2,0,0]) { 257 translate([-epsilon/2,0,0]) {
258 cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]); 258 cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]);
259 mirror([0,1,0]) 259 mirror([0,1,0])
260 cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]); 260 cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]);
261 }//translate 261 }//translate
262 }//hull 262 }//hull
263 }else{ 263 }else{
264 pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2; 264 pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2;
265 pfbd = pfb2a/cos(30); 265 pfbd = pfb2a/cos(30);
266 pfbs = pfb2a*tan(30); 266 pfbs = pfb2a*tan(30);
267 cylinder(d=pfbd,h=pfbl,$fn=6); 267 cylinder(d=pfbd,h=pfbl,$fn=6);
268 translate([-pfbs/2,0,0]) { 268 translate([-pfbs/2,0,0]) {
269 hull() { 269 hull() {
270 translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]); 270 translate([0,-pfba,0]) cube(size=[pfbs,pfb2a,pfbl]);
271 cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]); 271 cube(size=[pfbs,filament_elevation,pfbl-filament_elevation+pfba]);
272 mirror([0,1,0]) 272 mirror([0,1,0])
273 cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]); 273 cube(size=[pfbs,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfba]);
274 }//hull 274 }//hull
275 }//translate*/ 275 }//translate*/
276 }//if(pf_smooth) 276 }//if(pf_smooth)
277 }//translate rotate translate rotate translate 277 }//translate rotate translate rotate translate
278 }//union (first child of difference) 278 }//union (first child of difference)
279 279
280 // protrusion 280 // protrusion
281 translate([0,0,-1]) 281 translate([0,0,-1])
282 cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=fnd*(protrusion_d+protrusion_tolerance_h)); 282 cylinder(d=protrusion_d+protrusion_tolerance_h,h=protrusion_h+protrusion_tolerance_v+1,$fn=fnd*(protrusion_d+protrusion_tolerance_h));
283 // mount screw holes 283 // mount screw holes
284 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) { 284 for(zr=[0:90:359]) rotate([0,0,zr]) translate([mount_d/2,0,0]) {
285 translate([0,0,mount_screw_l-mounthole_depth/2-(bridges?layer_height:-epsilon)]) 285 translate([0,0,mount_screw_l-mounthole_depth/2-(bridges?layer_height:-epsilon)])
286 mirror([0,0,1]) 286 mirror([0,0,1])
287 cylinder(d=mount_screw_d+mount_screw_d_tolerance, 287 cylinder(d=mount_screw_d+mount_screw_d_tolerance,
288 h=mount_screw_l-mounthole_depth/2+1, 288 h=mount_screw_l-mounthole_depth/2+1,
289 $fn=fnd*(mount_screw_d+mount_screw_d_tolerance)); 289 $fn=fnd*(mount_screw_d+mount_screw_d_tolerance));
290 translate([0,0,mount_screw_l-mounthole_depth/2]) 290 translate([0,0,mount_screw_l-mounthole_depth/2])
291 cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d); 291 cylinder(d=mount_screwhead_d,h=body_h+1,$fn=fnd*mount_screwhead_d);
292 }//for 292 }//for
293 // pushfit 293 // pushfit
294 translate([0,0,filament_elevation]) 294 translate([0,0,filament_elevation])
295 rotate([0,0,45]) translate([pulley_d/2,0,0]) 295 rotate([0,0,45]) translate([pulley_d/2,0,0])
296 rotate([-90,0,0]) 296 rotate([-90,0,0])
297 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d+epsilon]) 297 translate([0,0,mount_d/sqrt(2)/2+mount_screw_d+epsilon])
298 rotate([0,0,180]) { 298 rotate([0,0,180]) {
299 pushfit(pf); 299 pushfit(pf);
300 cylinder(d=filament_guide_d,h=gearbox_d,center=true,$fn=fnd*filament_guide_d); 300 cylinder(d=filament_guide_d,h=gearbox_d,center=true,$fn=fnd*filament_guide_d);
301 translate([0,-filament_guide_d/2/sqrt(2),0]) 301 translate([0,-filament_guide_d/2/sqrt(2),0])
302 rotate([0,0,45]) 302 rotate([0,0,45])
303 cube(size=[filament_guide_d/2,filament_guide_d/2,gearbox_d],center=true); 303 cube(size=[filament_guide_d/2,filament_guide_d/2,gearbox_d],center=true);
304 }//rotate translate rotate translate rotate translate 304 }//rotate translate rotate translate rotate translate
305 // pulley 305 // pulley
306 cylinder(d=pulley_d+pulley_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_clearance)); 306 cylinder(d=pulley_d+pulley_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_clearance));
307 // leverspace 307 // leverspace
308 hull() for(x=[0,gearbox_d]) 308 hull() for(x=[0,gearbox_d])
309 rotate([0,0,45]) 309 rotate([0,0,45])
310 translate([x,0,ls_z-ls_h/2]) 310 translate([x,0,ls_z-ls_h/2])
311 cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance)); 311 cylinder(d=idler_d+idler_clearance,h=ls_h,$fn=fnd*(idler_d+idler_clearance));
312 312
313 // idler clearance 313 // idler clearance
314 a=cos(45)*(pulley_d+idler_d)/2; 314 a=cos(45)*(pulley_d+idler_d)/2;
315 b=mount_d/2-a; 315 b=mount_d/2-a;
316 x=sqrt(pow(a,2)+pow(b,2)); 316 x=sqrt(pow(a,2)+pow(b,2));
317 translate([mount_d/2,0,ls_z]) 317 translate([mount_d/2,0,ls_z])
318 intersection() { 318 intersection() {