move spring closer

1 files changed, 36 insertions, 37 deletions

diff --git a/another.scad b/another.scad
index 78d4320..b752f30 100644
--- a/another.scad
+++ b/another.scad
@@ -36,97 +36,97 @@ module the_extruder(
  // 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,
 
  // empty spaces
          idler_travel = 3,                      // how far should idler travel when pressed
  idler_clearance=1,
  pulley_d_clearance=2,
  pulley_small_d_clearance=0.5,
          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,
  st_split_w_tolerance = .3,
 
  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;
+ longwing=(mount_d+mount_screw_d+mount_screw_d_tolerance+spring_d+spring_d_clearance)/2+extrusion_width;
  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);
 
  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,$fn=fnr*rr);
   }else if(r) {
    hh=sqrt(pow(r,2)-pow(d,2)/4);
    translate([0,0,hh]) sphere(r=r,$fn=fnr*r);
   }
  }
 
  % if(vitamins) mirrorleft() {
   translate([0,0,-epsilon]) mirror([0,0,1]) cylinder(d=gearbox_d,h=1,$fn=60);
@@ -190,132 +190,108 @@ module the_extruder(
       sqrt(2)*(mount_d-pulley_d+lsd)/2
      ]) {
       cylinder(d1=filament_path_d,d2=2*filament_path_d,
                h=filament_path_d,$fn=2*filament_path_d*fnd);
       translate([0,0,filament_path_d-epsilon])
       cylinder(d=2*filament_path_d,h=lsd,$fn=2*filament_path_d*fnd);
      }//translate
     }//rotate translate place_idler
 
     // idler space and mounting hole
     place_idler() {
      difference() {
       cylinder(d=idler_d+idler_clearance*2,h=idler_h+idler_v_tolerance,center=true,$fn=60);
       if(supports) for(y=[-lsd/2+extrusion_width:(lsd-2*extrusion_width)/3:lsd/2-extrusion_width])
        translate([-lsd/2-1,y-extrusion_width/2,-idler_h/2-idler_v_tolerance/2-1])
        cube(size=[lsd+2,extrusion_width,idler_h+idler_v_tolerance+2]);
      }
      cylinder(d=idler_screw_d,h=lever_thickness+2,center=true,$fn=30);
      translate([0,0,lever_thickness/2-idler_screwhead_h])
      cylinder(d=idler_screwhead_d,h=idler_screwhead_h+1,$fn=fnd*idler_screwhead_d);
     }
     // mounting screw hole
     translate([mount_d/2,0,0])
     cylinder(d=mount_screw_d+mount_screw_d_tolerance,h=lever_thickness+2,center=true,$fn=fnd*mount_screw_d);
     
     // lever end
     translate([mount_d/2,0,0]) rotate([0,90,0]) {
      translate([0,-longwing,lsd/2]) finger_indent(d=lever_thickness-1,r=15);
      translate([0,-longwing,0])
      mirror([0,0,1])
      difference() {
       cylinder(d=spring_d+spring_d_clearance,h=lsd,$fn=fnd*(spring_d+spring_d_clearance));
       sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
      }
     }//rotate-translate
    }//difference
    // bridging patch
    if(bridges) place_idler()
    translate([0,0,lever_thickness/2-mount_screwhead_h])
    mirror([0,0,1])
    cylinder(d=mount_screwhead_d,h=layer_height);
   }//translate
  }//lever module
  
  module body() {
   difference() {
    union() {
     cylinder(d=gearbox_d,h=body_h,$fn=fnd*gearbox_d);
-    translate([-gearbox_d/2,0,0]) difference() {
-     union() {
-      hull() {
-       translate([0,-longwing,ls_z])
-       rotate([0,90,0])
-       cylinder(d=lever_thickness,h=fsw,$fn=fnd*lever_thickness);
-       hh=body_h-ls_z;
-       translate([0,0,ls_z])
-       mirror([0,1,0]) cube(size=[fsw,longwing+(st_thinshell+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]);
-      }
-     }
-     translate([0,-longwing,ls_z]) rotate([0,-90,0]) {
-      if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else {
-       mirror([0,0,1]) {
-        translate([0,0,st_thickshell])
-        hull() for(o=[0,spring_d]) translate([0,-o,0])
-        rotate([0,0,30])
-        cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
-        translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
-        bigd = spring_d+spring_d_clearance;
-        hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
-        translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) {
-         cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
-          h=hf+epsilon, $fn=fnd*bigd);
-         translate([0,-(st_thinshell+st_split_w_tolerance)/2,0])
-         cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]);
-        }
-        translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
-        cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
-       }
-      }
-     }
-    } // translate
+    // 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_thinshell+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:*/]) {
      pfbl = pf_h(pf)+gearbox_d/2; //TODO:
      if(pf_smooth) {
       pfbd = pf_d(pf)+2*pf_shell;
       hull() {
        cylinder(d=pfbd,h=pfbl,$fn=pfbd*fnd);
        translate([-epsilon/2,0,0]) {
         cube(size=[epsilon,filament_elevation,pfbl-filament_elevation+pfbd/2]);
         mirror([0,1,0])
         cube(size=[epsilon,body_h-filament_elevation,pfbl-body_h+filament_elevation+pfbd/2]);
        }//translate
       }//hull
      }else{
       pfb2a = pf_d(pf)+2*pf_shell; pfba = pfb2a/2;
       pfbd = pfb2a/cos(30);
       pfbs = pfb2a*tan(30);
       cylinder(d=pfbd,h=pfbl,$fn=6);
       translate([-pfbs/2,0,0]) {
        hull() {
         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
@@ -341,96 +317,119 @@ module the_extruder(
 
    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
     echo(atan(1-2*fsw/gearbox_d));
     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)
     /
     (
      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
    
    //translate([-mount_d/2,-longwing,filament_elevation])
    if(!tensioner) /* XXX: this seems to be bullshit, but it's so old, that it's historical bullshit */
    translate([mount_d/2,-longwing,filament_elevation])
    rotate([0,-90,0]) difference() {
     cylinder(d=spring_d+spring_d_clearance,h=spring_lc+spring_dl,$fn=fnd*(spring_d+spring_d_clearance));
     translate([0,0,spring_lc+spring_dl]) sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
    }
 
+   // spring tensioner
+   translate([-gearbox_d/2,-longwing,ls_z]) rotate([0,-90,0]) {
+    if(!tensioner) finger_indent(d=lever_thickness-1,r=15); else {
+     mirror([0,0,1]) {
+      translate([0,0,st_thickshell])
+      hull() for(o=[0,spring_d]) translate([0,-o,0])
+      rotate([0,0,30])
+      cylinder(d=st_nut_d+st_nut_d_tolerance,h=st_nut_h+st_nut_h_tolerance,$fn=6);
+      translate([0,0,-1]) cylinder(d=st_screw_d+st_screw_d_tolerance,h=fsw+2,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
+      bigd = spring_d+spring_d_clearance;
+      hf = (bigd-st_screw_d-st_screw_d_tolerance)/2;
+      translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell-epsilon]) {
+       cylinder(d1=st_screw_d+st_screw_d_tolerance,d2=bigd,
+        h=hf+epsilon, $fn=fnd*bigd);
+       translate([0,-(st_thinshell+st_split_w_tolerance)/2,0])
+       cube(size=[body_h-ls_z+1,st_thinshell+st_split_w_tolerance,fsw+1]);
+      }
+      translate([0,0,st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+hf-epsilon])
+      cylinder(d=bigd,h=fsw+1,$fn=fnd*bigd);
+     }
+    }
+   }
+
   }//difference
 
   if(supports) intersection() {
    difference() {
     translate([0,0,ls_z-ls_h/2-epsilon])
     cylinder(d=gearbox_d,h=ls_h+2*epsilon,$fn=fnd*gearbox_d);
     cylinder(d=pulley_d+pulley_d_clearance,h=body_h+1,$fn=fnd*(pulley_d+pulley_d_clearance));
    }
    // supports
    // TODO: hardcoded stuff below…
    if(false) { // parallel
     for(y=[-gearbox_d:4:gearbox_d])
      translate([0,y-extrusion_width/2,0])
      cube(size=[gearbox_d,extrusion_width,body_h]);
    }else{ // radial
     for(zr=[-65:(65+50)/7:50])
      rotate([0,0,zr]) translate([0,-extrusion_width/2,0])
      cube(size=[gearbox_d,extrusion_width,body_h]);
    }
   }
 
  }//body module
 
  module springpad() {
   smalld=st_screw_d+st_screw_d_tolerance+2*extrusion_width;
   bigd = spring_d+spring_d_clearance/2;
   hf = (bigd-smalld)/2;
   h = hf*3.5;
   translate([-gearbox_d/2+st_thickshell+st_nut_h+st_nut_h_tolerance+st_thinshell+1,-longwing,filament_elevation])
   rotate([0,90,0]) difference() {
    union() {
     cylinder(d1=smalld,d2=bigd,h=hf,$fn=fnd*bigd);
     translate([0,0,hf-epsilon])
     cylinder(d=bigd,h=h-hf,$fn=fnd*bigd);
     translate([0,0,h])
     sphere(d=spring_d*3/4,$fn=fnd*spring_d*3/4);
     l = body_h-ls_z;
     w = st_thinshell;
     hull() translate([0,-st_thinshell/2,0]) mirror([1,0,0]) {
      translate([0,0,w])
      cube(size=[l,st_thinshell,w]);
      cube(size=[l-w,st_thinshell,2*w]);
     }
    }
    translate([0,0,-epsilon])
    cylinder(d=st_screw_d+st_screw_d_tolerance,h=2*hf+epsilon,$fn=fnd*(st_screw_d+st_screw_d_tolerance));
   }
  }