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Pulleys and belts now T2.5 on kit version.

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JHead now attached by three screws and washers.
New extruder breakout PCB.
Lots of instruction manual improvements from user feedback.
This commit is contained in:
Chris Palmer
2012-12-24 13:15:00 +00:00
parent e9b6ff5101
commit 1fab28d832
170 changed files with 186944 additions and 165966 deletions
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231
scad/wade.scad
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@@ -39,8 +39,16 @@ filament_x = 75;
filament_z = 13;
extension = max(0, nozzle_length - hot_end_length(hot_end));
extension_width = 32;
extension_width = 30;
jhead_screw = M3_cap_screw;
jhead_screw_length = 16;
jhead_washer = M4_washer;
jhead_screw_pitch = max(hot_end_insulator_diameter(hot_end) / 2 + screw_head_radius(jhead_screw),
jhead_groove_dia() / 2 + washer_diameter(jhead_washer) / 2);
extension_rad = jhead_screw_pitch + 5;
extension_clearance = 1;
pscrew_y = [17.5, 45.5];
pscrew_z = [filament_z - 6.5, filament_z + 6.5];
@@ -65,7 +73,7 @@ module keyhole(r, h, l) {
entrance = 2 * R + 0.5;
y = sqrt(R * R - waist * waist / 4);
teardrop(h = h, r = R, center = true);
hull() {
*hull() {
translate([0, l, 0])
cube([entrance, 2 * eta, h ], center = true);
translate([0, y, 0])
@@ -75,6 +83,9 @@ module keyhole(r, h, l) {
nut_inset = min_wall;
jhead_screw_angle = 5;
jhead_nut_slot = nut_thickness(screw_nut(jhead_screw)) + 0.3;
module wades_block_stl() {
stl("wades_block");
@@ -85,6 +96,7 @@ module wades_block_stl() {
nut_slot = nut_thickness(M4_nut) + 0.3;
difference(){
union(){
cube([81, height, thickness]); // motor plate
@@ -105,10 +117,15 @@ module wades_block_stl() {
cube([11,11, width]);
if(extension)
translate([filament_x - extension_width / 2, -extension + eta, 0])
cube([extension_width, extension, width]);
translate([filament_x - extension_width / 2, -extension + extension_clearance + eta, 0])
intersection() {
cube([extension_width, extension - extension_clearance, width]);
translate([extension_width / 2, extension / 2, filament_z])
rotate([-90, 0, 0])
teardrop(r = extension_rad, h = extension + 1, center = true);
}
}
translate([92,base_thickness + 1,-1])
*translate([92,base_thickness + 1,-1])
rotate([0,0,45])
cube([10,9,30]); // chamfer on fillet
@@ -168,7 +185,7 @@ module wades_block_stl() {
// hole for hobbed bolt
//
difference() {
translate([driven_x, driven_y, 7 + layer_height - eta])
translate([driven_x, driven_y, 7 + layer_height + eta])
poly_cylinder(r = M8_clearance_radius + 0.25, h = 30);
translate([driven_x + 2, driven_y - 5, filament_z + 4 - eta])
@@ -188,16 +205,31 @@ module wades_block_stl() {
rotate([90,0,0]) {
if(hot_end_groove_mount(hot_end)) assign(relief = 0.5) {
translate([0, 0, -insulator_depth + jhead_groove_offset() / 2]) // slot for the flange
translate([0, 0, -insulator_depth + jhead_groove_offset() / 2 + eta]) // slot for the flange
keyhole(insulator / 2, jhead_groove_offset(), width - filament_z);
keyhole(12 / 2, insulator_depth * 2 - 1, width - filament_z); // slot fot the groove
translate([0, 0, -insulator_depth + jhead_groove_offset() - relief / 2])
keyhole(insulator / 2 + 0.5, relief, width - filament_z); // relief to avoid corner radius
translate([0, 0, -insulator_depth + relief / 2])
keyhole(insulator / 2 + 0.5, relief, width - filament_z); // relief to avoid corner radius
//
// Screw holes and nut traps
//
for(i = [0:2])
rotate([0, 0, i * 120 + jhead_screw_angle])
translate([jhead_screw_pitch, 0, 0])
rotate([0, 0, -i * 120 - jhead_screw_angle]) {
teardrop_plus(r = screw_clearance_radius(jhead_screw), h = jhead_screw_length * 2, center = true);
translate([0, 0, -base_thickness - extension - jhead_nut_slot / 2]) {
rotate([0, 0, [0, 30, 30][i]])
nut_trap(0, nut_radius(screw_nut(jhead_screw)), jhead_nut_slot / 2, horizontal = true);
assign(w = nut_flat_radius(screw_nut(jhead_screw)))
rotate([0, 0, [-90 ,0, 180][i]])
translate([-w, 0, -jhead_nut_slot / 2])
cube([w * 2, 100, jhead_nut_slot], center = false);
}
}
}
else {
teardrop_plus(h = insulator_depth * 2, r = insulator / 2, center = true); // insulator socket
@@ -215,29 +247,6 @@ module wades_block_stl() {
}
module jhead_insertion_jig_stl() {
stl("jhead_insertion_jig");
h1 = jhead_groove() - 1;
h2 = jhead_groove_offset() - 1;
l = width + 2 - filament_z;
w1 = hot_end_insulator_diameter(hot_end) - 2;
w2 = jhead_groove_dia() - 2;
color("blue")
union() {
difference() {
translate([-w1 / 2, 0, 0])
cube([w1, l, h1]);
poly_cylinder(r = hot_end_insulator_diameter(hot_end) / 2, h = 100, center = true);
}
difference() {
translate([- w2 / 2, 0, h1 - eta])
cube([w2, l, h2]);
poly_cylinder(r = jhead_groove_dia() / 2, h = 100, center = true);
}
}
}
spacer_length = 4 * 1.5;
gear_thickness = 6;
@@ -346,89 +355,96 @@ module extruder_motor_assembly(show_connector = true, exploded = exploded) {
end("extruder_motor_assembly");
}
module wades_assembly(show_connector = true) {
module wades_assembly(show_connector = true, show_drive = true) {
assembly("extruder_assembly");
color(wades_block_color) render()
difference() {
wades_block_stl();
*translate([-1,-1, filament_z]) // cross section
*translate([-1,-10, filament_z]) // cross section
cube([200,100,100]);
}
if(show_drive) {
// idler screws, washers and springs
for(i = [0,1])
translate([pscrew_x, pscrew_y[i], pscrew_z[i]])
rotate([90, 90, 90]) {
screw(M4_hex_screw, pscrew_length);
translate([0,0, -pscrew_length + nut_inset])
explode([12 - 24 * i, 0, 0])
nut(M4_nut);
translate([0,0, 0]) {
translate([0,0, -10 + 50 * exploded]) {
comp_spring(extruder_spring, 10);
for(i = [0,1])
translate([pscrew_x, pscrew_y[i], pscrew_z[i]])
rotate([90, 90, 90]) {
screw(M4_hex_screw, pscrew_length);
translate([0,0, -pscrew_length + nut_inset])
explode([12 - 24 * i, 0, 0])
nut(M4_nut);
translate([0,0, 0]) {
translate([0,0, -10 + 50 * exploded]) {
comp_spring(extruder_spring, 10);
}
}
}
}
// mounting screws
for(side = [-1, 1])
translate([filament_x + mount_pitch * side, base_thickness - 3, filament_z])
rotate([-90,0,0])
screw(M4_hex_screw, 20);
// mounting screws
for(side = [-1, 1])
translate([filament_x + mount_pitch * side, base_thickness - 3, filament_z])
rotate([-90,0,0])
screw(M4_hex_screw, 20);
//idler
translate([filament_x + 22 + 40 * exploded, driven_y, filament_z])
rotate([90, 0, -90])
wade_idler_assembly();
//idler
translate([filament_x + 22 + 40 * exploded, driven_y, filament_z])
rotate([90, 0, -90])
wade_idler_assembly();
// motor
translate([0, 0, 50 * exploded])
extruder_motor_assembly(show_connector, 0);
// motor
translate([0, 0, 50 * exploded])
extruder_motor_assembly(show_connector, 0);
translate([motor_x, motor_y, 0])
rotate([0, 180, -90])
NEMA_screws(NEMA17, 3, 10, M3_hex_screw);
translate([motor_x, motor_y, 0])
rotate([0, 180, -90])
NEMA_screws(NEMA17, 3, 10, M3_hex_screw);
}
// hobbed bolt and gear
translate([driven_x, driven_y, 0]) {
translate([0, 0, width - BB608[2] / 2])
translate([0, 0, width - BB608[2] / 2 + (!show_drive ? exploded * 20 : 0)])
ball_bearing(BB608);
translate([0, 0, BB608[2] / 2])
translate([0, 0, BB608[2] / 2 - (!show_drive ? exploded * 20 : 0)])
ball_bearing(BB608);
translate([0, 0, - 30 * exploded])
rotate([180, 0, 0])
color(wades_gear_spacer_color) render() wades_gear_spacer_stl();
translate([0, 0, -spacer_length - 50 * exploded])
rotate([180, 0, 0])
wades_big_gear_stl();
if(show_drive) {
translate([0,0, -spacer_length - gear_thickness])
rotate([180, 0, 0])
screw(M8_hex_screw, 60, spacer_length + gear_thickness + filament_z);
translate([0, 0, - 30 * exploded])
rotate([180, 0, 0])
color(wades_gear_spacer_color) render() wades_gear_spacer_stl();
translate([0,0, width]) {
if(spring) {
comp_spring(hob_spring, 8);
translate([0, 0, 8])
nut(M8_nut);
}
else explode([0, 0, 25]) group() {
translate([0, 0, -15 * exploded])
nut(M8_nut);
translate([0, 0, -spacer_length - 50 * exploded])
rotate([180, 0, 0])
wades_big_gear_stl();
translate([0, 0, nut_thickness(M8_nut) - 10 * exploded]) {
star_washer(M8_washer);
translate([0,0, -spacer_length - gear_thickness])
rotate([180, 0, 0])
screw(M8_hex_screw, 60, spacer_length + gear_thickness + filament_z);
translate([0, 0, washer_thickness(M8_washer) + 5 * exploded])
translate([0,0, width]) {
if(spring) {
comp_spring(hob_spring, 8);
translate([0, 0, 8])
nut(M8_nut);
}
else explode([0, 0, 25]) group() {
translate([0, 0, -15 * exploded])
nut(M8_nut);
translate([0, 0, nut_thickness(M8_nut) - 10 * exploded]) {
star_washer(M8_washer);
translate([0, 0, washer_thickness(M8_washer) + 5 * exploded])
nut(M8_nut);
}
}
}
}
}
//
@@ -436,13 +452,21 @@ module wades_assembly(show_connector = true) {
//
assembly("hot_end_assembly");
translate([filament_x, -extension, filament_z])
rotate([-90, 0, 0]) {
if(hot_end_style(hot_end) == m90)
m90_hot_end(hot_end);
if(hot_end_style(hot_end) == Stoffel)
stoffel_hot_end(hot_end);
if(hot_end_style(hot_end) == jhead)
jhead_hot_end(hot_end, exploded = 0);
rotate([-90, 0, 0]) difference() {
union() {
if(hot_end_style(hot_end) == m90)
m90_hot_end(hot_end);
if(hot_end_style(hot_end) == Stoffel)
stoffel_hot_end(hot_end);
if(hot_end_style(hot_end) == jhead)
jhead_hot_end(hot_end, exploded = 0, show_wires = false);
}
rotate([180, 0, 180])
translate([0, 0, hot_end_length(hot_end)] + hot_end_duct_offset(hot_end)) // trim the wires
tube(or = 100, ir = hot_end_duct_radius(hot_end) - 1, h = 30, center = true);
translate([0, 0, 60])
cube(100, center = true);
}
end("hot_end_assembly");
@@ -450,11 +474,22 @@ module wades_assembly(show_connector = true) {
for(side = [-1, 1])
translate([filament_x + hot_end_screw_pitch(hot_end) * side, screw_depth - extension, width])
screw(M3_cap_screw, 30);
else
translate([filament_x, -extension, filament_z])
for(i = [0:2]) assign(a = i * 120 - jhead_screw_angle)
rotate([90, a, 0]) {
translate([jhead_screw_pitch, 0, 0])
washer(jhead_washer)
star_washer(screw_washer(jhead_screw))
screw(jhead_screw, jhead_screw_length);
if(show_jigs)
translate([filament_x, hot_end_inset(hot_end) - 1 - extension, filament_z])
rotate([90, 0, 0])
jhead_insertion_jig_stl();
translate([jhead_screw_pitch, 0, -extension - base_thickness - jhead_nut_slot / 2 - nut_thickness(screw_nut(jhead_screw)) / 2])
explode([ [ 10 * cos(a), 10 * sin(a), 0],
[ 10 * sin(a), -10 * cos(a), 0],
[-10 * sin(a), 10 * cos(a), 0] ][i])
rotate([0, 0, [0, 30, 30][i]])
nut(screw_nut(jhead_screw));
}
end("extruder_assembly");
}