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This version used for the kits 1-6 at the GIST FOTM.

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Z axis length increased to 200mm.
Added the Dibond variant that uses nuts in the parts instead of tapped holes.
Added a ducted fan to the X carriage.
Added a spool holder and filament dust wiper.
Default hot end is now J-Head MK4.
Default electronics is now Melzi plus ATX PSU on the mendel and dibond versions.
The right hand stay has been moved inwards and base corner radius reduced to allow and ATX PSU to be mounted inboard.
Mounting brackets for ATX PSU added.
The electronics are now above the PSU.
Mains inlet cover added for non ATX PSUs.
Dummy load resistors added for ATX PSU.

The extruder now has a groove mount for the JHead.
Extruder connector increased from 9 way to 15 way to allow an IDC socket.
The extruder ribbon cable is now 14 way to allow three wires for the heater.
Added an extruder break out PCB.
Wade's idler bracket now a bit wider to allow more tolerance on the length of the axle.
Extruder motor screws now longer and hex head.
The hobbed bolt now has two nuts and a star washer instead of one nut and a spring.

Increased the bed ribbon cable to 26 way to make it standard size.
Y carriage made a bit smaller.
Thermistor added to the bed assembly.
Bed cooling fan made an optional extra.
Made the Z top limit switch the default.
The X idler now has two bearings.
Lead nuts now brass.
Added metal pulleys as an option.
T2.5 belts added as an option.
Nut traps added to the Y carrige ribbon clamp.
Corner shields and support material added to X motor bracket.

Belt length calculations more accurate.
Axis limit switch positions and overtravel optimised.
Washer sizes tweaked.
Ziptie length tweaked.
PVC tubing diameter changed.
This commit is contained in:
Chris Palmer
2012-11-15 17:45:30 +00:00
parent 5c17781aaa
commit 4141634677
597 changed files with 2119826 additions and 488871 deletions
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446
scad/spool_holder.scad Normal file
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//
// Mendel90
//
// GNU GPL v2
// nop.head@gmail.com
// hydraraptor.blogspot.com
//
// Filament spool holder
//
include <conf/config.scad>
include <positions.scad>
use <wade.scad>
bearing = BB608;
thickness = 6;
wall = 2;
angle = 45;
hook = 8;
hook_overlap = 3;
tube_r = 4;
hook_r = 3;
left = left_stay_x + sheet_thickness(frame) / 2;
right = right_stay_x - sheet_thickness(frame) / 2;
spool_x = (left + right) / 2;
spool_z = height - gantry_thickness + spool_diameter(spool) / 2 + 10;
spool_y = gantry_Y + sheet_thickness(frame) + 10 + spool_height(spool) / 2;
holes = psu_hole_list(psu);
bearing_r = (spool_diameter(spool) + ball_bearing_diameter(bearing)) / 2;
bearing_x = cos(angle) * bearing_r;
bearing_z = spool_z - sin(angle) * bearing_r;
bearing_y = spool_width(spool) / 2 + ball_bearing_width(bearing) / 2;
bracket_width = right - (spool_x + bearing_x);
bracket_height = height - bearing_z;
top_tube_x = bracket_width - tube_r;
top_tube_y = bracket_height + hook - tube_r;
bottom_tube_y = -bracket_height + tube_r;
middle_tube_x = washer_diameter(M8_washer) / 2 + 1 + tube_r;
dx = top_tube_x - middle_tube_x;
dy = top_tube_y;
tube_spacing = sqrt(dx * dx + dy * dy);
width = spool_width(spool) - 2 * (thickness + washer_thickness(M8_washer) + washer_thickness(M8_penny_washer));
sponge_length = 15;
sponge_depth = 15;
sponge_height = 15;
sponge_wall = 2;
feed_clip_length = 2 * (tube_r + 3);
feed_clip_width = sponge_depth + sponge_wall;
feed_clip_thickness = 3;
module pie_slice(r, start_angle, end_angle) {
R = r * sqrt(2) + 1;
a0 = (4 * start_angle + 0 * end_angle) / 4;
a1 = (3 * start_angle + 1 * end_angle) / 4;
a2 = (2 * start_angle + 2 * end_angle) / 4;
a3 = (1 * start_angle + 3 * end_angle) / 4;
a4 = (0 * start_angle + 4 * end_angle) / 4;
if(end_angle > start_angle)
intersection() {
circle(r);
polygon([
[0,0],
[R * cos(a0), R * sin(a0)],
[R * cos(a1), R * sin(a1)],
[R * cos(a2), R * sin(a2)],
[R * cos(a3), R * sin(a3)],
[R * cos(a4), R * sin(a4)],
[0,0]
]);
}
}
//
// Tube clips
//
module tube_clip() {
angle = atan(0.6);
linear_extrude(height = feed_clip_width, convexity = 5)
union() {
difference() {
pie_slice(tube_r + feed_clip_thickness, -angle, 180 + angle);
circle(tube_r);
}
for(a = [-angle, 180 + angle])
rotate(a)
translate([tube_r + feed_clip_thickness / 2, 0])
circle(feed_clip_thickness / 2);
}
}
filament_y = tube_r + feed_clip_thickness + feed_tube_tape_rad + eta;
module dust_filter_stl() {
stl("dust_filter");
filament_hole_r = 2;
box_height = sponge_height + 2 * sponge_wall;
box_length = sponge_length + 2 * sponge_wall;
box_depth = sponge_depth + sponge_wall;
box_x = tube_spacing - box_length - feed_clip_length / 2 - 2;
box_y = filament_y - box_height / 2;
filament_z = sponge_wall + sponge_depth / 2;
difference() {
union() {
tube_clip(); // clips at each end
translate([tube_spacing, 0, 0])
tube_clip();
translate([0, tube_r + eta, 0])
cube([tube_spacing, feed_clip_thickness, box_depth]); // joining strip
translate([box_x, box_y, 0])
cube([box_length, box_height, box_depth]); // box for dust trap
translate([0, filament_y, filament_z])
hull() {
rotate([-90, 0, 90])
cylinder(r = feed_tube_tape_rad + wall, h = wall + feed_tube_tape, center = true);
translate([-feed_tube_tape / 2, - wall / 2, - filament_z])
cube([feed_tube_tape, wall, 1]);
}
}
translate([box_x + sponge_wall, box_y + sponge_wall, sponge_wall])
cube([sponge_length, sponge_height, sponge_depth + 1]);
translate([box_x + box_length / 2, filament_y, filament_z])
rotate([90, 0, 90])
teardrop(r = filament_hole_r, h = box_length + 1, center = true);
translate([0, filament_y, filament_z])
rotate([90, 0, 90])
teardrop(r = feed_tube_rad, h = wall + feed_tube_tape + 1, center = true);
translate([wall, filament_y, filament_z])
rotate([90, 0, 90])
teardrop(r = feed_tube_tape_rad, h = wall + feed_tube_tape, center = true);
}
}
//
// P clip to hold in place
//
pclip_wall = 3;
pclip_tab = washer_diameter(screw_washer(frame_screw)) + 2;
pclip_screw_offset = tube_r + pclip_wall + pclip_tab / 2;
module spool_holder_p_clip_stl() {
stl("spool_holder_p_clip");
tab = pclip_tab;
h = tab;
r = tube_r + 0.1;
nut = screw_nut(frame_screw);
thickness = part_base_thickness + ((frame_nuts && cnc_sheets) ? nut_trap_depth(nut) : 0);
R = tube_r + pclip_wall;
difference() {
linear_extrude(height = h, convexity = 5)
difference() {
union() {
square([thickness, R + tab]);
translate([r, 0, 0])
intersection() {
circle(R);
translate([0, -R - 1])
square([R + 1 ,2 * R + 2]);
}
translate([0, -R])
square([r, 2 * R]);
}
translate([r, 0, 0])
circle(r);
translate([0, -r])
square([r, 2 * r]);
}
translate([part_base_thickness + nut_trap_depth(nut) + eta, R + tab / 2, h / 2])
rotate([90, 0, 90])
nut_trap(screw_clearance_radius(frame_screw), nut_radius(nut), nut_trap_depth(nut), true);
}
}
//
// Tube with a dowel on top
//
module tube(height) {
difference() {
union() {
cylinder(r = tube_r, h = height);
cylinder(r = tube_r - wall, h = height + thickness - wall - layer_height); // dowel
}
translate([0, 0, wall])
cylinder(r = tube_r - wall, h = height - 2 * wall);
}
}
//
// The outline of the bracket, triangle with rounded corners
//
module shape(width, height) {
hull() {
circle(washer_diameter(M8_washer) / 2 + 1);
translate([width - tube_r, height + hook - tube_r])
circle(tube_r);
translate([width - tube_r, -height + tube_r])
circle(tube_r);
}
}
//
// Inset to remove most of the plastic leaving a frame
//
module inner_shape(width, height) {
rad = 4;
inset = 8 + rad;
minkowski() {
render() difference() {
shape(width, height);
union() {
minkowski() {
difference() {
minkowski() {
shape(width, height);
circle(r = 1, center = true);
}
shape(width, height);
translate([width -1, -inset])
square([3, 2 * inset + 1]);
}
circle(r = inset);
}
translate([width - inset - eta, -2 * inset])
square([2 * inset + 1 + 2 * eta, 4 * inset]);
}
}
circle(rad);
}
}
//
// A bisexual bracket
//
module spool_bracket(width, height, tube) {
hole_r = screw_clearance_radius(M8_cap_screw);
difference() {
union() {
linear_extrude(height = thickness, convexity = 5)
difference() {
union() {
shape(width, height);
hull() {
translate([width - tube_r - eta, height - hook_overlap])
square([tube_r + 1, hook + hook_overlap]);
translate([width + sheet_thickness(frame) + hook - hook_r, height - hook_overlap + hook_r])
circle(hook_r);
translate([width + sheet_thickness(frame) + hook - hook_r, height + hook - hook_r])
circle(hook_r);
}
}
difference() {
inner_shape(width, height);
circle(washer_diameter(M8_washer) / 2 + 1 + 2 * tube_r);
}
poly_circle(hole_r); // hole for axel screw
translate([width, height - hook])
square([sheet_thickness(frame) + 0.2, hook]); // slot for frame
}
if(tube > 0)
for(v = [
[top_tube_x, bottom_tube_y, thickness - eta],
[top_tube_x, top_tube_y, thickness - eta],
[middle_tube_x, 0, thickness - eta],
]) translate(v)
tube(tube);
}
if(tube < 0)
for(v = [
[top_tube_x, bottom_tube_y, thickness],
[top_tube_x, top_tube_y, thickness],
[middle_tube_x, 0, thickness],
]) translate(v)
cylinder(r = tube_r - wall + 0.2, h = - 2 * tube, center = true); // socket for dowel
}
}
//
// Male and female versions
//
module spool_bracket_female_stl() {
stl("spool_bracket_female");
spool_bracket(bracket_width, bracket_height, wall - thickness);
}
module spool_bracket_male_stl() {
stl("spool_bracket_male");
mirror([0, 1, 0]) spool_bracket(bracket_width, bracket_height, width);
}
//
// One bearing and bracket
//
module spool_bracket_assembly(male)
{
rotate([-90, 0, 0]) {
ball_bearing(bearing);
translate([0, 0, ball_bearing_width(bearing) / 2])
screw(M8_cap_screw, 30);
rotate([180, 0, 0])
translate([0, 0, ball_bearing_width(bearing) / 2]) {
washer(M8_washer);
translate([0, 0, washer_thickness(M8_washer)]) {
washer(M8_penny_washer);
translate([0, 0, washer_thickness(M8_penny_washer)]) {
if(male)
color(plastic_part_color("lime")) render() mirror([0, 1, 0]) spool_bracket_male_stl();
else
color(plastic_part_color("red")) render() spool_bracket_female_stl();
translate([0, 0, thickness]) {
washer(M8_washer);
translate([0, 0, washer_thickness(M8_washer)])
nut(M8_nut, true);
}
}
}
}
if(male)
translate([right - (spool_x + bearing_x), height - bearing_z - tube_r, -bearing_y]) {
rotate([0, 0, 180])
translate([0, 0, - pclip_tab / 2])
color(plastic_part_color("red")) render() spool_holder_p_clip_stl();
translate([-part_base_thickness, -pclip_screw_offset, 0])
rotate([0, -90, 0])
rotate([0, 0, 30])
frame_screw(part_base_thickness);
}
}
}
//
// The full assembly
//
module spool_assembly() {
angle = atan(dx / dy);
assembly("spool_holder_assembly");
translate([spool_x, spool_y, spool_z])
rotate([90, 0, 0])
spool(spool);
for(side = [-1, 1]) {
translate([spool_x + side * bearing_x, spool_y + side * bearing_y, bearing_z])
rotate([0, 0, 90 - side * 90])
spool_bracket_assembly(false);
translate([spool_x + side * bearing_x, spool_y - side * bearing_y, bearing_z])
rotate([0, 0, 90 - side * 90])
mirror([0, 1, 0])
spool_bracket_assembly(true);
if(side == -1)
translate([spool_x + side * (bearing_x + top_tube_x), spool_y + feed_clip_width / 2 + sponge_wall / 2, bearing_z + top_tube_y])
rotate([90, 90 - angle, 0]) {
color("red") render() dust_filter_stl();
rotate([90, 0, 90])
translate([filament_y, feed_clip_width / 2 + sponge_wall / 2, -750 / 2 + (wall + feed_tube_tape) / 2])
tubing(PF7, 750);
}
}
end("spool_holder_assembly");
}
module spool_holder_holes()
for(side = [left, right])
translate([side, spool_y, bearing_z - bracket_height + tube_r + pclip_screw_offset])
rotate([0, 90, 0])
frame_screw_hole();
//
// A pair laid out for building
//
module spool_holder_brackets_stl() {
gap = max(wall + 2 * tube_r + feed_clip_thickness + feed_tube_tape_rad + sponge_height / 2 + wall, 2 * (hook + hook_overlap)) + 2;
spool_bracket_female_stl();
translate([bracket_width - 2 * tube_r - 2, 0, 0])
rotate([0, 0, 180])
spool_holder_p_clip_stl();
translate([2 * bracket_width + gap, hook, 0]) {
rotate([0, 0, 180])
spool_bracket_female_stl();
translate([-bracket_width + 2 * tube_r + 2, 0, 0])
spool_holder_p_clip_stl();
}
translate([bracket_width + tube_r + wall, -bracket_height + tube_r + wall + hook_overlap + 2 + tube_spacing, 0])
rotate([0, 0, -90])
dust_filter_stl();
translate([bracket_width + gap / 2, bracket_height - hook - hook_overlap - 2, 0])
feed_tube_connector_stl();
}
module spool_holder_tall_brackets_stl() {
gap = hook + hook_overlap + 2;
spool_bracket_male_stl();
translate([2 * bracket_width + gap, -hook, 0])
rotate([0, 0, 180])
spool_bracket_male_stl();
}
if(1)
spool_assembly();
else
if(0)
spool_holder_tall_brackets_stl();
else
spool_holder_brackets_stl();