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X-end mods for Huxley.

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This commit is contained in:
Chris Palmer 2016-01-10 19:50:32 +00:00
parent 9611c4743b
commit 4f56561bb7
1 changed files with 90 additions and 32 deletions
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122
scad/x-end.scad
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@ -96,16 +96,19 @@ idler_front = min(belt_edge - belt_width(X_belt) / 2 + idler_stack / 2, -bar_y -
idler_screw_length = 45;
idler_depth = idler_screw_length - idler_stack - 1;
idler_back = idler_front + idler_depth;
idler_width = ceil(2 * (M4_nut_radius + wall));
idler_min_offset = max(M4_nut_radius + 0.5, 4 / 2 + wall);
idler_max_offset = M4_nut_radius + wall;
idler_width = ceil((squeeze ? idler_min_offset : idler_max_offset) + M4_nut_radius + wall);
idler_offset = squeeze ? idler_min_offset : idler_width / 2;
motor_washers = X_motor == NEMA14 ? 5 : 3;
mbracket_thickness = 4;
mbracket_corner = 7;
motor_angle = 45;
motor_w = ceil(min(max(sin(motor_angle) + cos(motor_angle)) * NEMA_width(X_motor), NEMA_radius(X_motor) * 2) + 1);
mbracket_width = motor_w + 2 * mbracket_thickness;
mbracket_height = thickness / 2 + NEMA_radius(X_motor) + mbracket_thickness + 0.5;
mbracket_front = belt_edge + 14;
mbracket_depth = NEMA_length(X_motor) + 3 * washer_thickness(M3_washer) + 2 * mbracket_thickness;
mbracket_depth = NEMA_length(X_motor) + motor_washers * washer_thickness(M3_washer) + 2 * mbracket_thickness;
mbracket_centre = mbracket_front + mbracket_depth / 2 - mbracket_thickness;
nut_shelf = bearing_height -thickness / 2 - wall - nut_trap_depth(Z_nut);
@ -114,12 +117,12 @@ switch_op_z = x_carriage_offset() - 2; // hit the edge of the carriage
sbracket_top = switch_op_z + 12;
sbracket_height = sbracket_top + thickness / 2;
sbracket_depth = switch_op_x - 3 - front;
sbracket_thickness = bar_y - (X_bar_dia / 2) * sin(45) - bearing_width / 2 - 1.5 - microswitch_thickness();
sbracket_thickness = bar_y - bearing_width / 2 - (squeeze ? 0 : (X_bar_dia / 2) * sin(45) + 1.5) - microswitch_thickness();
sbracket_y = -bearing_width / 2 - 1 - sbracket_thickness / 2;
function x_motor_offset() = back - mbracket_thickness - motor_w / 2;
function x_motor_overhang() = back - mbracket_width;
function x_idler_offset() = back - idler_width / 2;
function x_motor_overhang() = back - mbracket_width + (squeeze ? mbracket_thickness : 0);
function x_idler_offset() = back - idler_offset;
function x_idler_overhang() = x_idler_offset() - washer_diameter(M5_penny_washer) / 2;
function x_end_bar_length() = -back;
function x_end_height() = bearing_height - thickness / 2;
@ -127,6 +130,7 @@ function x_end_thickness() = thickness;
function x_motor_height() = mbracket_height - thickness / 2;
function x_end_clearance() = switch_op_x;
function x_end_z_nut_z() = nut_shelf;
function x_end_length() = length;
ribbon_screw = M3_cap_screw;
ribbon_nut = screw_nut(ribbon_screw);
@ -175,8 +179,9 @@ module x_end_clamp_stl() {
}
}
function ribbon_bracket_counterbore() = washer_thickness(M3_washer) + screw_head_height(M3_cap_screw) + 0.5;
function ribbon_bracket_thickness() = ribbon_bracket_counterbore() + 2.4;
function ribbon_bracket_counterbore() = squeeze ? round_to_layer(screw_head_height(M3_cap_screw))
: washer_thickness(M3_washer) + screw_head_height(M3_cap_screw) + 0.5;
function ribbon_bracket_thickness() = ribbon_bracket_counterbore() + (squeeze ? 1.6 : 2.4);
module x_motor_ribbon_bracket_stl(support = true) {
stl("x_motor_ribbon_bracket");
@ -209,15 +214,20 @@ module x_motor_ribbon_bracket_stl(support = true) {
difference() {
union() {
poly_cylinder(r = M3_clearance_radius, h = 100, center = true);
poly_cylinder(r = washer_diameter(M3_washer) / 2 + 0.5, h = counterbore * 2, center = true);
poly_cylinder(r = (squeeze ? screw_head_radius(M3_cap_screw) : washer_diameter(M3_washer) / 2) + 0.5, h = counterbore * 2, center = true);
}
if(support)
hole_support(M3_clearance_radius, counterbore);
if(squeeze)
translate([0, 0, counterbore])
cylinder(r = 10, h = layer_height);
else
hole_support(M3_clearance_radius, counterbore);
}
//
// ribbon clamp holes
//
translate([0, 0, height])
translate([0, 0, squeeze ? height * 2 : height])
ribbon_clamp_holes(x_end_ways, ribbon_screw)
nut_trap(screw_clearance_radius(ribbon_screw), nut_radius(ribbon_nut), ribbon_nut_trap_depth);
}
@ -226,24 +236,46 @@ module x_motor_ribbon_bracket_stl(support = true) {
nut_trap_support_height = 10;
module x_idler_support_stl() {
hole_r = (Z_screw_dia + 1) / 2;
outer_r = corrected_radius(hole_r) + 2 * filament_width;
max_r = corrected_radius((Z_screw_dia + 1) / 2);
color("grey") {
translate([-z_bar_offset(), 0, 0])
hole_support(r = (Z_screw_dia + 1) / 2, h = bearing_height - wall);
hole_support(r = hole_r, h = bearing_height - wall, max_r = outer_r, closed = true, capped = true);
translate([-z_bar_offset(), 0, nut_shelf + thickness / 2 - nut_trap_support_height])
nut_trap_support(r = Z_nut_radius, h = nut_trap_support_height + eta, r2 = (Z_screw_dia + 1) / 2);
translate([-z_bar_offset(), 0, nut_shelf + thickness / 2])
difference() {
hull() {
nut_trap_support(r = Z_nut_radius, h = eta);
translate([0, 0, - nut_trap_support_height])
cylinder(r = outer_r - filament_width / 4 - eta, h = eta, $fn = sides(hole_r));
}
difference() {
hull() {
nut_trap_support(r = Z_nut_radius - 2 * filament_width, h = 2 * eta);
translate([0, 0, - nut_trap_support_height - eta])
cylinder(r = outer_r - 2 * filament_width - filament_width / 4 - eta, h = eta, $fn = sides(hole_r));
}
translate([0, 0, -4 * layer_height])
cylinder(r = Z_nut_radius + 1, h = 3 * layer_height);
}
}
for(side = [-1,1])
for(x = [front - clamp_hole_inset, back + clamp_hole_inset])
for(i = [-1,1])
translate([x, side * bar_y + i * (X_bar_dia / 2 + M3_clearance_radius), 0])
hole_support(r = M3_clearance_radius, h = M3_nut_trap_depth, max_r = nut_flat_radius(M3_nut));
hole_support(r = M3_clearance_radius, h = M3_nut_trap_depth + eta, max_r = nut_flat_radius(M3_nut));
}
}
module x_motor_support_stl() mirror([1,0,0]) x_idler_support_stl();
module x_end_bracket(motor_end, integral_support = false){
// Slope the front of the motor bracket to clear the screws and the motor boss if possible
slope_x = sqrt(2) * min(NEMA_big_hole(X_motor), NEMA_hole_pitch(X_motor) / 2 - washer_diameter(M3_washer) / 2 - 0.8);
if(motor_end)
stl("x_motor_bracket");
@ -295,6 +327,7 @@ module x_end_bracket(motor_end, integral_support = false){
// idler end
//
difference() {
screw_angle = atan2(M4_clearance_radius - 3.9 / 2, idler_depth);
union() {
translate([back - idler_width / 2 + eta + corner_rad, idler_back - idler_depth / 2, 0])
rounded_rectangle([idler_width + 2 * corner_rad, idler_depth, thickness], r = corner_rad, center = true);
@ -308,10 +341,9 @@ module x_end_bracket(motor_end, integral_support = false){
rotate([90, 0, 90])
teardrop(r = X_bar_dia / 2 + 0.5, h = 100, center = true);
assign(screw_angle = atan2(M4_clearance_radius - 3.9 / 2, idler_depth))
translate([x_idler_offset(), idler_back, 0])
rotate([90, 0, -screw_angle])
nut_trap(M4_clearance_radius, M4_nut_radius, M4_nut_trap_depth);
translate([x_idler_offset(), idler_back, 0])
rotate([90, 0, -screw_angle])
nut_trap(M4_clearance_radius, M4_nut_radius, M4_nut_trap_depth);
}
}
@ -379,10 +411,26 @@ module x_end_bracket(motor_end, integral_support = false){
translate([-M3_clearance_radius - wall - 100, -50, - 50]) // truncate front
cube(100);
translate([NEMA_big_hole(X_motor) * sqrt(2), 0, -mbracket_height / 2 + thickness / 2])
rotate([0, 45, 180]) // slope front tangential to motor boss
translate([0, 0, -50])
cube(100);
difference() {
union() {
translate([slope_x, 0, -mbracket_height / 2 + thickness / 2])
rotate([0, 45, 180]) // slope front tangential to motor boss
translate([0, 0, -50])
cube(100);
//
// big hole for motor boss
//
if(slope_x < sqrt(2) * NEMA_big_hole(X_motor))
translate([0, -mbracket_depth / 2, -50 / 2 - mbracket_height / 2 + thickness / 2])
rotate([90,0,0])
vertical_tearslot(r = NEMA_big_hole(X_motor), h = 2 * mbracket_thickness + 1, l = 50, center = true);
}
if(slope_x < sqrt(2) * NEMA_big_hole(X_motor) && integral_support)
translate([slope_x - NEMA_big_hole(X_motor), -mbracket_depth / 2, - mbracket_height / 2 - 1]) union() {
cube([8,8,4], true);
cube([filament_width * 2, mbracket_thickness + eta, mbracket_height]);
}
}
translate([-100 - NEMA_holes(X_motor)[0] * sqrt(2) - screw_head_radius(M3_cap_screw) - wall, 0, - 50])
cube(100); // truncate back
@ -421,7 +469,7 @@ module x_end_bracket(motor_end, integral_support = false){
//
// Mounting holes
//
assign(screw_offset = M3_clearance_radius - 2.9 / 2)
screw_offset = M3_clearance_radius - 2.9 / 2;
for(x = NEMA_holes(X_motor)) // motor screw holes
for(z = NEMA_holes(X_motor))
rotate([0, motor_angle, 0])
@ -452,7 +500,10 @@ module x_end_bracket(motor_end, integral_support = false){
}
}
module washer_stack(washer, n) if(n == 1) washer(washer) children(); else washer(washer) washer_stack(washer, n - 1) children();
module x_end_assembly(motor_end) {
motor_rear_screw = screw_shorter_than(NEMA_length(X_motor) + mbracket_thickness + (motor_washers + 2) * washer_thickness(M3_washer) - 8);
shift = exploded ? 2 : 0;
if(!motor_end)
assembly("x_idler_assembly");
@ -499,7 +550,7 @@ module x_end_assembly(motor_end) {
rotate([0, 0, -180]) translate(NEMA_holes(X_motor)) translate([0, 0, -NEMA_length(X_motor)])
rotate([180, 0, 0])
washer(M3_washer) washer(M3_washer) washer(M3_washer) screw(M3_cap_screw, 45);
washer_stack(M3_washer, motor_washers) screw(M3_cap_screw, motor_rear_screw);
translate([0, 0, 5])
pulley_assembly();
@ -528,12 +579,17 @@ module x_end_assembly(motor_end) {
translate([0, 0, ribbon_bracket_counterbore() - exploded * 7])
rotate([180, 0, 0])
washer(M3_washer)
screw(M3_cap_screw, 45);
if(squeeze)
screw(M3_cap_screw, motor_rear_screw);
else
screw_and_washer(M3_cap_screw, motor_rear_screw);
}
explode([0, 8, 0])
rotate([-90, 0, 0])
ribbon_clamp_assembly(x_end_ways, M3_cap_screw, 16, ribbon_bracket_thickness() - M3_nut_trap_depth);
if(!squeeze)
ribbon_clamp_assembly(x_end_ways, M3_cap_screw, 16, ribbon_bracket_thickness() - M3_nut_trap_depth);
else
ribbon_clamp_assembly(x_end_ways, M3_hex_screw, 16, ribbon_bracket_thickness(), hex = true, washer = true);
}
@ -582,10 +638,10 @@ module x_ends_stl() {
}
module facing_pair(dir = 1) {
child();
children();
translate([-dir * bearing_width / 4, dir * bearing_width / 2, 0])
rotate([0, 0, 180])
child();
children();
}
@ -606,5 +662,7 @@ else
else
mirror ([1,0,0]) x_end_assembly(true);
//x_motor_bracket_stl();
//x_motor_ribbon_bracket_stl();
//!x_motor_bracket_stl();
//!x_motor_ribbon_bracket_stl();