box_frame/z-axis.scad

   1 // PRUSA iteration3
   2 // Z axis
   3 // GNU GPL v3
   4 // Josef Průša <josefprusa@me.com>
   5 // Václav 'ax' Hůla <axtheb@gmail.com>
   6 // http://www.reprap.org/wiki/Prusa_Mendel
   7 // http://github.com/josefprusa/Prusa3
   8
   9 // ThingDoc entries
  10 /**
  11  * @id zMotorHolder
  12  * @name Z Axis Motor Holder
  13  * @category Printed
  14  */
  15
  16 /**
  17  * @id zRodHolder
  18  * @name Z Axis Rod Holder
  19  * @category Printed
  20  */
  21
  22 // todo
  23
  24 //  - fix motor holder wall removal so it is sensible and actually
  25 //    removes the right thing
  26 // - fix changing board_thickness, add way to specify # of bolts in
  27 //   side of frame (assume even spacing for now)
  28
  29 include <configuration.scad>
  30
  31 module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thickness=5){
  32     position_y = board_to_xz_distance + zaxis_delta_y + zmotor_delta_y;
  33     position_x = board_to_xz_distance + zaxis_delta_x + zmotor_delta_x;
  34     difference(){
  35         union(){
  36             // Motor holding part
  37             difference(){
  38                 union(){
  39                     zrodholder(thickness=thickness, xlen=45 + zmotor_delta_x + zaxis_delta_x, ylen=48 + 5 + zmotor_delta_y + zaxis_delta_y, zdelta=((i_want_to_use_single_plate_dxf_and_make_my_z_weaker == 0) ? 0 : 5), bottom_x = 50 + zaxis_delta_x + zmotor_delta_x, bottom_y = 15 + zmotor_delta_y + zaxis_delta_y, am_top=0, bottom_thickness=bottom_thickness);
  40                     translate([position_x, position_y, 0]) {
  41                          nema17(places=[1, 1, 1, 1], h=bottom_thickness + layer_height, $fn=23, shadow=layer_height + 2);
  42                     }
  43                 }
  44                 // remove any interfering walls
  45                 translate([position_x, position_y, layer_height + 2 + 21 +3]) {
  46                      cube([43 + zmotor_delta_x + zaxis_delta_x,43,42], center = true);
  47                 }
  48
  49                 // motor rotor clearance
  50                 translate([position_x, position_y, 0]) {
  51                      cylinder(r=11,h=20, center = true);
  52                 }
  53
  54                 // motor screw holes
  55
  56                 // FIXME: y = board_to_xz distance looks supicious --
  57                 // the smooth rod is offset by a fixed amount so why
  58                 // would the motor mount be moved in both directions
  59                 // instead of just away from the frame? X-axis does
  60                 // not use this to offset the leadscrew hole either.
  61                 translate([position_x, position_y, thickness]) {
  62                     mirror([0, 0, 1]) translate([0, 0, thickness-8])
  63                         #nema17(places=[1, 1, 1, 1], holes=true, h=bottom_thickness + 1, $fn=small_hole_segments);
  64                         //shadow=-6 + layer_height);
  65                 }
  66             }
  67         }
  68     }
  69 }
  70
  71
  72 module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thickness=5, ylen=44, xlen=34, zdelta=0, bottom_y=14, bottom_x=14, am_top=1){
  73     holder_inner_r = 9;
  74     holder_inner_r2 = 2;
  75     smooth_rod_insert_radius = bushing_z[0] + 5 * single_wall_width;
  76     difference(){
  77         union(){
  78             difference(){
  79                 union() {
  80                     //piece along the flat side of a board
  81                      cube_fillet([bottom_x, ylen, bottom_thickness], vertical=[8, 3, 0, 0]);
  82                     if (frame_type == frame_alu) {
  83                          top_radius = am_top ? thickness : thickness / 3;
  84                          cube_fillet([5, ylen, thickness], vertical=[0, 0, 0, 0], top = [top_radius, 0, 0, 0]);
  85
  86                          // FIXME: make rear/top bit optional, but don't remove entirely
  87                          //        (printer seems to make less noise with the rear bit)
  88                          %if (am_top) {
  89                               // rear bracket
  90                               translate ([-board_thickness - 5, 0, 0])
  91                                    cube_fillet([5, ylen, thickness], vertical=[0, 0, 0, 0], top = [top_radius, 0, 0, 0]);
  92                               translate ([-board_thickness, 5, 0])
  93                                    cube ([board_thickness, ylen - 6, bottom_thickness/2]);
  94                          }
  95                     }
  96                     else {
  97                          cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [thickness / 1.7, 0, 0, 5]);
  98                     }
  99
 100                     //hole for Z axis is thru this
 101                     cube_fillet([xlen + zaxis_delta_x, bottom_y, bottom_thickness], vertical=[3, 0, 0, 3]);
 102                     if (bottom_x < board_to_xz_distance - z_delta + zaxis_delta_x) {
 103                          translate([bottom_x, bottom_y, 0]) {
 104                               //large fillet that makes it stiffer by lot. Thanks to Marcus Wolschon
 105                               difference(){
 106                                    cube([holder_inner_r, holder_inner_r, bottom_thickness]);
 107                                    translate([holder_inner_r, holder_inner_r, -0.5])
 108                                         cylinder(r=holder_inner_r, h=bottom_thickness + 1);
 109                               }
 110                          }
 111                     }
 112                     if (frame_type != frame_alu) {
 113                          translate([5, 5, 0]) {
 114                               difference(){
 115                                    cube([holder_inner_r2, holder_inner_r2, thickness - 5.5]);
 116                                    translate([holder_inner_r2, holder_inner_r2, -0.5])
 117                                         cylinder(r=holder_inner_r2, h=thickness + 1, $fn=20);
 118                               }
 119                          }
 120                     }
 121                     // leadscrew bearing hole is cut from this
 122                     if (am_top) {
 123                          lead_bearing_y = board_to_xz_distance + zaxis_delta_y + zmotor_delta_y;
 124                          lead_bearing_x = board_to_xz_distance + zaxis_delta_x + zmotor_delta_x;
 125                          translate ([lead_bearing_x, lead_bearing_y, 0]) cylinder (d = bearing_608[0] + 1 + 2, h = bearing_608[2] + layer_height*4);
 126                     }
 127                     //piece along cut side of the board
 128                     if (frame_type == frame_box) {
 129                          translate([-board_thickness, 0, 0])
 130                               cube_fillet([board_thickness + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness], $fn=99);
 131                     } else if (frame_type == frame_alu) {
 132                          side_thickness = 5.0;// - zaxis_delta_y;
 133
 134                          translate ([0, 0 /* zaxis_delta_y */, 0]) {
 135                               // back
 136                               translate([-board_thickness, 0, 0]) {
 137                                    cube_fillet([board_thickness, side_thickness, thickness], vertical = [0, 0, 0, 0], top = [0, 0, 0, 0]);
 138                               }
 139
 140                               // front
 141                               //cube_fillet([am_top ? board_to_xz_distance + zaxis_delta_x - smooth_rod_insert_radius : xlen + zaxis_delta_x , side_thickness, thickness], vertical = [2, 0, 0, 0], top = [0, 0, 0, thickness]);
 142                               cube_fillet([am_top ? board_to_xz_distance + zaxis_delta_x - smooth_rod_insert_radius : xlen , side_thickness, thickness / (am_top ? 1 : 1.5)], vertical = [2, 0, 0, 0], top = [0, 0, 0, thickness]);
 143
 144                               // extra support for motor
 145                               if (!am_top) {
 146                                    translate ([0, ylen - side_thickness, 0]) cube_fillet([xlen/* board_to_xz_distance + zaxis_delta_x - smooth_rod_insert_radius */ , side_thickness, thickness/1.5], vertical = [2, 0, 0, 0], top = [0, 0, 0, thickness]);
 147                               }
 148                          }
 149
 150                          // extra support along edge of smooth rod hole
 151                          radius_diff = smooth_rod_insert_radius - bushing_z[0];
 152                          hull () {
 153                               translate([-board_thickness/3, -zaxis_delta_y/3, 0]) {
 154                                    cube_fillet([board_thickness/3 + board_to_xz_distance + zaxis_delta_x - bushing_z[0] , -zaxis_delta_y/3 , thickness/2], vertical = [2, 0, 4, 0], top = [0, 0, 4, thickness/2]);
 155                               }
 156                               translate([board_to_xz_distance/2, -zaxis_delta_x + radius_diff/6, 0]) {
 157                                    cube_fillet([board_to_xz_distance/2 + zaxis_delta_x  + smooth_rod_insert_radius*0.75, radius_diff/3 , bottom_thickness*2], vertical = [2, 0, 4, bushing_z[0] * smooth_rod_insert_radius/bushing_z[0]], top = [0, 0, 2, thickness/4]);
 158                               }
 159                          }
 160                     } else {
 161                         translate([-board_thickness/2, 0, 0])
 162                             cube_fillet([board_thickness/2 + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness], $fn=99);
 163                     }
 164                     //smooth rod insert
 165                     translate([board_to_xz_distance - z_delta + zaxis_delta_x, 9 + zaxis_delta_y, 0])
 166                         cylinder(h=bottom_thickness * (am_top ? 1.75 : 1.75), r=smooth_rod_insert_radius);
 167                 }
 168
 169                 // === difference ===
 170
 171                 //smooth rod hole
 172                 #translate([board_to_xz_distance - z_delta + zaxis_delta_x, 9 + zaxis_delta_y, -1]) cylinder(h=am_top ? thickness+20 : bottom_thickness, r=bushing_z[0] + single_wall_width / 4);
 173                 //inside rouned corner
 174                 if (frame_type != frame_alu) {
 175                      translate([0, 5, -1]) cylinder(r=0.8, h=100, $fn=8);
 176                 }
 177
 178                 // leadscrew hole
 179                 if (am_top) {
 180                      lead_bearing_y = board_to_xz_distance + zaxis_delta_y + zmotor_delta_y;
 181                      lead_bearing_x = board_to_xz_distance + zaxis_delta_x + zmotor_delta_x;
 182                      translate ([lead_bearing_x, lead_bearing_y, 0]) {
 183                           difference () {
 184                                union () {
 185                                     translate ([0, 0, 1]) cylinder (d = 10.8, h = bearing_608[2]*2);
 186                                     translate ([0, 0, -1]) cylinder (d = 23, h = bearing_608[2]+1);
 187                                }
 188                           }
 189                      }
 190                 }
 191
 192                 //front screws
 193                 if (frame_type == frame_single) {
 194                      //single plate has both screws on front
 195                      translate([16, 35, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
 196                           plate_screw();
 197                      }
 198                      translate([16, 15, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
 199                           plate_screw();
 200                      }
 201                      //motor mount has third screw
 202                      translate([16, 25, bottom_thickness + 4.5 + zdelta + 20]) rotate([0, -90, 0]) {
 203                           plate_screw();
 204                      }
 205                 } else if (frame_type == frame_alu) {
 206                      // three screws on front
 207                      translate([18, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, -90, 0]) plate_screw();
 208                      translate([18, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, -90, 0]) plate_screw();
 209                      translate([18, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, -90, 0])
 210                           plate_screw();
 211
 212                      // motor mount screw for opposite extrusion
 213                      translate([18, ylen - board_thickness/2, thickness - board_thickness/2]) rotate([0, -90, 0])
 214                           plate_screw();
 215
 216                      // back plate
 217                      translate([-board_thickness-18, ylen - board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
 218                           plate_screw();
 219                      translate([-board_thickness-18, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
 220                           plate_screw();
 221                      translate([-board_thickness-18, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
 222                      #translate([-board_thickness-18, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
 223
 224                      //side screws
 225                      #translate([-board_thickness/2, -13, thickness-board_thickness/2]) rotate([-90, 0, 0]) plate_screw();
 226                      translate([-board_thickness/2, -13, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([-90, 0, 0]) plate_screw();
 227                 } else if (frame_type == frame_box) {
 228                      translate([16, 30, bottom_thickness+4]) rotate([0, -90, 0]) {
 229                           plate_screw();
 230                      }
 231                     //side screw
 232                     translate([-board_thickness/2, -11, thickness/2]) rotate([-90, 0, 0]) plate_screw();
 233                 }
 234             }
 235         }
 236     }
 237 }
 238
 239 if (frame_type == frame_alu) {
 240      // 2020 aluminum frame parts are larger
 241      translate([0, -60, 0]) zmotorholder(thickness=55, bottom_thickness=6);
 242      translate([0, 60, 0]) mirror([0, 1, 0]) zmotorholder(thickness=55, bottom_thickness=6);
 243
 244      translate([110 + board_thickness, board_thickness+10, 0])  rotate([0,0,90])  zrodholder(thickness=board_thickness * 2 + 5, ylen = board_thickness * 2 + 10, bottom_x=48, bottom_thickness=6);
 245      translate([110 + board_thickness, -(board_thickness+10), 0]) rotate([0, 0, -90]) mirror([0, 1, 0]) zrodholder(thickness=board_thickness * 2 + 5, ylen = board_thickness * 2 + 10, bottom_x=48, bottom_thickness=6);
 246
 247 }
 248 else {
 249      translate([10, -50, 0]) zmotorholder();
 250      translate([0, 50, 0]) mirror([0, 1, 0]) zmotorholder();
 251      translate([67, 14, 0]) rotate([0,0,90]) zrodholder();
 252      translate([77, -14, 0]) rotate([0, 0, -90]) mirror([0, 1, 0]) zrodholder();
 253 }