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 include <configuration.scad>
  23
  24 module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thickness=5){
  25     position_y = board_to_xz_distance + zaxis_delta_y - zmotor_delta_y;
  26     position_x = board_to_xz_distance - zaxis_delta_x + zmotor_delta_x;
  27     difference(){
  28         union(){
  29             // Motor holding part
  30             difference(){
  31                 union(){
  32                     zrodholder(thickness=thickness, xlen=45 + zmotor_delta_x, ylen=44 - zmotor_delta_y, zdelta=((i_want_to_use_single_plate_dxf_and_make_my_z_weaker == 0) ? 0 : 5), bottom_x = 14 + zaxis_delta_x + zmotor_delta_x, am_top=0);
  33                     translate([position_y, position_x, 0]) {
  34                          nema17(places=[0, 1, 1, 1], h=bottom_thickness + layer_height, $fn=23, shadow=layer_height + 2);
  35                     }
  36                 }
  37                 // remove any interfering walls
  38                 translate([position_y, position_x, layer_height + 2 + 21 +3]) {
  39                      #cube([43 + zmotor_delta_x + zaxis_delta_x,43,42], center = true);
  40                 }
  41
  42                 // motor screw holes
  43
  44                 // FIXME: y = board_to_xz distance looks supicious --
  45                 // the smooth rod is offset by a fixed amount so why
  46                 // would the motor mount be moved in both directions
  47                 // instead of just away from the frame? X-axis does
  48                 // not use this to offset the leadscrew hole either.
  49                 translate([position_y, position_x, thickness]) {
  50                     mirror([0, 0, 1]) translate([0, 0, thickness-8])
  51                         nema17(places=[0, 1, 1, 1], holes=true, h=bottom_thickness + 1, $fn=small_hole_segments);
  52                         //shadow=-6 + layer_height);
  53                 }
  54             }
  55         }
  56     }
  57 }
  58
  59
  60 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){
  61     holder_inner_r = 9;
  62     holder_inner_r2 = 2;
  63     smooth_rod_insert_radius = bushing_z[0] + 5 * single_wall_width;
  64     difference(){
  65         union(){
  66             difference(){
  67                 union() {
  68                     //piece along the flat side of a board
  69                      cube_fillet([bottom_x, ylen, bottom_thickness], vertical=[8, 3, 0, 0]);
  70                     if (frame_type == frame_alu) {
  71                          top_radius = am_top ? thickness : thickness / 3;
  72                          cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [top_radius, 0, 0, 5]);
  73
  74                          if (am_top) {
  75                               // rear bracket
  76                               translate ([-board_thickness - 5, 0, 0])
  77                                    cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [top_radius, 5, 0, 0]);
  78                               translate ([-board_thickness, 5, 0])
  79                                    cube ([board_thickness, ylen - 6, bottom_thickness/2]);
  80                          }
  81                     }
  82                     else {
  83                          cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [thickness / 1.7, 0, 0, 5]);
  84                     }
  85
  86                     //hole for Z axis is thru this
  87                     cube_fillet([xlen + zaxis_delta_x, bottom_y, bottom_thickness], vertical=[3, 0, 0, 3]);
  88                     translate([bottom_x, bottom_y, 0]) {
  89                         //large fillet that makes it stiffer by lot. Thanks to Marcus Wolschon
  90                         difference(){
  91                             cube([holder_inner_r, holder_inner_r, bottom_thickness]);
  92                             translate([holder_inner_r, holder_inner_r, -0.5])
  93                                 cylinder(r=holder_inner_r, h=bottom_thickness + 1);
  94                         }
  95                     }
  96                     if (frame_type != frame_alu) {
  97                          translate([5, 5, 0]) {
  98                               difference(){
  99                                    cube([holder_inner_r2, holder_inner_r2, thickness - 5.5]);
 100                                    translate([holder_inner_r2, holder_inner_r2, -0.5])
 101                                         cylinder(r=holder_inner_r2, h=thickness + 1, $fn=20);
 102                               }
 103                          }
 104                     }
 105                     //piece along cut side of the board
 106                     if (frame_type == frame_box) {
 107                          translate([-board_thickness, 0, 0])
 108                               cube_fillet([board_thickness + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness], $fn=99);
 109                     } else if (frame_type == frame_alu) {
 110                          // split piece in front of and behind into separate pieces
 111                          translate([-board_thickness, 0, 0]) {
 112                               cube_fillet([board_thickness, 5.0, thickness], vertical = [0, 0, 0, 0], top = [0, 0, 0, 0]);
 113                          }
 114
 115                          cube_fillet([am_top ? board_to_xz_distance + zaxis_delta_y - smooth_rod_insert_radius : xlen + zaxis_delta_y , 5.0, thickness], vertical = [2, 0, 0, 0], top = [0, 0, 0, thickness]);
 116
 117                          // extra support along edge of smooth rod hole
 118                          radius_diff = smooth_rod_insert_radius - bushing_z[0];
 119                          hull () {
 120                               translate([-board_thickness/3, -zaxis_delta_x/3, 0]) {
 121                                    cube_fillet([board_thickness/3 + board_to_xz_distance + zaxis_delta_y - bushing_z[0] , zaxis_delta_x/3 , thickness/2], vertical = [2, 0, 4, 0], top = [0, 0, 4, thickness/2]);
 122                               }
 123                               translate([board_to_xz_distance/2, -zaxis_delta_x + radius_diff/6, 0]) {
 124                                    cube_fillet([board_to_xz_distance/2 + zaxis_delta_y  + 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]);
 125                               }
 126                          }
 127                     } else {
 128                         translate([-board_thickness/2, 0, 0])
 129                             cube_fillet([board_thickness/2 + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness], $fn=99);
 130                     }
 131                     //smooth rod insert
 132                     translate([board_to_xz_distance - z_delta + zaxis_delta_y, 9 - zaxis_delta_x, 0])
 133                         cylinder(h=bottom_thickness * (am_top ? 1.75 : 1.75), r=smooth_rod_insert_radius);
 134                 }
 135                 //smooth rod hole
 136                 #translate([board_to_xz_distance - z_delta + zaxis_delta_y, 9 - zaxis_delta_x, -1]) cylinder(h=am_top ? thickness+20 : bottom_thickness, r=bushing_z[0] + single_wall_width / 4);
 137                 //inside rouned corner
 138                 if (frame_type != frame_alu) {
 139                      translate([0, 5, -1]) cylinder(r=0.8, h=100, $fn=8);
 140                 }
 141
 142                 //front screws
 143                 if (frame_type == frame_single) {
 144                      //single plate has both screws on front
 145                      translate([16, 35, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
 146                           plate_screw();
 147                      }
 148                      translate([16, 15, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
 149                           plate_screw();
 150                      }
 151                      //motor mount has third screw
 152                      translate([16, 25, bottom_thickness + 4.5 + zdelta + 20]) rotate([0, -90, 0]) {
 153                           plate_screw();
 154                      }
 155                 } else if (frame_type == frame_alu) {
 156                      // three screws on front
 157                      translate([18, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, -90, 0]) plate_screw();
 158                      translate([18, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, -90, 0]) plate_screw();
 159                      translate([18, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, -90, 0])
 160                           plate_screw();
 161
 162                      // motor mount screw for opposite extrusion
 163                      translate([18, ylen - board_thickness/2, thickness - board_thickness/2]) rotate([0, -90, 0])
 164                           plate_screw();
 165
 166                      // back plate
 167                      translate([-board_thickness-18, ylen - board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
 168                           plate_screw();
 169                      translate([-board_thickness-18, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
 170                           plate_screw();
 171                      translate([-board_thickness-18, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
 172                      #translate([-board_thickness-18, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
 173
 174                      //side screws
 175                      #translate([-board_thickness/2, -13, thickness-board_thickness/2]) rotate([-90, 0, 0]) plate_screw();
 176                      translate([-board_thickness/2, -13, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([-90, 0, 0]) plate_screw();
 177                 } else if (frame_type == frame_box) {
 178                      translate([16, 30, bottom_thickness+4]) rotate([0, -90, 0]) {
 179                           plate_screw();
 180                      }
 181                     //side screw
 182                     translate([-board_thickness/2, -11, thickness/2]) rotate([-90, 0, 0]) plate_screw();
 183                 }
 184             }
 185         }
 186     }
 187 }
 188
 189 if (frame_type == frame_alu) {
 190      // 2020 aluminum frame parts are larger
 191      translate([10, -50, 0]) zmotorholder(thickness=55);
 192      translate([0, 50, 0]) mirror([0, 1, 0]) zmotorholder(thickness=55);
 193      translate([120, 30, 0]) rotate([0,0,90]) zrodholder(thickness=board_thickness * 2 + 5, ylen = 50);
 194      translate([120, -30, 0]) rotate([0, 0, -90]) mirror([0, 1, 0]) zrodholder(thickness=board_thickness * 2 + 5, ylen = 50);
 195 }
 196 else {
 197      translate([10, -50, 0]) zmotorholder();
 198      translate([0, 50, 0]) mirror([0, 1, 0]) zmotorholder();
 199      translate([67, 14, 0]) rotate([0,0,90]) zrodholder();
 200      translate([77, -14, 0]) rotate([0, 0, -90]) mirror([0, 1, 0]) zrodholder();
 201 }