z-axis: misc changes

* Clear hole for rotor in motor holder

* Motor holder now uses four instead of three screws, seems to make z-axis
  slightly more stable

* Removed material from back of extrusion for top rod holder, saves
  material if using corner brackets to hold the frame
  together (recommended, frame rigidity is improved enough to suffer
  another few vitamins, and they are inexpensive).

* Attempt at easier to remove support for leadscrew hole. Likely
  better solution would be to just use slicer support (build plate
  only).

diff --git a/box_frame/z-axis.scad b/box_frame/z-axis.scad
index e39f9ee..a77534b 100644 (file)
--- a/box_frame/z-axis.scad
+++ b/box_frame/z-axis.scad
@@ -12,13 +12,20 @@
  * @name Z Axis Motor Holder
  * @category Printed
  */
- 
+
 /**
  * @id zRodHolder
  * @name Z Axis Rod Holder
  * @category Printed
  */
- 
+
+// todo
+
+//  - fix motor holder wall removal so it is sensible and actually
+//    removes the right thing
+// - fix changing board_thickness, add way to specify # of bolts in
+//   side of frame (assume even spacing for now)
+
 include <configuration.scad>
 
 module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thickness=5){
@@ -39,6 +46,9 @@ module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thi
                     cube([43 + zmotor_delta_x + zaxis_delta_x,43,42], center = true);
                }
 
+               // motor rotor clearance
+               translate([position_x, position_y, 0]) {
+                    cylinder(r=11,h=20, center = true);
                }
 
                 // motor screw holes
@@ -50,7 +60,7 @@ module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thi
                // not use this to offset the leadscrew hole either.
                translate([position_x, position_y, thickness]) {
                     mirror([0, 0, 1]) translate([0, 0, thickness-8])
-                        nema17(places=[0, 1, 1, 1], holes=true, h=bottom_thickness + 1, $fn=small_hole_segments);
+                        #nema17(places=[1, 1, 1, 1], holes=true, h=bottom_thickness + 1, $fn=small_hole_segments);
                         //shadow=-6 + layer_height);
                 }
             }
@@ -71,12 +81,14 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                     cube_fillet([bottom_x, ylen, bottom_thickness], vertical=[8, 3, 0, 0]);
                    if (frame_type == frame_alu) {
                         top_radius = am_top ? thickness : thickness / 3;
-                        cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [top_radius, 0, 0, 5]);
+                        cube_fillet([5, ylen, thickness], vertical=[0, 0, 0, 0], top = [top_radius, 0, 0, 0]);
 
-                        if (am_top) {
+                        // FIXME: make rear/top bit optional, but don't remove entirely
+                        //        (printer seems to make less noise with the rear bit)
+                        %if (am_top) {
                              // rear bracket
                              translate ([-board_thickness - 5, 0, 0])
-                                  cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [top_radius, 5, 0, 0]);
+                                  cube_fillet([5, ylen, thickness], vertical=[0, 0, 0, 0], top = [top_radius, 0, 0, 0]);
                              translate ([-board_thickness, 5, 0])
                                   cube ([board_thickness, ylen - 6, bottom_thickness/2]);
                         }
@@ -117,12 +129,23 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                         translate([-board_thickness, 0, 0])
                              cube_fillet([board_thickness + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness], $fn=99);
                    } else if (frame_type == frame_alu) {
-                        // split piece in front of and behind into separate pieces
-                        translate([-board_thickness, 0, 0]) {
-                             cube_fillet([board_thickness, 5.0, thickness], vertical = [0, 0, 0, 0], top = [0, 0, 0, 0]);
-                        }
+                        side_thickness = 5.0;// - zaxis_delta_y;
 
-                        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]);
+                        translate ([0, 0 /* zaxis_delta_y */, 0]) {
+                             // back
+                             translate([-board_thickness, 0, 0]) {
+                                  cube_fillet([board_thickness, side_thickness, thickness], vertical = [0, 0, 0, 0], top = [0, 0, 0, 0]);
+                             }
+
+                             // front
+                             //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]);
+                             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]);
+
+                             // extra support for motor
+                             if (!am_top) {
+                                  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]);
+                             }
+                        }
 
                         // extra support along edge of smooth rod hole
                         radius_diff = smooth_rod_insert_radius - bushing_z[0];
@@ -162,7 +185,7 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                                    translate ([0, 0, 1]) cylinder (d = 10.8, h = bearing_608[2]*2);
                                    translate ([0, 0, -1]) cylinder (d = 23, h = bearing_608[2]+1);
                               }
-                              #translate ([0, 0, bearing_608[2]-layer_height]) cylinder (d = 23, h = layer_height);
+                              translate ([0, 0, bearing_608[2]-layer_height*2]) cylinder (d = 23 - single_wall_width/2, h = layer_height);
                          }
                     }
                }