z-axis support for aluminum extrusion frame

Also makes the rod holder insert a bit stronger.

diff --git a/box_frame/z-axis.scad b/box_frame/z-axis.scad
index 41735d8..df400f8 100644 (file)
--- a/box_frame/z-axis.scad
+++ b/box_frame/z-axis.scad
@@ -21,20 +21,26 @@
  
 include <configuration.scad>
 
-module zmotorholder(thickness=(i_am_box == 0 ? 38 : 23), bottom_thickness=5){
+module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thickness=5){
     difference(){
         union(){
             // Motor holding part
             difference(){
                 union(){
-                    zrodholder(thickness=thickness, xlen=45, ylen=44, zdelta=((i_want_to_use_single_plate_dxf_and_make_my_z_weaker == 0) ? 0 : 5));
+                    zrodholder(thickness=thickness, xlen=45, ylen=44, zdelta=((i_want_to_use_single_plate_dxf_and_make_my_z_weaker == 0) ? 0 : 5), am_top=0);
                     translate([board_to_xz_distance, board_to_xz_distance, 0]) {
-                        nema17(places=[0, 1, 1, 1], h=bottom_thickness + layer_height, $fn=23, shadow=layer_height + 2);
+                        nema17(places=[0, 1, 1, 1], h=bottom_thickness + layer_height, $fn=23, shadow=layer_height + 2);
                     }
                 }
 
                 // motor screw holes
-                translate([board_to_xz_distance, board_to_xz_distance, thickness]) {
+
+               // FIXME: y = board_to_xz distance looks supicious --
+               // the smooth rod is offset by a fixed amount so why
+               // would the motor mount be moved in both directions
+               // instead of just away from the frame? X-axis does
+               // not use this to offset the leadscrew hole either.
+               translate([board_to_xz_distance, board_to_xz_distance, 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);
                         //shadow=-6 + layer_height);
@@ -45,19 +51,34 @@ module zmotorholder(thickness=(i_am_box == 0 ? 38 : 23), bottom_thickness=5){
 }
 
 
-module zrodholder(thickness=(i_am_box == 0 ? 14 : 15), bottom_thickness=5, ylen=44, xlen=34, zdelta=0){
+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){
     holder_inner_r = 9;
     holder_inner_r2 = 2;
     difference(){
         union(){
             difference(){
-                union(){
+                union() {
                     //piece along the flat side of a board
-                    cube_fillet([14, ylen, bottom_thickness], vertical=[8, 3, 0, 0]);
-                    cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [thickness / 1.7, 0, 0, 5]);
-                    //hole for Z axis is thru this
-                    cube_fillet([xlen, 14, bottom_thickness], vertical=[3, 0, 0, 3]);
-                    translate([14, 14, 0]) {
+                    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, (frame_type == frame_alu ? 0 : 5)]);
+
+                        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]);
+                             translate ([-board_thickness, 5, 0])
+                                  cube ([board_thickness, ylen - 6, bottom_thickness/2]);
+                        }
+                   }
+                   else {
+                        cube_fillet([5, ylen, thickness], vertical=[3, 3, 0, 0], top = [thickness / 1.7, 0, 0, 5]);
+                   }
+
+                   //hole for Z axis is thru this
+                    cube_fillet([xlen, bottom_y, bottom_thickness], vertical=[3, 0, 0, 3]);
+                    translate([bottom_x, bottom_y, 0]) {
                         //large fillet that makes it stiffer by lot. Thanks to Marcus Wolschon
                         difference(){
                             cube([holder_inner_r, holder_inner_r, bottom_thickness]);
@@ -65,48 +86,80 @@ module zrodholder(thickness=(i_am_box == 0 ? 14 : 15), bottom_thickness=5, ylen=
                                 cylinder(r=holder_inner_r, h=bottom_thickness + 1);
                         }
                     }
-                    translate([5, 5, 0]) {
-                        difference(){
-                            cube([holder_inner_r2, holder_inner_r2, thickness - 5.5]);
-                            translate([holder_inner_r2, holder_inner_r2, -0.5])
-                                cylinder(r=holder_inner_r2, h=thickness + 1, $fn=20);
-                        }
+                   if (frame_type != frame_alu) {
+                        translate([5, 5, 0]) {
+                             difference(){
+                                  cube([holder_inner_r2, holder_inner_r2, thickness - 5.5]);
+                                  translate([holder_inner_r2, holder_inner_r2, -0.5])
+                                       cylinder(r=holder_inner_r2, h=thickness + 1, $fn=20);
+                             }
+                        }
                     }
                     //piece along cut side of the board
-                    if (i_am_box == 1) {
-                        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);
+                   if (frame_type == frame_box) {
+                        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) {
+                        translate([-board_thickness, 0, 0]) {
+                             cube_fillet([board_thickness + xlen, am_top ? 2.5 : 5.0, thickness], vertical = (frame_type == frame_alu ? [2, 0, 0, 2] : [2, 2, 2, 2]), top = [0, 0, 0, thickness]);
+                             // avoid interfering with the smooth rod hole
+                             translate ([0, 2.5, 0])
+                                  cube_fillet([board_thickness + board_to_xz_distance - bushing_z[0], 2.5, thickness], vertical = (frame_type == frame_alu ? [2, 0, 0, 2] : [2, 2, 2, 2]), top = [0, 0, 0, thickness]);
+                        }
                     } else {
                         translate([-board_thickness/2, 0, 0])
                             cube_fillet([board_thickness/2 + board_to_xz_distance + bushing_z[0], 5, thickness], radius=2, top = [0, 0, 0, thickness], $fn=99);
                     }
                     //smooth rod insert
                     translate([board_to_xz_distance - z_delta, 9, 0])
-                        cylinder(h=bottom_thickness / 2, r=(bushing_z[0] + 5 * single_wall_width));
+                        cylinder(h=bottom_thickness * (am_top ? 1.75 : 1.0), r=(bushing_z[0] + 5 * single_wall_width));
                 }
                 //smooth rod hole
                 translate([board_to_xz_distance - z_delta, 9, -1]) cylinder(h=board_thickness+20, r=bushing_z[0] + single_wall_width / 4);
                 //inside rouned corner
-                translate([0, 5, -1]) cylinder(r=0.8, h=100, $fn=8);
-                //side screw
-                //translate([-board_thickness/2, 0, thickness/2-1.5]) rotate([-90, 0, 0]) screw(h=30, r_head=4);
+               if (frame_type != frame_alu) {
+                    translate([0, 5, -1]) cylinder(r=0.8, h=100, $fn=8);
+               }
+
                 //front screws
-                if (i_am_box != 1) {
-                    //single plate has both screws on front
-                    translate([16, 35, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
-                        plate_screw();
-                    }
-                    translate([16, 15, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
-                        plate_screw();
-                    }
-                    //motor mount has third screw
-                    translate([16, 25, bottom_thickness + 4.5 + zdelta + 20]) rotate([0, -90, 0]) {
-                        plate_screw();
-                    }
-                } else {
-                    translate([16, 30, bottom_thickness+4]) rotate([0, -90, 0]) {
-                        plate_screw();
-                    }
+                if (frame_type == frame_single) {
+                    //single plate has both screws on front
+                    translate([16, 35, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
+                         plate_screw();
+                    }
+                    translate([16, 15, bottom_thickness + 4.5 + zdelta]) rotate([0, -90, 0]) {
+                         plate_screw();
+                    }
+                    //motor mount has third screw
+                    translate([16, 25, bottom_thickness + 4.5 + zdelta + 20]) rotate([0, -90, 0]) {
+                         plate_screw();
+                    }
+                } else if (frame_type == frame_alu) {
+                    // three screws on front
+                    translate([16, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, -90, 0]) plate_screw();
+                    translate([16, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, -90, 0]) plate_screw();
+                    translate([16, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, -90, 0])
+                         plate_screw();
+
+                    // motor mount screw for opposite extrusion
+                    translate([16, ylen - board_thickness/2, thickness - board_thickness/2]) rotate([0, -90, 0])
+                         plate_screw();
+
+                    // back plate
+                    translate([-board_thickness-17, ylen - board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
+                         plate_screw();
+                    translate([-board_thickness-17, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
+                         plate_screw();
+                    translate([-board_thickness-17, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
+                    translate([-board_thickness-17, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
+
+                    //side screws
+                    translate([-board_thickness/2, -11, thickness-board_thickness/2]) rotate([-90, 0, 0]) plate_screw();
+                    translate([-board_thickness/2, -11, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([-90, 0, 0]) plate_screw();
+               } else if (frame_type == frame_box) {
+                    translate([16, 30, bottom_thickness+4]) rotate([0, -90, 0]) {
+                         plate_screw();
+                    }
                     //side screw
                     translate([-board_thickness/2, -11, thickness/2]) rotate([-90, 0, 0]) plate_screw();
                 }