z-axis: improve strength, cleanup

 * Use three point mounting for motors again, otherwise they can't be
   installed or removed without accessing the underside of the
   printer. Doesn't seem to affect stiffness in the end.

 * Increase strength of top bearing holder (intended to be printed
   with three perimeters)

 * Increase perimeter count for rod holder

 * Shift x-axis back in toward frame. The only reason to push it out
   was for the Wilson TS frame braces, which I am no longer
   using. Will eventually shift back in along x as well (need new
   x-ends first; z adjuster would hit the extrusions
   currently). AFAICT it only needs to be shifted outward in x to
   compensate for the 10mm travel lost by the endstop holder, which
   can be moved to under the x motor end as is done on the i3 MK2
   instead.

 * Take zaxis delta into account when generating final parts

diff --git a/box_frame/inc/settings.scad b/box_frame/inc/settings.scad
index 02ed98d..5bc51a3 100644 (file)
--- a/box_frame/inc/settings.scad
+++ b/box_frame/inc/settings.scad
@@ -20,7 +20,7 @@ m3_nut_diameter_bigger = ((m3_nut_diameter / 2) / cos (180 / 6)) * 2;
 i_am_box = (frame_type == frame_box);
 
 // shift smooth rod and leadscrew mounts simultaneously
-zaxis_delta_x = (frame_type == frame_alu) ? 5 : 0;
+zaxis_delta_x = (frame_type == frame_alu) ? 0 : 0;
 zaxis_delta_y = (frame_type == frame_alu) ? -5 : 0;
 
 // shift motor/leadscrew mount to clear bearings and x-rods

diff --git a/box_frame/z-axis.scad b/box_frame/z-axis.scad
index c1de637..a3042c1 100644 (file)
--- a/box_frame/z-axis.scad
+++ b/box_frame/z-axis.scad
@@ -36,9 +36,9 @@ module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thi
             // Motor holding part
             difference(){
                 union(){
-                    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);
+                    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 = 14 + zaxis_delta_x + zmotor_delta_x, bottom_y = 15 + zmotor_delta_y + zaxis_delta_y, am_top=0, bottom_thickness=bottom_thickness);
                     translate([position_x, position_y, 0]) {
-                        nema17(places=[1, 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);
                     }
                 }
                // remove any interfering walls
@@ -72,7 +72,7 @@ module zmotorholder(thickness=(frame_type == frame_single ? 38 : 23), bottom_thi
 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;
-    smooth_rod_insert_radius = bushing_z[0] + 5 * single_wall_width;
+    smooth_rod_insert_radius = bushing_z[0] + 6 * single_wall_width;
     difference(){
         union(){
             difference(){
@@ -122,7 +122,7 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                    if (am_top) {
                         lead_bearing_y = board_to_xz_distance + zaxis_delta_y + zmotor_delta_y;
                         lead_bearing_x = board_to_xz_distance + zaxis_delta_x + zmotor_delta_x;
-                        translate ([lead_bearing_x, lead_bearing_y, 0]) cylinder (d = bearing_608[0] + 1 + 2, h = bearing_608[2] + layer_height*4);
+                        translate ([lead_bearing_x, lead_bearing_y, 0]) cylinder (d = bearing_608[0] + single_wall_width * 6, h = bearing_608[2] + layer_height*6);
                    }
                     //piece along cut side of the board
                    if (frame_type == frame_box) {
@@ -140,21 +140,18 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                              // 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];
-                        hull () {
-                             translate([-board_thickness/3, -zaxis_delta_y/3, 0]) {
-                                  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]);
-                             }
-                             translate([board_to_xz_distance/2, -zaxis_delta_x + radius_diff/6, 0]) {
-                                  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]);
+                        if (zaxis_delta_x > 0 || zaxis_delta_y < 0) {
+                             // extra support along edge of smooth rod hole, if it has been moved away from the frame
+                             radius_diff = smooth_rod_insert_radius - bushing_z[0];
+                             hull () {
+                                  translate([-board_thickness/3, zaxis_delta_x/3, 0]) {
+                                       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]);
+                                  }
+                                  translate([board_to_xz_distance/2, zaxis_delta_y + radius_diff/6, 0]) {
+                                       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]);
+                                  }
                              }
                         }
                     } else {
@@ -180,11 +177,9 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                     lead_bearing_y = board_to_xz_distance + zaxis_delta_y + zmotor_delta_y;
                     lead_bearing_x = board_to_xz_distance + zaxis_delta_x + zmotor_delta_x;
                     translate ([lead_bearing_x, lead_bearing_y, 0]) {
-                         difference () {
-                              union () {
-                                   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);
-                              }                               
+                         union () {
+                              translate ([0, 0, 1]) cylinder (d = 10.8, h = bearing_608[2]*2);
+                              translate ([0, 0, -1]) cylinder (d = bearing_608[0], h = bearing_608[2]+1);
                          }
                     }
                }
@@ -219,10 +214,10 @@ module zrodholder(thickness=(frame_type == frame_single ? 14 : 15), bottom_thick
                     translate([-board_thickness-18, 5 + board_thickness/2, thickness - board_thickness/2]) rotate([0, 90, 0])
                          plate_screw();
                     translate([-board_thickness-18, ylen - board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
-                    #translate([-board_thickness-18, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
+                    translate([-board_thickness-18, 5 + board_thickness/2, bottom_thickness/2 + board_thickness/2 + zdelta]) rotate([0, 90, 0]) plate_screw();
 
                     //side screws
-                    #translate([-board_thickness/2, -13, thickness-board_thickness/2]) rotate([-90, 0, 0]) plate_screw();
+                    translate([-board_thickness/2, -13, thickness-board_thickness/2]) rotate([-90, 0, 0]) plate_screw();
                     translate([-board_thickness/2, -13, 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]) {
@@ -241,8 +236,9 @@ if (frame_type == frame_alu) {
      translate([0, -60, 0]) zmotorholder(thickness=55, bottom_thickness=6);
      translate([0, 60, 0]) mirror([0, 1, 0]) zmotorholder(thickness=55, bottom_thickness=6);
 
-     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);
-     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);
+     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=43 + zaxis_delta_x, bottom_thickness=6);
+     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=43 + zaxis_delta_x, bottom_thickness=6);
+
 
 }
 else {