x-end: improve integration

motor and idler now render properly at least, but are not using all
parameters yet.

Basic x-end parts now use same parameters to control positioning,
except for the smooth rod holes and belt slot which need to be updated
to handle the x-end size changing based on the bearing and rod
diameter.

Carriage will not work properly with these yet.

diff --git a/box_frame/inc/settings.scad b/box_frame/inc/settings.scad
index 55763b9..b1ef8fa 100644 (file)
--- a/box_frame/inc/settings.scad
+++ b/box_frame/inc/settings.scad
@@ -3,6 +3,9 @@
 board_to_xz_distance = 26;
 xaxis_rod_distance = 45;
 
+x_box_height = 5 + xaxis_rod_distance + bushing_xy[0] * 2 + 0.25;
+x_box_width = (bushing_xy[0] <= 4) ? 17.5 : bushing_xy[0] * 2 + 9.5;
+
 //calculated from settings
 single_wall_width = width_over_thickness * layer_height;
 

diff --git a/box_frame/x-end.scad b/box_frame/x-end.scad
index 3ad0cf1..1eebc13 100644 (file)
--- a/box_frame/x-end.scad
+++ b/box_frame/x-end.scad
@@ -25,36 +25,38 @@
 use <bushing.scad>
 include <configuration.scad>
 
-pushfit_d = bushing_xy[0] * 2 + 0.25; //smooth_rod_d + 0.25;
-rod_distance = 50;
-x_box_height = 5 + rod_distance + bushing_xy[0] * 2 + 0.25;
-hex_nut_r = 4.75;
-thinwall = 3;
-
-module vertical_bushing_base(bushing){
-     bushing_size = bushing[1]*2 + 2 * thinwall;
-     translate(v=[-2-bushing_size/4,0,x_box_height/2]) cube(size = [4+bushing_size/2,bushing_size,x_box_height], center = true);
-     cylinder(h = x_box_height, r=bushing_size/2, $fn = 90);
+pushfit_d = bushing_xy[0] * 2 + 0.25;
+thinwall = single_wall_width * 6; // 3 perimeters
+vertical_bushing_base_size = bushing_z[1]*2 + 2 * thinwall;
+
+x_box_length = 45; // TODO: auto-adjust based on bearing size?
+
+module vertical_bushing_base(){
+     translate(v=[-2-vertical_bushing_base_size/4,0,x_box_height/2]) cube(size = [4+vertical_bushing_base_size/2,vertical_bushing_base_size,x_box_height], center = true);
+     cylinder(h = x_box_height, r=vertical_bushing_base_size/2, $fn = 90);
 }
 
-module vertical_bushing_holes(bushing){
-     bushing_cut_extra = 0.2; // padding so it's not too tight
-  translate(v=[0,0,-4]) cylinder(h = x_box_height + 3, r=bushing[1] + bushing_cut_extra, $fn = 60);
-  translate(v=[0,0,x_box_height-4]) cylinder(h=x_box_height,r=bushing[1]-1,$fn=60);
-  // TODO: make translate(z) use x_box_height to correctly position slit
-  #rotate(a=[0,0,-50]) translate(v=[8,0,24/*was 31.5 mjr*/]) cube(size = [10,2 /*was 1 mjr*/ ,x_box_height+13], center = true);
-  translate([0,0,-1]) cylinder(h=9,r1=bushing[1]+thinwall/2+1,r2=4,$fn=60);
-  //#translate([0,0,49]) cylinder(h=9,r2=bushing[1]+thinwall/2,r1=4,$fn=60);
+module vertical_bushing_holes(){
+  // FIXME: is extra cut necessary? check conf_bushing
+  bushing_cut_extra = 0.2; // padding so it's not too tight
+  translate(v=[0,0,-4]) cylinder(h = x_box_height + 3, r=bushing_z[1] + bushing_cut_extra, $fn = 60);
+  translate(v=[0,0,x_box_height-4]) cylinder(h=x_box_height,r=bushing_z[1]-1,$fn=60);
+  // TODO: is slit too wide or too low? Wilson increased width from 1
+  // -> 2 mm, slit also might need to end 1-2mm before the base
+  #rotate(a=[0,0,-50]) translate(v=[thinwall*2 + 1,0,x_box_height/2 - 2]) cube(size = [bushing_z[2]/2, 2 ,x_box_height], center = true);
+  translate([0,0,-1]) cylinder(h=9,r1=bushing_z[1]+thinwall/2+1,r2=4,$fn=60);
 }
 
 
 module nut_trap_base () {
+     // TODO: cube doesn't line up with edge of base, cylinder is slightly asymmetrical
+     // adapt newer nut trap from prusa i3 mk3 instead of wilson2
      cube(size=[16,21,8],center=true);
      translate ([2,0,0]) cylinder(h=8,r=12.5,$fn=50,center=true);
 }
 
 module nut_trap () {
-     union() { 
+     union() {
                // center post of brass nut
                    cylinder(h=12,r=5.45,$fn=50,center=true);
                    // holes for m3 screws in brass nut
@@ -67,48 +69,48 @@ module nut_trap () {
 
 module x_end_base(){
 // Main block
-height = x_box_height;
-// TODO: calculate correct translate(y) + cube(y) using size of bearing
-translate(v=[-15,-10,height/2]) cube(size = [17,45,height], center = true);
+translate(v=[-10 - bushing_xy[0], -x_box_length/2 + vertical_bushing_base_size/2,x_box_height/2]) cube(size = [x_box_width,x_box_length,x_box_height], center = true);
 // Bearing holder
- vertical_bushing_base(bushing_z);     
+ vertical_bushing_base();
 //Nut trap
  translate(v=[-4+zmotor_delta_x,-17-zmotor_delta_y,4]) nut_trap_base ();
- // Cube
-// #translate(v=[-2-2,-17,4]) cube(size = [8,16,8], center = true);
- // Hexagon
-// #translate(v=[0,-17,0]) rotate([0,0,30]) cylinder(h = 8, r=8, $fn = 6);
 }
 
+// TODO: x translation of belt and smooth rods needs to adapt to
+// x_end_width and motor/idler pulley position.
+
 module x_end_holes(){
- vertical_bushing_holes(bushing_z);
+ vertical_bushing_holes();
  // Belt hole
  translate(v=[-1,0,0]){
  // Stress relief
  translate(v=[-5.5-10+1.5,-bushing_z[1]-4,30]) cube(size = [20,1,28], center = true);
  // Cut out for belt (this is NOT centered because the motor isn't centered)
+ x_box_offset = -x_box_length/2 + vertical_bushing_base_size/2;
  difference(){
-       translate(v=[-5.5-10+1.5,-10,30]) cube(size = [10,46,28], center = true);
+       translate(v=[-5.5-10+1.5, x_box_offset ,30]) cube(size = [10, x_box_length + 1,28], center = true);
 
        // Nice edges
-       translate(v=[-5.5-10+1.5,-10,30+23]) rotate([0,45,0]) cube(size = [10,46,28], center = true);
-       translate(v=[-5.5-10+1.5,-10,30+23]) rotate([0,-45,0]) cube(size = [10,46,28], center = true);
-       translate(v=[-5.5-10+1.5,-10,30-23]) rotate([0,45,0]) cube(size = [10,46,28], center = true);
-       translate(v=[-5.5-10+1.5,-10,30-23]) rotate([0,-45,0]) cube(size = [10,46,28], center = true);
+       translate(v=[-5.5-10+1.5,x_box_offset,30+23]) rotate([0,45,0]) cube(size = [10,x_box_length + 1,28], center = true);
+       translate(v=[-5.5-10+1.5,x_box_offset,30+23]) rotate([0,-45,0]) cube(size = [10,x_box_length + 1,28], center = true);
+       translate(v=[-5.5-10+1.5,x_box_offset,30-23]) rotate([0,45,0]) cube(size = [10,x_box_length + 1,28], center = true);
+       translate(v=[-5.5-10+1.5,x_box_offset,30-23]) rotate([0,-45,0]) cube(size = [10,x_box_length + 1,28], center = true);
 
-}
+ }
 }
 
-
+ // FIXME: z rod placement isn't consistent with carriage
  pushrod_extra_z = 2.5;
-// Bottom pushfit rod
-#translate(v=[-15,-41.5,bushing_xy[0]+pushrod_extra_z]) rotate(a=[-90,0,0]) pushfit_rod(pushfit_d,50);
-// Top pushfit rod
-translate(v=[-15,-41.5,rod_distance+bushing_xy[0]+pushrod_extra_z]) rotate(a=[-90,0,0]) pushfit_rod(pushfit_d,50);
+
+ // FIXME: confirm length of smooth rod doesn't change when x_box_length or bearing size changes
+ // should also make sure this is long enough if x-ends somehow end up larger than 50mm
+ //Bottom pushfit rod
+ #translate(v=[-15,-41.5,bushing_xy[0]+pushrod_extra_z]) rotate(a=[-90,0,0]) pushfit_rod(pushfit_d,50);
+ // Top pushfit rod
+ translate(v=[-15,-41.5,xaxis_rod_distance+bushing_xy[0]+pushrod_extra_z]) rotate(a=[-90,0,0]) pushfit_rod(pushfit_d,50);
+
 // Nut trap
-translate(v=[zmotor_delta_x,-17-zmotor_delta_y,3]) rotate ([0, 0, 45]) nut_trap ();
-// #translate(v=[0,-17,-0.5]) cylinder(h = 4, r1=3.4, r2=2.9, $fn=25);
-// translate(v=[0,-17,3]) rotate([0,0,30]) cylinder(h = 10, r=hex_nut_r, $fn = 6);
+ translate(v=[zmotor_delta_x,-17-zmotor_delta_y,3]) rotate ([0, 0, 45]) nut_trap ();
 }
 
 
@@ -126,10 +128,10 @@ x_end_plain();
 module pushfit_rod(diameter,length){
  translate([0,-0.3,0])  cylinder(h = length, r=diameter/2, $fn=30);
  translate([0,0.3,0])  cylinder(h = length, r=diameter/2, $fn=30);
+ // TODO: reintroduce teardrop holes?
 // difference(){
 //     translate(v=[0,-diameter/2.85,length/2]) rotate([0,0,45]) cube(size = [diameter/2,diameter/2,length], center = true);
 //     translate(v=[0,-diameter/4-diameter/2-0.4,length/2]) rotate([0,0,0]) cube(size = [diameter,diameter/2,length], center = true);
 // }
- 
-}
 
+}