fuellfix-v2/hardware/table.scad

/*
 * Resources used:
 * https://www.thingiverse.com/thing:16627
 * https://www.chiefdelphi.com/t/timing-pulley-design-tutorial/383204
 *
 * Hardware required:
 * https://www.banggood.com/15pcs-Transparent-Pulley-Wheel-with-625zz-Double-Bearing-for-V-slot-3D-Printer-p-1575067.html?cur_warehouse=CN&rmmds=search
 * 2x NEMA17 stepper
 * 2040 extrusions, lengths see console output
 * 2020 extrusions, lengths see console output
 * GT2 belt, lengths see console output
 */

include <config.scad>;
use <gt2_pulley.scad>;
use <common.scad>;

$fn = 42;

/***********************************
 ********** Printed Parts **********
 ***********************************/

module belt_pulley(tc, dia, for_motor = 1) {
    difference() {
        union() {
            cylinder(d = dia + belt_pulley_rim * 2, h = (belt_pulley_width - belt_pulley_tooth_width) / 2);
            
            translate([0, 0, (belt_pulley_width - belt_pulley_tooth_width) / 2])
            gt2_2mm_pulley(tc, belt_pulley_tooth_width);
            cylinder(d = dia, h = (belt_pulley_width - belt_pulley_tooth_width) / 2);
            
            translate([0, 0, (belt_pulley_width - belt_pulley_tooth_width) / 2 + belt_pulley_tooth_width])
            cylinder(d = dia + belt_pulley_rim * 2, h = (belt_pulley_width - belt_pulley_tooth_width) / 2);
        }
        
        if (for_motor) {
            // motor shaft hole
            translate([0, 0, -1])
            cylinder(d = belt_pulley_axis_hole, h = belt_pulley_width + 2);
        
            // grub screw
            for (i = [0, 90])
            translate([0, 0, belt_pulley_width / 2])
            rotate([90, 0, i])
            cylinder(d = belt_pulley_fix_dia, h = dia / 2 + 1);
        } else {
            // bearing hole
            translate([0, 0, -1])
            cylinder(d = bearing_outer, h = belt_pulley_width + 2);
        
            // grub screw
            for (i = [0, 90, 180, 270])
            translate([0, 0, (i > 90 ? 1 : -1) * 2])
            translate([0, 0, belt_pulley_width / 2])
            rotate([90, 0, i])
            cylinder(d = belt_pulley_fix_dia, h = dia / 2 + 1);
        }
    }
}

module belt_tensioner_diff() {
    translate([-50, -belt_tensioner_diff_len, -belt_tensioner_diff_height / 2])
    cube([100, belt_tensioner_diff_len, belt_tensioner_diff_height]);
    
    translate([-belt_tensioner_diff_width / 2, -belt_tensioner_diff_len, -50])
    cube([belt_tensioner_diff_width, belt_tensioner_diff_len, 100]);
}

module belt_tensioner_mount_rail(height) {
    echo("belt tensioner", "t-nut", str(height * 2, "x"), str(motor_mount_hole_size_nominal, "mm"));
    
    difference() {
        if (height == 1) {
            for (i = [ 10, -10 - belt_tensioner_wall ])
            translate([i, 0, 0])
            cube([belt_tensioner_wall, belt_tensioner_mount_depth, 20 + belt_tensioner_wall]);
        } else {
            for (i = [ 10, -10 - belt_tensioner_wall ])
            translate([i, 0, -20])
            cube([belt_tensioner_wall, belt_tensioner_mount_depth, 40 + belt_tensioner_wall]);
        }
        
        for (i = [ 10, -10 ])
        translate([-10 - belt_tensioner_wall - 1, belt_tensioner_mount_depth / 2, i])
        rotate([0, 90, 0])
        cylinder(d = motor_mount_hole_size, h = 20 + 2 * belt_tensioner_wall + 2);
    }
}

module belt_tensioner_mount(height) {
    echo("belt tensioner", "screw", "1x", str("M", belt_tensioner_screw), str(">", belt_tensioner_diff_len + belt_tensioner_wall + 5 - real_belt_pulley_dia, "mm"));
    
    echo("belt tensioner", "nut", "1x", str("M", belt_tensioner_screw));
    
    belt_tensioner_mount_rail(height);
    
    difference() {
        hull() {
            if (height == 1) {
                for (i = [ 10, -10 - belt_tensioner_wall ])
                translate([i, 0, 0])
                cube([belt_tensioner_wall, 1, 20 + belt_tensioner_wall]);
            } else {
                for (i = [ 10, -10 - belt_tensioner_wall ])
                translate([i, 0, -20])
                cube([belt_tensioner_wall, 1, 40 + belt_tensioner_wall]);
            }
            
            translate([-10, -belt_tensioner_diff_len - belt_tensioner_wall - 5, 25 - 21])
            cube([20, belt_tensioner_wall, 20 + 1]);
        }
        
        translate([-10 - belt_tensioner_wall - 1, 0, -22])
        cube([20 + 2 * belt_tensioner_wall + 2, 50, 50]);
        
        translate([-10, 0, -22])
        cube([20, 50, 50]);
        
        translate([0, 0, 10 + belt_pulley_off])
        belt_tensioner_diff();
        
        translate([0, -belt_tensioner_diff_len - belt_tensioner_wall - 5 + 30 - 1, real_belt_pulley_dia / 2 + 0.175])
        rotate([90, 0, 0])
        cylinder(d = belt_tensioner_screw_hole, h = 30);
    }
}

module belt_tensioner_moving() {
    %color("red")
    translate([-belt_pulley_width / 2, 0, 0])
    rotate([0, 90, 0])
    rotate([0, 0, -acos(anim_pos_x * -2 + 1)])
    belt_pulley(teethcount, real_belt_pulley_dia, 0);
    
    color("cyan")
    difference() {
        for (i = [-1, 1])
        scale([i, 1, 1])
        translate([belt_pulley_width / 2 + belt_tensioner_moving_gap, belt_tensioner_moving_overlap - belt_tensioner_moving_len, -belt_tensioner_moving_height / 2])
        cube([belt_tensioner_wall, belt_tensioner_moving_len, belt_tensioner_moving_height]);
        
        translate([-belt_pulley_width / 2 - belt_tensioner_wall - belt_tensioner_moving_gap - 1, 0, 0])
        rotate([0, 90, 0])
        cylinder(d = axis_hole_diameter, h = belt_pulley_width + 2 * (belt_tensioner_wall + belt_tensioner_moving_gap) + 2);
    }
    
    color("cyan")
    translate([-belt_pulley_width / 2 - belt_tensioner_moving_gap, -belt_tensioner_moving_len + belt_tensioner_moving_overlap, -belt_tensioner_moving_height / 2])
    difference() {
        cube([belt_pulley_width + 2 * belt_tensioner_moving_gap, belt_tensioner_wall, belt_tensioner_moving_height]);
        
        translate([belt_pulley_width / 2 + belt_tensioner_moving_gap, belt_tensioner_wall + 1, belt_tensioner_moving_height / 2])
        rotate([90, 0, 0])
        cylinder(d = belt_tensioner_screw_hole, h = belt_tensioner_wall + 2);
    }
}

module belt_tensioner(height, length = 100, visual = 1) {
    if (visual)
    %translate([-10, 0, 0])
    if (length > 0) {
        if (height == 1) {
            rail_2020_y(length, "only for visualization");
        } else {
            rail_2040_y(length, "only for visualization");
        }
    }
    
    translate([0, -belt_tensioner_travel * $t, 0])
    translate([0, -real_belt_pulley_dia / 2, 10 + belt_pulley_off])
    belt_tensioner_moving();
    
    color("orange")
    belt_tensioner_mount(height);
    
    %color("yellow")
    translate([-belt_width / 2, -real_belt_pulley_dia / 2, 10 + real_belt_pulley_dia / 2 + belt_pulley_off - belt_thickness / 2])
    cube([belt_width, length + real_belt_pulley_dia / 2 + nema17_size / 2, belt_thickness]);
    
    %color("yellow")
    translate([-belt_width / 2, -real_belt_pulley_dia / 2, 10 - real_belt_pulley_dia / 2 - belt_thickness / 2 + belt_pulley_off])
    cube([belt_width, length + real_belt_pulley_dia / 2 + nema17_size / 2, belt_thickness]);
}

module motor_mount(height) {
    echo("motor mount", "t-nut", str(height * 2, "x"), str(motor_mount_hole_size_nominal, "mm"));
    
    echo("motor mount", "screw", "4x", str("M", nema17_hole_size), str(motor_mount_height + 2, "-", motor_mount_height + 4, "mm"));
    
    %color("yellow")
    translate([-nema17_len, 0, nema17_size - belt_pulley_off])
    rotate([0, 90, 0])
    nema17(nema17_len);
    
    %color("red")
    translate([motor_mount_height - belt_pulley_width / 2 + 10, nema17_size / 2, nema17_size / 2 - belt_pulley_off])
    rotate([0, 90, 0])
        rotate([0, 0, -acos(anim_pos_x * -2 + 1)])
    belt_pulley(teethcount, real_belt_pulley_dia, 1);
    
    color("cyan")
    difference() {
        hull() {
            translate([0, 0, -belt_pulley_off])
            cube([motor_mount_height, nema17_size, nema17_size]);
            
            translate([0, nema17_size, (nema17_size - 20) / 2])
            cube([motor_mount_height, motor_mount_length, height * 20]);
        }
        
        translate([0, 0, -belt_pulley_off])
        translate([-nema17_len, 0, nema17_size])
        rotate([0, 90, 0]) {
            nema17_holes_face(nema17_len, motor_mount_height + 5, nema17_hole_size + screw_gap);
            
            translate([nema17_size / 2, nema17_size / 2, nema17_len - 1])
            cylinder(d = nema17_center_size + 2, h = motor_mount_height + 2);
        }
        
        for (i = [0, motor_mount_hole_off])
        for (j = [0, 20 * (height - 1)])
        translate([0, i, j])
        translate([-1, nema17_size - motor_mount_hole_off / 2 + motor_mount_length / 2, nema17_size / 2])
        rotate([0, 90, 0]) {
            cylinder(d = motor_mount_hole_size, h = motor_mount_height + 2);
        }
    }
}

/***********************************
 ************** Plate **************
 ***********************************/

module plate_holes(h) {
    for (i = [-1, 1])
    for (j = [-1, 1])
    translate([i * plate_mount_screws_distance_x / 2, j * plate_mount_screws_distance_y / 2, -1])
    cylinder(d = plate_mount_screw_hole, h = h + 2);
}

module plate() {
    echo("alu plate", "bed", plate_x, plate_y, "holes", plate_mount_screws_distance_x, plate_mount_screws_distance_y);
    
    difference() {
        cube([plate_x, plate_y, plate_z]);
        
        translate([plate_x / 2, plate_y / 2, 0])
        plate_holes(plate_z);
    }
}

/************************************
 ************** Y-Axis **************
 ************************************/

module belt_mount(h) {
    difference() {
        hull() {
            translate([-belt_mount_width / 2, -belt_mount_depth / 2, 0])
            cube([belt_mount_width, belt_mount_depth, h]);
            
            translate([-belt_mount_full_width / 2, belt_mount_depth / 2, 0])
            cube([belt_mount_full_width, 1, h]);
        }
        
        translate([-belt_slot_width / 2, -belt_slot_depth / 2, -1])
        cube([belt_slot_width, belt_slot_depth, h + 2]);
        
        translate([-belt_mount_full_width / 2, -belt_mount_depth / 2 - 0.1, h / 2])
        rotate([-90, 0, 0])
        prism(belt_mount_full_width, h / 2 + 0.1, belt_mount_depth + 0.1);
    }
}

module y_carriage_post() {
    rotate([0, 0, 90])
    difference() {
        cylinder(d = y_carriage_post_dia, h = y_carriage_post_len, $fn = 6);
        
        translate([0, 0, -1])
        cylinder(d = y_carriage_post_screw_hole, h = (y_carriage_post_len - y_carriage_post_center) / 2 + 1);
        
        translate([y_carriage_post_hole_off, 0, (y_carriage_post_len + y_carriage_post_center) / 2])
        cylinder(d = y_carriage_post_screw_hole, h = (y_carriage_post_len - y_carriage_post_center) / 2 + 1);
    }
}

module y_carriage_posts() {
    for (i = [-1, 1])
    for (j = [-1, 1])
    translate([i * y_carriage_wheel_x_dist / 2, j * y_carriage_wheel_y_dist / 2, 0]) {
        color("blue")
        y_carriage_post();
        
        %color("yellow")
        translate([0, y_carriage_post_hole_off, y_carriage_pulley_off])
        rail_wheel();
    }
}

// also used as base for x-carriage
// axis = 0 --> all holes, usable for both
// axis = 1 --> holes for x-carriage
// axis = 2 --> holes for y-carriage
module y_carriage(axis = 0) {
    if (axis == 1) {
        echo("t-nut", "x-carriage", "2");
    }

    color("green")
    difference() {
        union() {
            cube([y_carriage_x, y_carriage_y, y_carriage_h]);
            
            translate([y_carriage_x / 2, y_carriage_y / 2, 0])
            for (i = [-1, 1])
            translate([0, i * (y_carriage_y + belt_mount_depth) / 2, 0])
            scale([1, -i, 1])
            belt_mount(y_carriage_h);
        }
        
        translate([y_carriage_x / 2, y_carriage_y / 2, 0])
        plate_holes(y_carriage_h);
        
        // holes to mount y-axis to x-carriage
        if ((axis == 0) || (axis == 1)) {
            translate([(y_carriage_x - plate_mount_screws_distance_x) / 2, 0, 0])
            for (i = [0, 1])
            translate([i * plate_mount_screws_distance_x, y_carriage_y / 2, -1])
            cylinder(d = y_carriage_post_screw_hole, h = y_carriage_h + 2);
            
            for (i = [x_carriage_holder_l - x_carriage_holder_hole_off, y_carriage_y - x_carriage_holder_l + x_carriage_holder_hole_off])
            translate([y_carriage_x / 2, i, -1])
            cylinder(d = y_carriage_post_screw_hole, h = y_carriage_h + 2);
        }
        
        translate([y_carriage_x / 2, y_carriage_y / 2, 0])
        for (i = [-1, 1])
        for (j = [-1, 1])
        translate([i * y_carriage_wheel_x_dist / 2, j * y_carriage_wheel_y_dist / 2, -1]) {
            cylinder(d = y_carriage_post_screw_hole, h = y_carriage_h + 2);
        }
    }
    
    %translate([y_carriage_x / 2, y_carriage_y / 2, y_carriage_h])
    y_carriage_posts();
}

module y_axis() {
    translate([y_carriage_x / 2, y_axis_animation_position, 20 + y_carriage_h + y_carriage_rail_dist])
    rotate([0, 180, 0])
    y_carriage(2);
    
    color("grey")
    translate([-10, 0, 0])
    rail_2040_y(y_axis_rail_len, "y-axis");
    
    translate([- motor_mount_height - 10, y_axis_rail_len + nema17_size, nema17_size / 2 + 10])
    rotate([180, 0, 0])
    motor_mount(2);
    
    belt_tensioner(2, y_axis_rail_len, 0);
}

/************************************
 ************** X-Axis **************
 ************************************/

module x_carriage_holder() {
    echo("t-nut", "x-carriage-holder", "2");

    difference() {
        union() {
            cube([x_carriage_holder_l, x_carriage_holder_w, x_carriage_holder_h]);
            cube([x_carriage_holder_h, x_carriage_holder_w, 20]);
        }
        
        translate([0, (x_carriage_holder_w - x_carriage_holder_rail_hole_dist) / 2, 0])
        for (i = [0, x_carriage_holder_rail_hole_dist])
        translate([-1, i, 10])
        rotate([0, 90, 0])
        cylinder(d = y_carriage_post_screw_hole, h = x_carriage_holder_h + 2);
        
        translate([-(y_carriage_y - plate_mount_screws_distance_y) / 2, y_carriage_x / 2, 0])
        rotate([0, 0, 90])
        plate_holes(x_carriage_holder_h);
        
        translate([x_carriage_holder_hole_off, x_carriage_holder_w / 2, -1])
        cylinder(d = y_carriage_post_screw_hole, h = x_carriage_holder_h + 2);
    }
}

module x_carriage() {
    translate([0, -y_carriage_x / 2, y_carriage_h + y_carriage_rail_dist + 20])
    rotate([0, 180, -90])
    y_carriage(1);
    
    color("purple")
    for (i = [-1, 1])
    translate([y_carriage_y / 2, 0, 0])
    scale([i, 1, 1])
    translate([y_carriage_y / 2 - x_carriage_holder_l, 0, 0])
    translate([0, -x_carriage_holder_w / 2, 20 + y_carriage_h + y_carriage_rail_dist])
    x_carriage_holder();
}

module x_axis() {
    translate([x_axis_animation_position + 10, 0, 0])
    x_carriage();
    
    color("grey")
    translate([0, -10, 0])
    rail_2040_x(x_axis_rail_len, "x-axis");
    
    translate([x_axis_rail_len + nema17_size, motor_mount_height + 10, nema17_size / 2 + 10])
    rotate([0, 180, 90])
    motor_mount(2);
    
    rotate([0, 0, -90])
    belt_tensioner(2, x_axis_rail_len, 0);
}

/************************************
 ************* Assembly *************
 ************************************/

module assembly_y_axis_plate() {
    translate([0, -y_carriage_y / 2 - y_axis_animation_position, 0])
    y_axis();
    
    %translate([-plate_x / 2, -plate_y / 2, 20 + y_carriage_h + y_carriage_rail_dist])
    plate();
}

module assembly_x_axis() {
    x_axis();
    
    translate([x_axis_animation_position + y_carriage_y / 2, -y_axis_rail_len / 2, 20 + y_carriage_h + y_carriage_rail_dist])
    translate([10, y_axis_animation_position + y_carriage_y / 2, 20])
    assembly_y_axis_plate();
}

module assembly() {
    translate([-x_axis_rail_len / 2, 0, 20]) {
        assembly_x_axis();
        
        color("grey")
        for (i = [1, -1])
        scale([1, i, 1])
        translate([left_support_off, -left_support_len - 10, -20])
        rail_2020_y(left_support_len, "left support");
        
        color("grey")
        for (i = [1, -1])
        scale([1, i, 1])
        translate([x_axis_rail_len - 20 - right_support_off, -right_support_len - 10, -20])
        rail_2020_y(right_support_len, "right support");
    }
}

module xy_table() {
    translate([-point_that_reaches_everywhere_x, -point_that_reaches_everywhere_y, -40 + -40 + (y_carriage_rail_dist + y_carriage_h) * -2 + -plate_z])
    assembly();
}

/***********************************
 ************ Rendering ************
 ***********************************/

//dispenser();
//rail_2020_x(100);
//rail_wheel();

//motor_mount(1);
//motor_mount(2);
//belt_pulley(teethcount, real_belt_pulley_dia, 1);

//belt_tensioner_mount(2);
//belt_tensioner_moving();
//belt_tensioner(1);
//belt_tensioner(2);
//belt_pulley(teethcount, real_belt_pulley_dia, 0);

//y_carriage_post();
//x_carriage_holder();

translate([0, -50, 0])
y_carriage(0);
//y_carriage(1);
//y_carriage(2);
//x_carriage();

//y_axis();
//x_axis();

//assembly();
//xy_table();