xyRepRap/lib/linear_bearing.scad

include <bearing_idler.scad>

// #######################################################
// ################### Linear Bearings ###################
// #######################################################

lm8uu_outer = 15;
lm8uu_inner = 8;
lm8uu_height = 24;

x_rail_dist = 60;

lm8uu_dia_add = 0.5;
lm8uu_len_add = 1.0;
rail_dia_add = 3.0;
y_carriage_wall = 10; // z-axis
y_carriage_len_add = 15; // y-axis
y_carriage_width = 25; // x-axis
y_carriage_block_width = 10; // x-axis
y_carriage_block_height = 10; // z-axis
y_carriage_rail_support = 2; // dist between rail and edge

y_carriage_length = x_rail_dist + (2 * y_carriage_len_add);

rail_mount_dia_add = 0.4;
x_rail_mount_width = 10;
x_rail_cutout_z = 0.5; // in x-axis
x_rail_cutout_x = 0.5; // in z-axis
x_rail_cutout_y = x_rail_dist - (2 * y_carriage_len_add);
x_rail_hole_off = 5;
x_rail_block_len = (y_carriage_length - x_rail_cutout_y) / 2;

x_carriage_width = 80;
x_carriage_len_add = 10;
x_carriage_wall = 10;
x_carriage_bearing_off = 3;

x_carriage_belt_off = 19;
x_carriage_belt_block_width = 8;
x_carriage_belt_block_length = 8;
x_carriage_belt_block_height = 25;
x_carriage_belt_block_height_b = x_carriage_belt_block_height - 7;
x_carriage_block_hole_off = 4.5;
x_carriage_block_length = 4;
x_carriage_block_off = 2.5;
x_carriage_block_add = 4.4;

x_carriage_length = x_rail_dist + (2 * x_carriage_len_add);

x_carriage_block_height = 2 * (x_carriage_block_hole_off + x_carriage_block_add);

draw_x_carriage = false;
draw_y_carriage = false;
draw_y_carriage_idlers = true;
draw_rail_len = 200;

// y-carriage belt idlers
idler_a_blue = [  19,               15,  5.5];
idler_a_red  = [  19, x_rail_dist + 15, 12.5];
idler_b_blue = [30.3, x_rail_dist + 15, 12.5];
idler_b_red  = [30.3,               15,  5.5];

module lm8uu() {
    $fn = 15;
    difference() {
        cylinder(d = lm8uu_outer, h = lm8uu_height);
        translate([0, 0, -1])
            cylinder(d = lm8uu_inner, h = lm8uu_height + 2);
    }
}

// TODO add cable tie canal for lm8uu mounting

module generate_spacer(pos) {
    color("green")
    translate([pos[0], pos[1], -0.5])
        bearing_spacer(pos[2] + 0.5 + ((idler_outer_height - bearing_height) / 2), 2, 1, true, 3);
}

module y_carriage(idler_a = [0, 0, 0], idler_b = [0, 0, 0]) {
    $fn = 20;
    
    // attaching to x-rails
    color("green")
    translate([y_carriage_width, 0, -y_carriage_block_height])
    difference() {
        cube([x_rail_mount_width, y_carriage_length, y_carriage_block_height + y_carriage_wall]);
        
        translate([0, -1, y_carriage_block_height])
            cube([x_rail_cutout_z, y_carriage_length + 2, y_carriage_wall + 1]);
        
        translate([0, -1, y_carriage_block_height - (x_rail_cutout_x / 2)])
            cube([y_carriage_block_width + 1, y_carriage_length + 2, x_rail_cutout_x]);
        
        translate([0, (y_carriage_length - x_rail_cutout_y) / 2, y_carriage_block_height])
            cube([y_carriage_block_width + 1, x_rail_cutout_y, y_carriage_wall + 1]);
        
        for (i = [y_carriage_len_add : x_rail_dist : x_rail_dist + y_carriage_len_add]) {
            translate([0, i, y_carriage_block_height])
                rotate([0, 90, 0])
                cylinder(d = lm8uu_inner + rail_mount_dia_add, h = y_carriage_block_width + 1);
        }
        
        for (i = [0 : x_rail_block_len + x_rail_cutout_y : x_rail_block_len + x_rail_cutout_y]) {
            translate([y_carriage_block_width / 2, x_rail_hole_off + i, -1]) {
                cylinder(d = 3.2, h = y_carriage_wall + 2 + y_carriage_block_height);
                cylinder(d = 6.1, h = 3.8, $fn = 6);
                translate([0, 0, y_carriage_wall + y_carriage_block_height - 2.5])
                    cylinder(d = 6.1, h = 3.8);
            }
            
            translate([y_carriage_block_width / 2, x_rail_block_len - x_rail_hole_off + i, -1]) {
                cylinder(d = 3.2, h = y_carriage_wall + 2 + y_carriage_block_height);
                cylinder(d = 6.1, h = 3.8, $fn = 6);
                translate([0, 0, y_carriage_wall + y_carriage_block_height - 2.5])
                    cylinder(d = 6.1, h = 3.8);
            }
        }
    }
    
    // attaching to y-rail
    color("green")
    difference() {
        union() {
            cube([y_carriage_width, y_carriage_length, y_carriage_wall]);
            
            translate([y_carriage_width - y_carriage_block_width, 0, -y_carriage_block_height])
                cube([y_carriage_block_width, y_carriage_length, y_carriage_block_height]);
        }
        
        translate([(lm8uu_outer + lm8uu_dia_add) / 2 + y_carriage_rail_support, 0, 0])
        rotate([-90, 0, 0]) {
            translate([0, 0, -1])
                cylinder(d = lm8uu_inner + rail_dia_add, h = y_carriage_length + 2);
            
            translate([0, 0, y_carriage_rail_support - lm8uu_len_add / 2])
                cylinder(d = lm8uu_outer + lm8uu_dia_add, h = lm8uu_height + lm8uu_len_add);
        
            translate([0, 0, y_carriage_length - lm8uu_height - y_carriage_rail_support - lm8uu_len_add / 2])
                cylinder(d = lm8uu_outer + lm8uu_dia_add, h = lm8uu_height + lm8uu_len_add);
        }
    }
    
    color("magenta")
    translate([(lm8uu_outer + lm8uu_dia_add) / 2 + y_carriage_rail_support, 0, 0])
    rotate([-90, 0, 0]) {
        // y-bearings
        %translate([0, 0, y_carriage_rail_support])
            lm8uu();
        %translate([0, 0, y_carriage_length - lm8uu_height - y_carriage_rail_support])
            lm8uu();
    }
    
    // idlers for the corexy belts
    translate([0, 0, y_carriage_wall]) {
        if (draw_y_carriage_idlers) {
            translate(idler_a)
                bearing_idler();
            
            translate(idler_b)
                bearing_idler();
        }
        
        generate_spacer(idler_a);
        generate_spacer(idler_b);
    }
}

module belt_fix() {
    difference() {
        color("green")
        cube([x_carriage_belt_block_width, x_carriage_block_length, x_carriage_block_height]);
        
        translate([x_carriage_belt_block_width / 2, -1, x_carriage_block_hole_off - 0.2])
        rotate([-90, 0, 0]) {
            cylinder(d = 3.2, h = x_carriage_belt_block_length + 2);
            cylinder(d = 6.1, h = 3.8, $fn = 6);
        }
            
        translate([x_carriage_belt_block_width / 2, -1, x_carriage_block_hole_off + 8.8])
        rotate([-90, 0, 0]) {
            cylinder(d = 3.2, h = x_carriage_belt_block_length + 2);
            cylinder(d = 6.1, h = 3.8, $fn = 6);
        }
    }
}

module belt_mount(top, up) {
    $fn = 15;
    
    difference() {
        color("green")
        if (top) {
            cube([x_carriage_belt_block_width, x_carriage_belt_block_length, x_carriage_belt_block_height]);
        } else {
            cube([x_carriage_belt_block_width, x_carriage_belt_block_length, x_carriage_belt_block_height_b]);
        }
        
        if (top) {
            translate([-1, x_carriage_belt_block_length / 2, 16])
                rotate([0, 90, 0])
                cylinder(d = 2.6, h = x_carriage_belt_block_width + 2);
            
            translate([x_carriage_belt_block_width / 2, -1, 16 + x_carriage_block_hole_off])
                rotate([-90, 0, 0])
                cylinder(d = 3.2, h = x_carriage_belt_block_length + 2);
            translate([x_carriage_belt_block_width / 2, -1, 16 - x_carriage_block_hole_off])
                rotate([-90, 0, 0])
                cylinder(d = 3.2, h = x_carriage_belt_block_length + 2);
        } else {
            translate([-1, x_carriage_belt_block_length / 2, 9])
                rotate([0, 90, 0])
                cylinder(d = 2.7, h = x_carriage_belt_block_width + 2);
            translate([x_carriage_belt_block_width / 2, -1, 9 + x_carriage_block_hole_off])
                rotate([-90, 0, 0])
                cylinder(d = 3.2, h = x_carriage_belt_block_length + 2);
            translate([x_carriage_belt_block_width / 2, -1, 9 - x_carriage_block_hole_off])
                rotate([-90, 0, 0])
                cylinder(d = 3.2, h = x_carriage_belt_block_length + 2);
        }
    }
    
    if (up) {
        if (top) {
            translate([0, x_carriage_belt_block_length + x_carriage_block_off, x_carriage_belt_block_height - x_carriage_block_height])
                belt_fix();
        } else {
            translate([0, x_carriage_belt_block_length + x_carriage_block_off, x_carriage_belt_block_height_b - x_carriage_block_height])
                belt_fix();
        }
    } else {
        if (top) {
            translate([0, -x_carriage_block_length - x_carriage_block_off, x_carriage_belt_block_height - x_carriage_block_height])
                belt_fix();
        } else {
            translate([0, -x_carriage_block_length - x_carriage_block_off, x_carriage_belt_block_height_b - x_carriage_block_height])
                belt_fix();
        }
    }
}

module belt_mounts() {
    translate([0, x_carriage_belt_off, 0])
        belt_mount(false, true);
    
    translate([0, x_carriage_length - x_carriage_belt_off - x_carriage_belt_block_length, 0])
        belt_mount(true, false);
    
    translate([x_carriage_width - x_carriage_belt_block_width, x_carriage_belt_off, 0])
        belt_mount(true, true);
    
    translate([x_carriage_width - x_carriage_belt_block_width, x_carriage_length - x_carriage_belt_off - x_carriage_belt_block_length, 0])
        belt_mount(false, false);
}

module x_carriage() {
    //color("green")
    difference() {
        union() {
            color("green")
            cube([x_carriage_width, x_rail_dist + (2 * x_carriage_len_add), x_carriage_wall]);
            
            translate([0, 0, x_carriage_wall])
                belt_mounts();
        }
        
        // big center cutout
        translate([x_carriage_width / 2, x_carriage_length / 2, x_carriage_wall / 2])
            cube([x_carriage_width - (2 * x_carriage_belt_block_width) - 5, x_rail_dist - 25, x_carriage_wall + 2], center=true);
        
        for (i = [0 : 1 : 1]) {
            translate([lm8uu_height + x_carriage_bearing_off + (i * (x_carriage_width - (2 * x_carriage_bearing_off) - lm8uu_height)), 0, ])
            rotate([0, -90, 0]) {
                // x-bearings
                color("magenta")
                %translate([0, x_carriage_len_add, 0])
                    lm8uu();
                
                color("magenta")
                %translate([0, x_rail_dist + x_carriage_len_add, 0])
                    lm8uu();
                
                color("green")
                translate([0, x_carriage_len_add, 0])
                    cylinder(d = lm8uu_outer + lm8uu_dia_add, h = lm8uu_height + lm8uu_len_add);
                
                color("green")
                translate([0, x_rail_dist + x_carriage_len_add, 0])
                    cylinder(d = lm8uu_outer + lm8uu_dia_add, h = lm8uu_height + lm8uu_len_add);
                
                color("green")
                translate([0, x_carriage_len_add, -x_carriage_width])
                    cylinder(d = lm8uu_inner + rail_dia_add, h = x_carriage_width * 2);
                
                color("green")
                translate([0, x_rail_dist + x_carriage_len_add, -x_carriage_width])
                    cylinder(d = lm8uu_inner + rail_dia_add, h = x_carriage_width * 2);
            }
        }
    }
}

if (draw_y_carriage) {
    translate([(lm8uu_outer + lm8uu_dia_add) / 2 + y_carriage_rail_support, 0, 0])
    rotate([-90, 0, 0]) {
        // y-bearings
        %translate([0, 0, y_carriage_rail_support])
            lm8uu();
        %translate([0, 0, y_carriage_length - lm8uu_height - y_carriage_rail_support])
            lm8uu();
    }

    // x-rails
    for (i = [y_carriage_len_add : x_rail_dist : x_rail_dist + y_carriage_len_add]) {
        %translate([y_carriage_width + 1, i, 0])
            rotate([0, 90, 0])
            cylinder(d = lm8uu_inner, h = draw_rail_len);
    }

    y_carriage(idler_a_blue, idler_b_blue);

    translate([(2 * y_carriage_width + y_carriage_block_width) + draw_rail_len -5, y_carriage_length, 0])
        rotate([0, 0, 180])
        y_carriage(idler_a_red, idler_b_red);
    
    if (draw_x_carriage) {
        translate([y_carriage_width + y_carriage_block_width + ((draw_rail_len - x_carriage_width) / 2), y_carriage_len_add - x_carriage_len_add, 0])
            x_carriage();
    }
} else if (draw_x_carriage) {
    x_carriage();
}