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Merge branch 'master' of https://github.com/mjrice/Wilson2

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Martin Rice 9 years ago
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10
README.md
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# Wilson2
This is the Wilson II - a reprap 3D printer based on Wilson TS
The respository has these sub directories:
stl/ contains the STL files needed to build the printer
doc/ contains documentation, images, bom, etc.
scad/ contains the design files of those parts for which OpenSCAD was used.
sketchup/ contains the design files of those parts for which SketchUp was used.

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scad/FanductOvalE3dv6.scad
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/*
* Oval Fanduct
* Copyright (C) 2014 Kit Adams
*
* This program is free software; you can redistribute it and/or modify
* it under the terms of the GNU General Public License as published by
* the Free Software Foundation; either version 3 of the License, or
* (at your option) any later version.
*
* This program is distributed in the hope that it will be useful,
* but WITHOUT ANY WARRANTY; without even the implied warranty of
* MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
* GNU General Public License for more details.
*
* You should have received a copy of the GNU General Public License
* along with this program; if not, write to the Free Software
* Foundation, Inc., 59 Temple Place, Suite 330, Boston, MA 02111-1307 USA
*
*/
/*
* Fan duct for active cooling of PLA prints.
* Designed to be printed in ABS without support.
* The intention is that you measure the height from the fan mounting hinge on the extruder
* to the bottom of the nozzle (in mm) and set the mountToHotEndBottomZ parameter to that value.
* Then set the bedClearanceGap to the distance above the nozzle you wish the lowest part of the duct to be at.
*
* Inspired by http://www.thingiverse.com/thing:63123, which I would have used if I could have tweaked it to fit using
* OpenSCAD.
* Uses:
* http://www.thingiverse.com/thing:18273, thanks doommeister, and
* http://svn.clifford.at/openscad/trunk/libraries/shapes.scad, thanks Catarina Mota.
*/
use <fan_holder_v2.scad>
use <shapes.scad>
use <ruler.scad>
$fn=10;
pi = 3.1415926535897932384626433832795;
//Important: before generating the stl, change this to the layer height you intend to
//use for printing!
layerHeight = 0.26; //Layer height used for printing - Cura OK with this.
//layerHeight = 1;
outerRadius = 1.6; //outer corner radius
wall = 2; //wall thickness
m3_diameter = 3.7;
kFanSize = 40;
/////Settings for E3D V5 hotend and extruder from http://www.thingiverse.com/thing:119616
heaterBlockW = 18;
nozzleOffsetFromBlockCenter = 2; //+ve if towards mount
heaterBlockGap = 7; //Horizontal gap between vented tube and heated block - 7 ended up being 6 mm
mountToFilamentHoriz = 21.25;
fanAngleFromVert = 30;
mountToHotEndBottomZ = 56; //vertical distance from center of mounting hinge to tip of nozzl
//For E3D v6
//mountToHotEndBottomZ = 57.5; //vertical distance from center of mounting hinge to tip of nozzl
//For E3Dv5
//mountToHotEndBottomZ = 65; //vertical distance from center of mounting hinge to tip of nozzle.
bedClearanceGap = 10; //Bottom of each vented duct is this far above the tip of the nozzle.
//Something not quite right with this parameter, since I set it to 7mm but it
//ended up being about 4 mm
//The vented duct reduces in area by changing from oval to round
ventedDuctMaxHeight = 22; // 22
ventedDuctWidth = 10;
endCapDia = 14;
slotAngleFromVertical = 45;
slotWidthDegrees = 60;
///End settings
///////Settings for J-Head V5 hotend and extruder from http://www.thingiverse.com/thing:119616
//heaterBlockW = 18;
//nozzleOffsetFromBlockCenter = 5; //+ve if towards mount
//heaterBlockGap = 6; //Horizontal gap between vented tube and heated block - 7 ended up being 6 mm
//mountToFilamentHoriz = 21.25;
//fanAngleFromVert = 30;
//mountToHotEndBottomZ = 45;//for J-head//65; for E3Dv5; //vertical distance from center of mounting hinge to tip of nozzle.
//bedClearanceGap = 10; //Bottom of each vented duct is this far above the tip of the nozzle.
// //Something not quite right with this parameter, since I set it to 7mm but it
// //ended up being about 4 mm
////The vented duct reduces in area by changing from oval to round
//ventedDuctMaxHeight = 22;
//ventedDuctWidth = 18;//14;
//endCapDia = 16;
//
//slotAngleFromVertical = 50;//60;
//slotWidthDegrees = 50;
/////End settings
slotMaxWidthFrac = 0.2;
camberAngle = 60; //Oval part of vented duct is rotated from vertical by this amount (i.e. bottoms inwards).
toeInAngle = 12; //Increase this to compensate for the air tending to blow forwards more than backwards.
//Mounting parameters
mountingHingeDia = 8;
hingeInsideWidth = 7.2; // width of the hinge block on the extruder from http://www.thingiverse.com/thing:119616
hingeOuterWidth = 4; // Thickness of each hinge strut on the fan duct
hingeLen = 4.2; // Distance out to the center of the hole
rulery = 0;//kFanSize/2;//-21;
hingePos = [kFanSize+hingeLen-m3_diameter/2,rulery,-mountingHingeDia/2];
FanSplitter(mountToHotEndBottomZ,kFanSize,heaterBlockW,ventedDuctMaxHeight,ventedDuctWidth /*,mountToHeatBlockHorizontal*/);
mirror([0,1,0])
FanSplitter(mountToHotEndBottomZ,kFanSize,heaterBlockW,ventedDuctMaxHeight,ventedDuctWidth/*,mountToHeatBlockHorizontal*/);
translate([-outerRadius,-kFanSize/2,-mountingHingeDia])
{
_fan_mount(
fan_size = kFanSize,
fan_mounting_pitch = 32,
fan_m_hole_dia = 2.5, //For self-tapping M3 screws
holder_thickness = mountingHingeDia
);
//Airflow splitter
translate([0,(kFanSize-wall)/2,0])
{
//Shear the rectangle to get half the splitter
multmatrix(m = [ [1, 0, 0, 0],
[0, 1, wall/(2*mountingHingeDia), 0],
[0, 0, 1, 0],
[0, 0, 0, 1]
])
cube([kFanSize,wall,mountingHingeDia]);
//Shear the other half the other way
multmatrix(m = [ [1, 0, 0, 0],
[0, 1, -wall/(2*mountingHingeDia), 0],
[0, 0, 1, 0],
[0, 0, 0, 1]
])
cube([kFanSize,wall,mountingHingeDia]);
}
//Mounting hinge
translate([kFanSize,kFanSize/2+hingeInsideWidth/2,0])
MountingHinge(mountingHingeDia,hingeLen,hingeOuterWidth);
translate([kFanSize,kFanSize/2-hingeInsideWidth/2-hingeOuterWidth,0])
MountingHinge(mountingHingeDia,hingeLen,hingeOuterWidth);
}
//Testing
//mirror([0,1,0])
// ventedTube();
//MountingHinge();
module MountingHinge(dia = 8, lenIn = 12,thickness = 4)
{
len = lenIn;//-dia/2;
difference()
{
union()
{
translate([len,thickness,dia/2])
rotate([90,0,0])
cylinder(h = thickness,r = dia/2);
cube([len,thickness,dia]);
}
translate([len,thickness,dia/2])
rotate([90,0,0])
cylinder(h = thickness,r = m3_diameter/2);
}
}
module FanSplitter(mountToHotEndBottomZ, fanSizeIn = 30, heaterBlockW = 20, smallDuctH = 20, smallDuctW = 12 /*,mountToHeatBlockHorizontal,*/)
{
//Two mirrored versions of this attach to the fan mount and duct the air to the level of the heated block of the hotend.
fanSize = fanSizeIn-2*outerRadius;
minAngle = 30;
ventedDuctsSeparation = heaterBlockW + 2*heaterBlockGap;
ventedDuctsSeparationMax = ventedDuctsSeparation + sin(toeInAngle)*ventedDuctsSeparation;
xTrans = cos(fanAngleFromVert)*(mountToHotEndBottomZ-bedClearanceGap)+
sin(fanAngleFromVert)*mountingHingeDia/2-
hingeLen-fanSizeIn-max(cos(camberAngle)*smallDuctH/2, smallDuctW/2);
zTrans = tan(minAngle)*xTrans+fanSize/2+smallDuctH/2; //keep the steepest angle >= minAngle deg from x y plane.
yTrans = ventedDuctsSeparationMax/2 + max(smallDuctW/2, sin(camberAngle)*smallDuctH/2);
width = fanSize/2;
nzSteps = zTrans/layerHeight;
di = 1/nzSteps;
stepZ = zTrans*di;
union()
{
for(i=[0:di:1])
{
assign(width = fanSize/2*(1-i)+i*smallDuctW, height = fanSize*(1-i)+i*smallDuctH )
{
translate([-xTrans*pow(i,2/*5*/),yTrans*((1-i)*pow(i,1.05)+i*pow(i,0.5)),zTrans*i])
difference()
{
minkowski()
{
cube([(1-i)*height,(1-i)*width,stepZ]);
rotate([0,0,camberAngle])
oval(((1-i)*outerRadius+i*height/2),((1-i)*outerRadius+i*width/2),stepZ);
}
translate([(1-i)*wall,(1-i)*wall,0])
scale([(height-2*wall)/height, (width-2*wall)/width,1])
minkowski()
{
cube([(1-i)*height,(1-i)*width,stepZ]);
rotate([0,0,camberAngle])
oval(((1-i)*outerRadius+i*height/2),((1-i)*outerRadius+i*width/2),stepZ);
}
}
}
}
translate([-xTrans,yTrans,zTrans])
mirror([0,1,0])
ventedTube(smallDuctH,smallDuctW,0.8*(ventedDuctsSeparation),fanAngleFromVert);
}
//#cylinder_ep(hingePos,[-(xTrans+smallDuctH/2),rulery,zTrans]);
}
module ventedTube(height, width, slotLen, fanAngleFromVert)
{
len = mountToFilamentHoriz+slotLen/2; //horizontal center of slot should be at nozzle
xTrans = len*sin(fanAngleFromVert)
-cos(camberAngle)*(height-width)/2; //Compensate for blend from oval to circular below, so as to keep bottom to tube horizontal
yTrans = sin(camberAngle)*(height-width)/2+sin(toeInAngle)*len;
//slotAngle = fanAngleFromVert-atan(0.5*(height-width)/len);
zTrans = len*cos(fanAngleFromVert);
nzSteps = zTrans/layerHeight;
di = 1/nzSteps;
stepZ = zTrans*di;
r1 = height/2;
r2 = width/2;
//slotWidth = r2*3.1459*45/180; //Corresponds to 45 degrees
slotWidth = r2*3.1459*slotWidthDegrees/180; //Corresponds to 45 degrees
difference() //Comment this line to see the slot airflow direction
{
union()
{
for(i = [0:di:1])
{//Blend from oval to circular to reduce volume in a linear fashion
assign(r1 = (height/2)*(1-i)+i*endCapDia/2,r2 = (width/2)*(1-i)+i*endCapDia/2)
{
//translate([xTrans*i,yTrans*(1-cos(i*90)),zTrans*i])
translate([xTrans*i,yTrans*pow(i,2),zTrans*i])
rotate([0,0,-camberAngle])
ovalTube(stepZ,r1,r2,wall);
}
}
//End cap
translate([xTrans,yTrans,zTrans])
endCap(endCapDia/2,wall,fanAngleFromVert/2);
}
//rotate([0,slotAngle,0]) //Second, rotate the slot to be parallel to the ventedTube
multmatrix(m = [ [1, 0, xTrans/len, 0],
[0, 1, (yTrans)/len, 0],
[0, 0, 1, 0],
[0, 0, 0, 1]
])
rotate([0,0,90-slotAngleFromVertical]) //First, rotate the slot to point down at an angle of 90 from horizontal
translate([-slotWidth/2,0,mountToFilamentHoriz-slotLen/2-nozzleOffsetFromBlockCenter]) //horizontal center of slot should be at nozzle])
{
hull()
{
#translate([0,0,1.3*slotMaxWidthFrac*slotLen]) cube([slotWidth,2*r2,(1-slotMaxWidthFrac)*slotLen-slotWidth]);
//Add prism at top to avoid need for support
#translate([slotWidth/2,0,slotLen-slotWidth/2]) cube([0.5,2*r2,0.5*slotWidth]);
//Add prism at bottom for symmetry
#translate([slotWidth/2,0,-slotWidth/2])
cube([0.5,2*r2,0.5*slotWidth]);
}
}
}
}
//End cap for the vented ducts
module endCap(r,wall,fanAngleFromVert)
{
len = .5*r; // 1.4
xTrans = len*sin(fanAngleFromVert);
zTrans = len*cos(fanAngleFromVert);
nzSteps = zTrans/layerHeight;
di = 1/nzSteps;
stepZ = zTrans*di;
r1 = r-wall;
for(i = [0:di:1])
{
assign(r1 = (r-wall)*(1-i)+wall)
{
translate([xTrans*i,0,zTrans*i])
ovalTube(stepZ,r1,r1,wall);
}
}
}
module coneTube(h, r1, r2, wall, center = false)
{
difference()
{
cylinder(h, r1, r2, center);
cylinder(h, r1-wall, r2-wall, center);
}
}

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scad/fan_holder_v2.scad
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/*
OPENSCAD Library file by the DoomMeister
Mounting surround for small DC fans (25 - 120mm)
Data taken from various places around the internet.
http://www.qwikflow.com/dc_fans.html
//Released under the terms of the GNU GPL v3.0
This program is free software: you can redistribute it and/or modify
it under the terms of the GNU General Public License as published by
the Free Software Foundation, either version 3 of the License, or
(at your option) any later version.
This program is distributed in the hope that it will be useful,
but WITHOUT ANY WARRANTY; without even the implied warranty of
MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
GNU General Public License for more details.
You should have received a copy of the GNU General Public License
along with this program. If not, see <http://www.gnu.org/licenses/>.
*/
//uncomment this for example
fan_mount(size=40,thick=3);
module fan_mount(size=40,thick = 4)
{
if(size == 25)
{
_fan_mount(
fan_size = 25,
fan_mounting_pitch = 20,
fan_m_hole_dia = 3,
holder_thickness = thick
);
}
if(size == 30)
{
_fan_mount(
fan_size = 30,
fan_mounting_pitch = 24,
fan_m_hole_dia = 3,
holder_thickness = thick
);
}
if(size == 40)
{
_fan_mount(
fan_size = 40,
fan_mounting_pitch = 32,
fan_m_hole_dia = 3.7,
holder_thickness = thick
);
}
if(size == 45)
{
_fan_mount(
fan_size = 45,
fan_mounting_pitch = 37,
fan_m_hole_dia = 4.3,
holder_thickness = thick
);
}
if(size == 60)
{
_fan_mount(
fan_size = 60,
fan_mounting_pitch = 50,
fan_m_hole_dia = 4.4,
holder_thickness = thick
);
}
if(size == 80)
{
_fan_mount(
fan_size = 80,
fan_mounting_pitch = 71.5,
fan_m_hole_dia = 4.4,
holder_thickness = thick
);
}
if(size == 120)
{
_fan_mount(
fan_size = 120,
fan_mounting_pitch = 105,
fan_m_hole_dia = 4.4,
holder_thickness = thick
);
}
}
//inner module
module _fan_mount(
fan_size, //nominsl size of fan
fan_mounting_pitch, //pitch between mounting holes
fan_m_hole_dia, //mounting hole diameter
holder_thickness //user defined thickness
)
{
offset1 = (fan_size-(fan_mounting_pitch + fan_m_hole_dia))/2;
offset2 = (fan_size-(fan_mounting_pitch))/2;
offset3 = offset2 + fan_mounting_pitch;
thickness = (fan_size-fan_mounting_pitch)/2;
//difference()
//{
linear_extrude(height = holder_thickness)
union()
{
difference()
{
translate([fan_m_hole_dia/2,fan_m_hole_dia/2,0])
minkowski()
{
square([fan_size - fan_m_hole_dia,fan_size - fan_m_hole_dia]);
circle(r= fan_m_hole_dia/2, $fn=20);
}
translate([offset1,offset1,0])
square([fan_mounting_pitch + fan_m_hole_dia,fan_mounting_pitch + fan_m_hole_dia]);
}
translate([offset2,offset2,0])
rotate([0,0,0])_corner_hole();
translate([offset3,offset2,0])
rotate([0,0,90])_corner_hole();
translate([offset2,offset3,0])
rotate([0,0,90])_corner_hole();
translate([offset3,offset3,0])
rotate([0,0,0])_corner_hole();
}
module _corner_hole()
{
difference(){
union(){
difference(){
square([fan_m_hole_dia + thickness,fan_m_hole_dia + thickness],center=true);
square([(fan_m_hole_dia + thickness)/2,(fan_m_hole_dia + thickness)/2],center=false);
translate([-(fan_m_hole_dia + thickness)/2,-(fan_m_hole_dia + thickness)/2])
square([(fan_m_hole_dia + thickness)/2,(fan_m_hole_dia + thickness)/2],center=false);
}
circle(r=(fan_m_hole_dia + thickness)/2, $fn=20);
}
circle(r=(fan_m_hole_dia)/2, $fn=20);
}
}
echo(offset1,offset2,thickness);
}

148
scad/shapes.scad
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/*
* OpenSCAD Shapes Library (www.openscad.org)
* Copyright (C) 2009 Catarina Mota
*
* This program is free software; you can redistribute it and/or modify
* it under the terms of the GNU General Public License as published by
* the Free Software Foundation; either version 2 of the License, or
* (at your option) any later version.
*
* This program is distributed in the hope that it will be useful,
* but WITHOUT ANY WARRANTY; without even the implied warranty of
* MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the
* GNU General Public License for more details.
*
* You should have received a copy of the GNU General Public License
* along with this program; if not, write to the Free Software
* Foundation, Inc., 59 Temple Place, Suite 330, Boston, MA 02111-1307 USA
*
*/
//box(width, height, depth);
//roundedBox(width, height, depth, factor);
//cone(height, radius);
//oval(width, height, depth);
//tube(height, radius, wall);
//ovalTube(width, height, depth, wall);
//hexagon(height, depth);
//octagon(height, depth);
//dodecagon(height, depth);
//hexagram(height, depth);
//rightTriangle(adjacent, opposite, depth);
//equiTriangle(side, depth);
//12ptStar(height, depth);
//----------------------
// size is a vector [w, h, d]
module box(size) {
cube(size, true);
}
// size is a vector [w, h, d]
module roundedBox(size, radius) {
cube(size - [2*radius,0,0], true);
cube(size - [0,2*radius,0], true);
for (x = [radius-size[0]/2, -radius+size[0]/2],
y = [radius-size[1]/2, -radius+size[1]/2]) {
translate([x,y,0]) cylinder(r=radius, h=size[2], center=true);
}
}
module cone(height, radius, center = false) {
cylinder(height, radius, 0, center);
}
module oval(w,h, height, center = false) {
scale([1, h/w, 1]) cylinder(h=height, r=w, center=center);
}
// wall is wall thickness
module tube(height, radius, wall, center = false) {
difference() {
cylinder(h=height, r=radius, center=center);
cylinder(h=height, r=radius-wall, center=center);
}
}
// wall is wall thickness
module ovalTube(height, rx, ry, wall, center = false) {
difference() {
scale([1, ry/rx, 1]) cylinder(h=height, r=rx, center=center);
scale([(rx-wall)/rx, (ry-wall)/rx, 1]) cylinder(h=height, r=rx, center=center);
}
}
// size is the XY plane size, height in Z
module hexagon(size, height) {
boxWidth = size/1.75;
for (r = [-60, 0, 60]) rotate([0,0,r]) cube([boxWidth, size, height], true);
}
// size is the XY plane size, height in Z
module octagon(size, height) {
intersection() {
cube([size, size, height], true);
rotate([0,0,45]) cube([size, size, height], true);
}
}
// size is the XY plane size, height in Z
module dodecagon(size, height) {
intersection() {
hexagon(size, height);
rotate([0,0,90]) hexagon(size, height);
}
}
// size is the XY plane size, height in Z
module hexagram(size, height) {
boxWidth=size/1.75;
for (v = [[0,1],[0,-1],[1,-1]]) {
intersection() {
rotate([0,0,60*v[0]]) cube([size, boxWidth, height], true);
rotate([0,0,60*v[1]]) cube([size, boxWidth, height], true);
}
}
}
module rightTriangle(adjacent, opposite, height) {
difference() {
translate([-adjacent/2,opposite/2,0]) cube([adjacent, opposite, height], true);
translate([-adjacent,0,0]) {
rotate([0,0,atan(opposite/adjacent)]) dislocateBox(adjacent*2, opposite, height);
}
}
}
module equiTriangle(side, height) {
difference() {
translate([-side/2,side/2,0]) cube([side, side, height], true);
rotate([0,0,30]) dislocateBox(side*2, side, height);
translate([-side,0,0]) {
rotate([0,0,60]) dislocateBox(side*2, side, height);
}
}
}
module 12ptStar(size, height) {
starNum = 3;
starAngle = 360/starNum;
for (s = [1:starNum]) {
rotate([0, 0, s*starAngle]) cube([size, size, height], true);
}
}
//-----------------------
//MOVES THE ROTATION AXIS OF A BOX FROM ITS CENTER TO THE BOTTOM LEFT CORNER
//FIXME: Why are the dimensions changed?
// why not just translate([0,0,-d/2]) cube([w,h,d]);
module dislocateBox(w,h,d) {
translate([w/2,h,0]) {
difference() {
cube([w, h*2, d+1]);
translate([-w,0,0]) cube([w, h*2, d+1]);
}
}
}

315226
stl/fanduct-e3dlite6.stl
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