Wilson II initial commit

scad/x-end.scad

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+// Wilson II X Ends
+// By M. Rice
+// GNU GPL v3
+// Adapted from design by Josef Průša <iam@josefprusa.cz> and contributors
+// http://www.reprap.org/wiki/Prusa_Mendel
+// http://prusamendel.org
+
+include <configuration.scad>
+
+rod_distance = 50;       // vertical distance between X axis smooth rods (was 45mm on original prusa i3 xends)
+pushfit_d = 10.3;        // slightly larger than the rods themselves to accomodate extrusion
+bearing_diameter = 19;   // 19=LM10UU 15=LM8UU
+bearing_cut_extra = 0.4; // extra cut for linear bearings so they are not too tight.
+thinwall = 3;            // thickness of the wall that holds in the linear bearings
+height = rod_distance+15;// height of the x ends
+
+center_z = 30.25 -1;
+tensioner_size_z = 12;
+
+bearing_size = bearing_diameter + 2 * thinwall;
+
+// MODULE -------------------------------------
+module vertical_bearing_base(){
+ translate(v=[-2-bearing_size/4,0,height/2]) cube(size = [4+bearing_size/2,bearing_size,height], center = true);
+ cylinder(h = height, r=bearing_size/2, $fn = 90);
+}
+
+// MODULE -------------------------------------
+module vertical_bearing_holes(){
+  #translate(v=[0,0,-4]) cylinder(h = height+3, r=bearing_diameter/2 + bearing_cut_extra, $fn = 60);
+  translate(v=[0,0,height-4]) cylinder(h=10,r=bearing_diameter/2-1,$fn=60);
+  
+  // the slit cut along the vertical bearing holder for some flex
+  rotate(a=[0,0,80]) translate(v=[8,0,27]) cube(size = [10,5 ,height+13], center = true);
+
+  translate([0,0,-1]) cylinder(h=9,r1=bearing_diameter/2+thinwall/2+1,r2=4,$fn=60);
+
+}
+
+// MODULE -------------------------------------
+module x_end_base(){
+  // Main block
+  height = rod_distance + 15;
+  translate(v=[-15,-10,height/2]) cube(size = [17,45,height], center = true);
+
+  // Bearing holder
+  vertical_bearing_base();	
+
+  // thing to hold the brass nut
+  translate(v=[-3.5,-22,4]) cube(size=[7.8,20,8],center=true);
+
+  translate(v=[5.5,-24,4]) cylinder(h=8,r=12.5,$fn=50,center=true);
+              
+
+}
+
+// MODULE -------------------------------------
+module x_end_holes(){
+ vertical_bearing_holes();
+ // Belt hole
+ translate(v=[-1,0,0]){
+ // Stress relief
+ translate(v=[-5.5-10+1.5,-10-1,30]) cube(size = [20,1,28], center = true);
+ difference(){
+	translate(v=[-5.5-10+1.5,-10,30]) cube(size = [10,46,28], 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);
+   }
+ }
+ 
+ // Bottom pushfit rod
+ translate(v=[-15,-41.5,7.5]) rotate(a=[-90,0,0]) pushfit_rod(pushfit_d,50);
+ // Top pushfit rod
+ translate(v=[-15,-41.5,rod_distance+7.5]) rotate(a=[-90,0,0]) pushfit_rod(pushfit_d,50);
+
+ // the holes for the brass nut
+ translate(v=[5.5,-24,4]) // <-- This is the offset from the smooth rod to the threaded rod (5.5,-24)
+     union() { 
+               // center post of brass nut
+                   cylinder(h=10,r=5.45,$fn=50,center=true);
+                   // holes for m3 screws in brass nut
+                   #translate(v=[8,0,0]) cylinder(h=12,r=1.8,$fn=20,center=true);
+                   #rotate([0,0,90]) translate(v=[8,0,0]) cylinder(h=12,r=1.8,$fn=20,center=true);
+                   #rotate([0,0,180]) translate(v=[8,0,0]) cylinder(h=12,r=1.8,$fn=20,center=true);
+                   #rotate([0,0,270]) translate(v=[8,0,0]) cylinder(h=12,r=1.8,$fn=20,center=true);
+           }
+
+}
+
+// MODULE -------------------------------------
+module pushfit_rod(diameter,length){
+ // intentionally making the holes oblong in the Z direction to help with binding of the X axis
+ translate([0,-0.2,0])  cylinder(h = length, r=diameter/2, $fn=30);
+ translate([0,0.2,0])  cylinder(h = length, r=diameter/2, $fn=30);
+}
+
+// X END IDLER -----------------------------------------------------------
+idler_offs_z = -1; // negative here means "up" when installed
+idler_offs_y = 7;
+M4_head_d = 8;
+
+module x_end_idler_base(){
+ x_end_base();
+}
+
+module x_end_idler_holes(){
+ x_end_holes();
+ translate([0,idler_offs_y,idler_offs_z]) {
+   translate(v=[0,-22,30.25]) { 
+    translate(v=[0,0,0])   rotate(a=[0,-90,0]) cylinder(h = 80, r=idler_bearing_inner_d/2+.3, $fn=30);
+    translate(v=[6,0,0])   rotate(a=[0,-90,0]) cylinder(h = 12.5, r=M4_head_d/2+.1, $fn=30);
+    translate(v=[-22,0,0]) rotate(a=[0,-90,0]) rotate(a=[0,0,30]) cylinder(h = 80, r=idler_bearing_inner_d, $fn=6);   
+
+    // create a notch for the X tensioner, to improve the length of travel available
+    translate(v=[-10,-20,1]) #difference() { rotate(a=[45,0,0])  cube(size=[30,22,22],center=true); 
+                                             translate(v=[0,14,0]) cube(size=[31,4,8],center=true); }
+   }
+ }
+}
+ 
+// Final part
+module x_end_idler(){
+ mirror([0,1,0]) union() { 
+      difference(){
+  x_end_idler_base();
+  x_end_idler_holes();
+      }
+
+difference() { 
+union() { 
+  // added ridges to keep the tensioner from pitching
+  translate(v=[-10,1,center_z-tensioner_size_z/2 - .5]) rotate([0,0,90]) rotate([45,0,0]) cube(size=[20,1.25,1.25],center=true);
+  translate(v=[-10,1,center_z+tensioner_size_z/2 + .5]) rotate([0,0,90]) rotate([45,0,0]) cube(size=[20,1.25,1.25],center=true);
+  translate(v=[-20,1,center_z-tensioner_size_z/2 - .5]) rotate([0,0,90]) rotate([45,0,0]) cube(size=[20,1.25,1.25],center=true);
+  translate(v=[-20,1,center_z+tensioner_size_z/2 + .5]) rotate([0,0,90]) rotate([45,0,0]) cube(size=[20,1.25,1.25],center=true);
+} 
+#translate(v=[0,0,-4]) cylinder(h = height+3, r=bearing_diameter/2 + bearing_cut_extra, $fn = 60);
+}
+}
+}
+
+// X END MOTOR ------------------------------------------------------------
+offs_adjuster_y = 5.5;
+adj_block_x = 12;
+adj_block_y = 10;
+adj_block_z = 32;
+motor_offs_z = 0;
+screw_head_r = 3.5;
+
+module adjustomatic() { // small holder for a M3 screw pointing down toward the Z endstop
+
+   difference() {     
+       translate(v=[-(15+17/2+adj_block_x/2),offs_adjuster_y,height-adj_block_z/2]) 
+          cube(size=[adj_block_x,adj_block_y,adj_block_z],center=true);
+       
+       translate(v=[-(15+17/2+adj_block_x/2)-5,offs_adjuster_y,height-adj_block_z/2-8]) 
+         rotate([0,-30,0]) cube(size=[adj_block_x,adj_block_y+2,adj_block_z],center=true);
+
+       translate(v=[-(15+17/2+adj_block_x/2-1),offs_adjuster_y,height-adj_block_z/2-3]) 
+          cube(size=[adj_block_x,adj_block_y-2,adj_block_z-2],center=true);
+
+       translate(v=[-(15+17/2+adj_block_x/2),offs_adjuster_y,height-adj_block_z/2+14]) 
+           {
+         rotate([0,0,30]) #cylinder(h = 4, r = 7.5/2 , $fn = 6);
+         translate([0,0,-20]) #cylinder(h=30,r=2,$fn=16);
+}
+
+   }
+
+}
+
+// the endstop mount will be translated by this much (negative values mean it moves away 
+// from the motor and toward the X carriage, giving more room for leads and also extra space
+// for the auto bedleveling servo housing which is on this side of the extruder):
+endstop_sw_offs_adjust = -5;
+
+module pocket_endstop() // endstop holder grafted onto the side toward the rods
+{
+  translate([-7,-50,0]) 
+    union() {
+      // angled wall that attaches to the endstop holder
+      translate([-1,18,0]) rotate([0,0,-30]) cube(size=[8.5,2,22]);
+      // little bit of extra support at the bottom corner 
+      translate([-1.5,15.,2]) rotate([0,90,0]) cube(size=[2,3,10]);
+      
+      difference() {
+       translate([-1.5,endstop_sw_offs_adjust,0]) cube(size=[9,20.5,22]);
+           
+       translate([-2,endstop_sw_offs_adjust,1]) cube(size=[7,21,22]);
+       #translate([0,15.5,8]) cube(size=[10,5,20]);
+
+       // screw holes for endstop switch
+       translate([-2,7+endstop_sw_offs_adjust,1.5+5.5]) rotate([0,90,0]) cylinder(r=1.5,h=15);
+       translate([-2,7+endstop_sw_offs_adjust,1.5+5.5+9.5]) rotate([0,90,0]) cylinder(r=1.5,h=15);
+      }
+    }
+}
+
+module x_end_motor_base(){
+   x_end_base();
+   // motor arm
+   translate(v=[-15,31,26.5+motor_offs_z]) cube(size = [17,44,53], center = true);
+   // z stop adjuster
+   adjustomatic();
+   // x endstop holder
+   pocket_endstop();
+
+}
+
+module x_end_motor_holes(){
+ x_end_holes();
+ // Position to place
+ translate(v=[-1,32,30.25+motor_offs_z]){
+  // Belt hole
+  translate(v=[-14,1,0]) cube(size = [10,46,22], center = true);
+  // Motor mounting holes
+  translate(v=[20,-15.5,-15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 70, r=1.8, $fn=30);
+  translate(v=[1,-15.5,-15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 12, r=screw_head_r, $fn=30);
+ 
+
+  translate(v=[20,-15.5,15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 70, r=1.8, $fn=30);
+  translate(v=[1,-15.5,15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 12, r=screw_head_r, $fn=30);
+
+
+  translate(v=[20,15.5,-15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 70, r=1.8, $fn=30);
+  translate(v=[1,15.5,-15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 12, r=screw_head_r, $fn=30);
+
+
+  translate(v=[20,15.5,15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 70, r=1.8, $fn=30);
+  translate(v=[1,15.5,15.5]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 12, r=screw_head_r, $fn=30);
+
+  // Material saving cutout 
+  translate(v=[-10,12,10]) cube(size = [60,42,42], center = true);
+
+  // Material saving cutout
+  translate(v=[-10,40,-30]) rotate(a=[45,0,0])  cube(size = [60,42,42], center = true);
+  // Motor shaft cutout
+  translate(v=[0,0,0]) rotate(a=[0,-90,0]) rotate(a=[0,0,90]) cylinder(h = 70, r=17, $fn=6);
+
+  // zip tie retainer for securing end stop wiring
+  translate([-5,-63,16]) difference() { cylinder(r=4.5,h=4,$fn=16);
+                                          translate([0,0,-1]) cylinder(r=2.5,h=7,$fn=16);
+                                        }
+
+  #translate([-5,-48,34]) rotate([90,0,0]) difference() { cylinder(r=4.5,h=4,$fn=16,center=true);
+                                          translate([0,0,-1]) cylinder(r=2.5,h=7,$fn=16,center=true);
+                                        }
+
+
+ }
+}
+
+module x_end_motor_sr() {
+    difference() { 
+       cube(size=[8,12,10]);
+       #translate([4,11.5,9]) rotate([0,90,0]) 
+               difference() { cylinder(r=4.5,h=4,$fn=16,center=true);
+                              translate([0,0,-1]) cylinder(r=2.5,h=7,$fn=16,center=true);
+               }
+
+        #translate([9,10.6,10]) rotate([0,45,90]) cube(size=[2,11,2]);
+    }
+}
+
+// Final part
+module x_end_motor(){
+ difference(){
+  x_end_motor_base();
+  x_end_motor_holes();
+ }
+   // strain relief (zip tie point) below the motor 
+   translate([-23.5,9,53]) x_end_motor_sr(); 
+
+}
+
+// Make parts
+//x_end_idler();
+translate([40,0,0]) rotate([0,0,180]) x_end_motor();
+
+
+
+
+
+
+