fuellfix-v2/hardware/config.scad

// 3d printer specific
screw_gap = 0.3;
nut_gap = -0.2;

dispenser_rim_dia = 210; // TODO
dispenser_rim_height = 2.0; // TODO

dispenser_top_dia = 200;
dispenser_top_height = 108;
dispenser_mid_dia = 35.5;
dispenser_nozzle_top_height = 45;
dispenser_nozzle_top_dia = 35.3;
dispenser_nozzle_mid_height = 20;
dispenser_nozzle_mid_dia = 40;
dispenser_nozzle_cap_height = 17;
dispenser_nozzle_cap_dia_1 = 5.8;
dispenser_nozzle_cap_dia_2 = dispenser_nozzle_mid_dia;
dispenser_nozzle_end_length = 10;
dispenser_nozzle_end_dia_1 = 3.4;
dispenser_nozzle_end_dia_2 = dispenser_nozzle_cap_dia_1;
dispenser_wall = 3;
dispenser_handle_dia = 21;
dispenser_handle_length = 100;
dispenser_handle_angle = 38;
dispenser_height = dispenser_top_height + dispenser_nozzle_top_height + dispenser_nozzle_mid_height + dispenser_nozzle_cap_height + dispenser_nozzle_end_length;

dispenser_arm_dia = 7.0;
dispenser_arm_len = 250;
dispenser_arm_height = 75;
dispenser_arm_tab_off = 21;
dispenser_arm_tab_hole_off = 14;
dispenser_arm_handle_overlap = 20;
dispenser_arm_handle_width = 20;
dispenser_arm_handle_len = 30;
dispenser_arm_handle_height = 2;
dispenser_arm_handle_y = 10;
dispenser_arm_handle_z = 15;

dispenser_arm_angle_top = -5;
dispenser_arm_angle_bottom = 6;

disp_mount_wall = 20;
disp_mount_overlap_x = 50;
disp_mount_overlap_y = 40;
disp_mount_add_x = 20;
disp_mount_add_y = 50;
disp_mount_width = dispenser_rim_dia / 2 - disp_mount_overlap_x + disp_mount_add_x;
disp_mount_len = dispenser_rim_dia / 2 + disp_mount_overlap_y + disp_mount_add_y;
disp_mount_off_x = dispenser_rim_dia / 2 - disp_mount_overlap_x;
disp_mount_off_y = disp_mount_overlap_y;

dispenser_mount_rail_off = dispenser_rim_dia / 2 + disp_mount_add_y;

rail_wheel_height = 11;
rail_wheel_center_height = 5;
rail_wheel_outer = 24;
rail_wheel_mid = 18;
rail_wheel_inner = 5;

nema17_len = 40;
nema17_size = 42.3;
nema17_hole_off = 31.0 / 2;
nema17_hole_size = 3.0;
nema17_shaft_size = 5.0;
nema17_shaft_length = 24.0;
nema17_center_size = 22.0;
nema17_center_height = 2.0;

motor_mount_height = 8;
motor_mount_length = 35;
motor_mount_l = nema17_size + motor_mount_length;
motor_mount_hole_size_nominal = 5;
motor_mount_hole_size = motor_mount_hole_size_nominal + screw_gap;
motor_mount_hole_off = motor_mount_length - 15;

belt_width = 6;
belt_pitch = 2;
belt_thickness = 1.35;

/**********************************
 ************ Extruder ************
 **********************************/

function dia_from_teeth(teeth) = teeth * belt_pitch / 3.14159;

pulley_teeth_height = belt_width + 4;
pulley_mount_height = 5;
pulley_mount_dia = 8;
pulley_height = pulley_teeth_height + pulley_mount_height;

large_teeth = 60;
small_teeth = 20;

large_dia = dia_from_teeth(large_teeth);
small_dia = dia_from_teeth(small_teeth);
perimeter_large_wheel = large_dia * 3.14159;
perimeter_small_wheel = small_dia * 3.14159;

axis_diameter = 5.0;
axis_hole_diameter = axis_diameter + screw_gap;

// MR115 2RS
bearing_inner = axis_diameter;
bearing_outer = 11.0 + screw_gap;
bearing_height = 4.0;

belt_length = 200;
belt_length_wheels = perimeter_large_wheel / 2 + perimeter_small_wheel / 2;
belt_length_center = belt_length - belt_length_wheels;
gears_dist = belt_length_center / 2;

gear_stages = 1;

// allow room for metal pulleys
gear_stage_height = pulley_height + 15;

gear_stages_dist = (bearing_height + 1) * 2;
gearbox_wall = gear_stages_dist; //bearing_height + 1;

gearbox_gap = 2;
gearbox_height = gears_dist + large_dia + (gearbox_wall + gearbox_gap) * 2;
gearbox_width = large_dia + (gearbox_wall + gearbox_gap) * 2;
gearbox_depth = 2 * gearbox_wall + gear_stages * gear_stage_height + (gear_stages - 1) * gear_stages_dist;

echo("gearbox_depth", gearbox_depth);

extruder_travel = 60;
extruder_wall_screw = 3.0;
extruder_use_threaded_rods = true;

extruder_wall_hole_screw = extruder_wall_screw + screw_gap;
extruder_wall_hole_nut = extruder_use_threaded_rods ? extruder_wall_hole_screw : (extruder_wall_screw + nut_gap);
extruder_wall_hole_depth = extruder_use_threaded_rods ? gearbox_height : 8.0;

/***********************************
 ************** Table **************
 ***********************************/

// size of woking area
plate_x = 250;
plate_y = 350;
plate_z = 5;

plate_mount_screws_nominal = 5.0;
plate_mount_screws_distance_x = 60;
plate_mount_screws_distance_y = 80;
plate_mount_screw_hole = plate_mount_screws_nominal + screw_gap;

belt_slot_width = belt_width + 4;
belt_slot_depth = belt_thickness + 2;
belt_mount_width = belt_slot_width + 2;
belt_mount_depth = belt_slot_depth + 4;
belt_mount_full_width = belt_mount_width * 3;

y_carriage_add_material_around_holes = 10;
y_carriage_h = 10;
y_carriage_rail_dist = 6.5;

y_carriage_post_dia = 2 * 13 / sqrt(3);
y_carriage_post_screw = 5.0;
y_carriage_post_hole_off = 2;
y_carriage_post_center = 1;
y_carriage_post_screw_hole = y_carriage_post_screw + nut_gap;
y_carriage_post_len = y_carriage_rail_dist - rail_wheel_height / 2 + 10;
echo("y_carriage_post_len", y_carriage_post_len);

eccentric_height_main = 8.5;
eccentric_height_inset = 2.4;
eccentric_dia_inset = 7.3;
eccentric_dia_main = 11.5;
eccentric_hole_off = 0.75;
eccentric_screw_hole = y_carriage_post_screw_hole + 2 * eccentric_hole_off;
eccentric_height_add = y_carriage_post_len - eccentric_height_main;
eccentric_inset_wall = 15.0;
eccentric_inset_hole = eccentric_height_inset + 0.6;
eccentric_screw_hole_h = 6.5;
eccentric_screw_hole_dia = 15.0 + 2 * eccentric_hole_off;

use_custom_eccentric = true;

y_carriage_wheel_off_x = 20.4;
y_carriage_wheel_off_y = 28;

y_carriage_pulley_off = y_carriage_rail_dist - rail_wheel_height / 2 + 10;

y_carriage_x = plate_mount_screws_distance_x + 2 * y_carriage_add_material_around_holes;
y_carriage_y = plate_mount_screws_distance_y + 2 * y_carriage_add_material_around_holes;

y_carriage_wheel_x_dist = y_carriage_x - 2 * y_carriage_wheel_off_x;
y_carriage_wheel_y_dist = y_carriage_y - 2 * y_carriage_wheel_off_y;

x_carriage_holder_w = y_carriage_x;
x_carriage_holder_l = (y_carriage_y - 20) / 2;
x_carriage_holder_h = 4;
x_carriage_holder_rail_hole_dist = x_carriage_holder_w - 20;
x_carriage_holder_hole_off = x_carriage_holder_h + 10;

ideal_belt_pulley_dia = 20 - belt_thickness * 2 + y_carriage_rail_dist + belt_thickness / 4;
belt_pulley_off = y_carriage_rail_dist / 2 - belt_thickness / 4;

teethcount = round((ideal_belt_pulley_dia + belt_thickness) * 3.14159 / belt_pitch);
echo("belt pulley teeth count", teethcount);
real_belt_pulley_dia = teethcount * belt_pitch / 3.14159;
belt_pulley_width = belt_width + 4;
belt_pulley_tooth_width = belt_width + 2;

belt_pulley_rim = 1;
belt_pulley_axis_hole = nema17_shaft_size + screw_gap;
belt_pulley_fix_dia = 3.0 + nut_gap;

belt_tensioner_screw = 3.0;
belt_tensioner_screw_hole = belt_tensioner_screw + screw_gap;
belt_tensioner_wall = 5;
belt_tensioner_mount_depth = 20;
belt_tensioner_travel = 15;
belt_tensioner_moving_height = 10;
belt_tensioner_moving_len = real_belt_pulley_dia / 2 + 20;
belt_tensioner_moving_overlap = 10;
belt_tensioner_moving_gap = 0.3;
belt_tensioner_diff_len = real_belt_pulley_dia / 2 + belt_tensioner_moving_len - belt_tensioner_moving_overlap + belt_tensioner_travel + 5;
belt_tensioner_diff_width = belt_pulley_width + 2 * belt_tensioner_moving_gap + 0.5;
belt_tensioner_diff_height = belt_tensioner_moving_height + 0.5;

y_axis_travel_len = plate_y + 15;
y_axis_rail_len = y_axis_travel_len + y_carriage_y + motor_mount_length + belt_tensioner_mount_depth;

x_axis_travel_len = plate_x + 15;
x_axis_rail_len = x_axis_travel_len + y_carriage_y + motor_mount_length + belt_tensioner_mount_depth;

// TODO!
point_that_reaches_everywhere_x = -7.5;
point_that_reaches_everywhere_y = -17.5;

use_anim = true;
x_axis_position = 1.0;
y_axis_position = 0.5;

anim_pos_x = use_anim ? sin($t * 360) * 0.5 + 0.5 : x_axis_position;
anim_pos_y = use_anim ? sin($t * 360 + 90) * 0.5 + 0.5 : y_axis_position;
echo("animation position x", anim_pos_x);
echo("animation position y", anim_pos_y);

x_axis_animation_position = anim_pos_x * x_axis_travel_len;
y_axis_animation_position = anim_pos_y * y_axis_travel_len;

extruder_axis_position = 0.0;

anim_pos_extruder = use_anim ? -cos($t * 360) * 0.5 + 0.5 : extruder_axis_position;

draw_pulleys = false;

left_support_len = 200;
left_support_off = 50;
right_support_len = left_support_len;
right_support_off = left_support_off;

echo("distance between bottom support rails", x_axis_rail_len - left_support_off - right_support_off - 40, -left_support_off, -right_support_off);

bottom_support_len = 500;
bottom_support_off = 80;

use_double_supports = false;

endstop_pcb_width = 16.0;
endstop_pcb_height = 40.0;
endstop_pcb_depth = 1.6;
endstop_pcb_hole = 3.2;
endstop_pcb_hole_dist_x = 3.2;
endstop_pcb_hole_dist_y = 3.2;
endstop_pcb_hole_dist = 19.0;
endstop_pcb_switchpoint = 4.5;
endstop_mount_width = 12;
endstop_mount_depth = 5;
endstop_mount_slot_width = 6;
endstop_mount_slot_depth = 4;
endstop_mount_slot_length = 8;
endstop_mount_add_height = 15;
endstop_mount_nut_hole = 6.5;
endstop_pcb_mount_off_h = y_carriage_rail_dist + endstop_pcb_switchpoint + 2; // TODO is now -3
endstop_pcb_mount_off_d = 18; // TODO was 8
endstop_pcb_mount_off_w = endstop_mount_slot_length;

use_endstop_mount_v2 = false;

foot_screw_dia = 5.3;
foot_screw_head_dia = 10.0;
foot_screw_head_height = 7.0;
foot_nut_base_dia = foot_screw_head_dia;
foot_dia_add = 10.0;
foot_dia = max(foot_screw_dia, foot_screw_head_dia) + foot_dia_add;

carriage_spacer_height = 5;
carriage_spacer_cut = 4;
carriage_spacer_cut_x = y_carriage_x / 2 - carriage_spacer_cut;
carriage_spacer_cut_y = y_carriage_y / 2 - carriage_spacer_cut;