fuellfix-v2/hardware/gearbox.scad

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

extruder_slot_gap_vert = 1;
extruder_slot_gap_horz = 2;

extruder_real_nut_dia = 6.3;
extruder_add_nut_height = 5.0;

extruder_arm_dia = extruder_travel + extruder_slot_gap_vert;
extruder_arm_post_dia = 9.5;
extruder_arm_width = 15.0;
extruder_arm_axis_dia = 20.0;
extruder_arm_flare_off = 3.0;
extruder_arm_axis_h = 10.0;
extruder_arm_post_h = 20.0;
extruder_arm_off = 10;

actuator_slot_w = extruder_arm_dia + bearing_outer + extruder_slot_gap_horz;
actuator_slot_h = bearing_outer + extruder_slot_gap_vert;
actuator_width = actuator_slot_w + 20;
actuator_height = actuator_slot_h + 20;
actuator_wall = bearing_height + 2;

actuator_rod_len = 100;
actuator_rod_len_add_bottom = 50;

show_extruder_maximum_positions = false;
extruder_maximum_positions = 12;

linear_bearing_inner = 8.2;
linear_bearing_outer = 15.0;
linear_bearing_height = 25.0;

linear_mount_inner = linear_bearing_outer + 0.5;
linear_mount_wall = 3.0;
linear_mount_outer = linear_mount_inner + 2 * linear_mount_wall;
linear_mount_height = linear_bearing_height;
linear_mount_width = 40.0;
linear_mount_cut = 5.0;
linear_mount_tab_off = linear_mount_wall;
linear_mount_tab_width = 7.0;

linear_mount_add_width = 8.0;
linear_mount_add_height = 35.0;

actuator_rod = 8.0;
actuator_rod_wall = 2.5;
actuator_rod_width = actuator_rod + 2 * actuator_rod_wall;
actuator_rod_h = 6.0;
actuator_rod_inset = 3.0;
actuator_bearing_off = 12.5;
actuator_bearing_dist = extruder_arm_off + extruder_arm_post_h - actuator_wall + actuator_rod_width - 1.5; // TODO not correct formula, but matches for now

gearbox_spacer = gearbox_wall / 2;

gb_endstop_off = 21;
gb_endstop_slit_len = 1.0;

$fn = 42;

echo("extruder gear factor", pow(large_teeth / small_teeth, gear_stages));

module linear_bearing() {
    difference() {
        cylinder(d = linear_bearing_outer, h = linear_bearing_height);
        
        translate([0, 0, -1])
        cylinder(d = linear_bearing_inner + 1, h = linear_bearing_height + 2);
    }
}

module gear_pulley(dia, teeth) {
    if (draw_pulleys) {
        gt2_2mm_pulley(teeth, pulley_teeth_height);
    } else {
        cylinder(d = dia, h = pulley_teeth_height);
    }
    
    translate([0, 0, pulley_teeth_height])
    cylinder(d = pulley_mount_dia, h = pulley_mount_height);
}

module gear_stage() {
    translate([0, gears_dist / 2, (gear_stage_height - pulley_height) / 2]) {
        %color("yellow")
        rotate([0, 0, -acos(anim_pos_extruder * -2 + 1)])
        gear_pulley(large_dia, large_teeth);
        
        %color("yellow")
        translate([0, -gears_dist, 0])
        rotate([0, 0, -acos(anim_pos_extruder * -2 + 1)])
        gear_pulley(small_dia, small_teeth);
    }
}

module center_plate() {
    difference() {
        cube([gearbox_width, gearbox_height, gear_stages_dist]);
        
        for(i = [-1, 1])
        translate([gearbox_width / 2, gearbox_height / 2 + i * gears_dist / 2, 0]) {
            for(j = [-1, gear_stages_dist - bearing_height])
            translate([0, 0, j])
            cylinder(d = bearing_outer, h = bearing_height + 1);
        
            translate([0, 0, -1])
            cylinder(d = axis_hole_diameter, h = gear_stages_dist + 2);
        }
        
        for (i = [0, gearbox_width - gear_stages_dist])
        for (j = [-1, gearbox_height - extruder_wall_hole_depth])
        translate([gear_stages_dist / 2 + i, j, gear_stages_dist / 2])
        rotate([-90, 0, 0])
        cylinder(d = extruder_wall_hole_nut, h = extruder_wall_hole_depth + 1);
    }
}

module outer_plate() {
    difference() {
        cube([gearbox_width, gearbox_height, gearbox_wall]);
        
        for (i = [0, gearbox_width - gearbox_wall])
        for (j = [-1, gearbox_height - extruder_wall_hole_depth])
        translate([gearbox_wall / 2 + i, j, gearbox_wall / 2])
        rotate([-90, 0, 0])
        cylinder(d = extruder_wall_hole_nut, h = extruder_wall_hole_depth + 1);
    }
}

module gb_front_wall() {
    difference() {
        color("cyan")
        translate([-gearbox_width / 2, -gearbox_height / 2, -gearbox_wall])
        outer_plate();
        
        for (i = [-1, 1])
        translate([0, i * gears_dist / 2, -bearing_height])
        outer_bearings();
    }
}

module gb_back_wall() {
    difference() {
        color("cyan")
        translate([-gearbox_width / 2, -gearbox_height / 2, gear_stage_height * gear_stages + gear_stages_dist * (gear_stages - 1)])
        outer_plate();
        
        translate([-gearbox_width / 2, -gearbox_height / 2, gear_stage_height * gear_stages + gear_stages_dist * (gear_stages - 1)])
        translate([0, (gear_stages % 2) ? 0 : gears_dist, 0])
        translate([(gearbox_width - nema17_size) / 2, -nema17_size / 2 + (gearbox_height - gears_dist) / 2, 0]) {
            nema17_holes_face(3, motor_mount_height + 5, nema17_hole_size + screw_gap);
            
            translate([nema17_size / 2, nema17_size / 2, -1])
            cylinder(d = nema17_center_size + 2, h = gearbox_wall + 2);
        }
    
        for (i = [-1, 1])
        translate([0, i * gears_dist / 2, -bearing_height])
        outer_bearings();
    }
}

module gearbox() {
    gb_back_wall();
    gb_front_wall();

    %color("yellow")
    translate([0, (gear_stages % 2) ? 0 : gears_dist, 0])
    translate([-gearbox_width / 2, -gearbox_height / 2, gear_stage_height * gear_stages + gear_stages_dist * (gear_stages - 1)])
    translate([0, nema17_size, nema17_len + gearbox_wall])
    translate([(gearbox_width - nema17_size) / 2, -nema17_size / 2 + (gearbox_height - gears_dist) / 2, 0])
    rotate([180, 0, 0])
    nema17(nema17_len);

    for (i = [0 : gear_stages - 1])
    translate([0, 0, i * (gear_stage_height + gear_stages_dist)])
    rotate([0, 0, i * 180]) {
        %gear_stage();
        
        color("cyan")
        if (i < (gear_stages - 1))
        translate([-gearbox_width / 2, -gearbox_height / 2, gear_stage_height])
        center_plate();
    }
}

module outer_bearings() {
    cylinder(d = bearing_outer, h = bearing_height + 0.1);
    
    translate([0, 0, -gearbox_wall + bearing_height - 1])
    cylinder(d = axis_hole_diameter, h = gear_stages * gear_stage_height + gearbox_wall * 2 + gear_stages_dist * (gear_stages - 1) + 2);
    
    translate([0, 0, gear_stage_height * gear_stages + gear_stages_dist * (gear_stages - 1) + bearing_height - 0.1])
    cylinder(d = bearing_outer, h = bearing_height + 0.1);
}

module linear_bearing_mount(w = linear_mount_width) {
    %color("magenta")
    linear_bearing();
    
    difference() {
        color("green")
        hull() {
            cylinder(d = linear_mount_outer, h = linear_mount_height);
            
            translate([-w / 2, -(linear_mount_wall + linear_mount_outer) / 2, 0])
            cube([w, linear_mount_wall, linear_mount_height]);
        }
        
        translate([0, 0, -1])
        cylinder(d = linear_mount_inner, h = linear_mount_height + 2);
        
        translate([-linear_mount_cut / 2, 0, -1])
        cube([linear_mount_cut, linear_mount_outer, linear_mount_height + 2]);
    }
    
    for (i = [1, -1])
    scale([i, 1, 1])
    translate([linear_mount_cut / 2, linear_mount_outer / 2 - linear_mount_tab_off, 0])
    difference() {
        color("green")
        cube([linear_mount_wall, linear_mount_tab_width + linear_mount_tab_off, linear_mount_height]);
        
        for (i = [1, 3])
        translate([-1, linear_mount_tab_off * 3 / 4 + linear_mount_tab_width / 2, linear_mount_height / 4 * i])
        rotate([0, 90, 0])
        cylinder(d = extruder_wall_hole_screw, h = linear_mount_wall + 2);
    }
}

module top_cover_holes(h, nuts = 0) {
    for (i = [0, gearbox_width - gearbox_wall])
    for (j = [gearbox_wall / 2, gearbox_depth - gearbox_wall / 2])
    translate([gearbox_wall / 2 + i, -1, j])
    rotate([-90, 0, 0])
    if (nuts)
    rotate([0, 0, 360 / 12])
    cylinder(d = extruder_real_nut_dia, h = h + 2, $fn = 6);
    else
    cylinder(d = extruder_wall_hole_screw, h = h + 2);
    
    for (i = [0, gearbox_width - gear_stages_dist])
    if (gear_stages > 1)
    for (j = [1 : gear_stages - 1])
    translate([gear_stages_dist / 2 + i, -1, j * (gear_stage_height + gear_stages_dist) + gear_stages_dist / 2])
    rotate([-90, 0, 0])
    cylinder(d = extruder_wall_hole_screw, h = h + 2);
}

module top_cover_plate(variant = 0) {
    difference() {
        if (variant == 0) {
            color("green")
            translate([0, 0, -linear_mount_add_width])
            cube([gearbox_width, gearbox_wall, gearbox_depth + linear_mount_add_width]);
        } else if (variant == 1) {
            color("green")
            cube([gearbox_width, gearbox_wall, gearbox_depth]);
        } else if (variant == 2) {
            color("red")
            cube([gearbox_width, gearbox_spacer, gearbox_depth]);
        } else {
            color("red")
            translate([-endstop_mount_slot_depth, 0, 0])
            cube([gearbox_width + endstop_mount_slot_depth, gearbox_spacer, gearbox_depth]);
        }
        
        if (variant == 1) {
            top_cover_holes(gearbox_wall + actuator_bearing_off);
        } else {
            top_cover_holes(gearbox_wall);
        }
    }
}

module top_cover(variant) {
    top_cover_plate(variant);
    
    if (variant == 0) {
        translate([gearbox_width / 2, gearbox_wall + actuator_bearing_off, -actuator_bearing_dist])
        rotate([-90, 0, 0])
        linear_bearing_mount();
    } else if (variant == 1) {
        for (i = [-1, 1])
        translate([gearbox_width / 2 + i * gearbox_width / 4, gearbox_wall + actuator_bearing_off, -actuator_bearing_dist])
        rotate([-90, 0, 0])
        linear_bearing_mount(gearbox_width / 2);
    }
    
    color("green")
    difference() {
        hull() {
            if (variant == 0) {
                translate([(gearbox_width - linear_mount_width) / 2, gearbox_wall + actuator_bearing_off, (linear_mount_wall + linear_mount_outer) / 2 - linear_mount_wall - actuator_bearing_dist])
                cube([linear_mount_width, linear_mount_height, linear_mount_wall]);
            } else if (variant == 1) {
                translate([0, gearbox_wall + actuator_bearing_off, (linear_mount_wall + linear_mount_outer) / 2 - linear_mount_wall - actuator_bearing_dist])
                cube([gearbox_width, linear_mount_height, linear_mount_wall]);
            }
            
            if (variant == 0) {
                translate([0, gearbox_wall, -linear_mount_add_width])
                cube([gearbox_width, linear_mount_add_height, linear_mount_add_width]);
            } else if (variant == 1) {
                translate([0, gearbox_wall - 1, 0])
                cube([gearbox_width, extruder_add_nut_height + 1, gearbox_depth]);
            }
        }
        
        if (variant == 1) {
            translate([0, gearbox_wall - 2, 0])
            top_cover_holes(actuator_bearing_off + linear_mount_height, 1);
        }
    }
    
    if (variant == 3) {
        difference() {
            union() {
                translate([-endstop_pcb_depth - endstop_mount_slot_depth, gb_endstop_off, 0])
                rotate([180, 0, 90]) {
                    %color("yellow")
                    endstop_pcb();
                    
                    color("red")
                    hull()
                    for (i = [0, 1])
                    translate([0, endstop_pcb_depth, endstop_pcb_height - endstop_pcb_hole_dist_y - i * endstop_pcb_hole_dist - endstop_mount_slot_width / 2])
                    cube([endstop_mount_slot_length, endstop_mount_slot_depth, endstop_mount_slot_width]);
                }
                
                color("red")
                hull() {
                    translate([-endstop_mount_slot_depth, 0, 0])
                    cube([endstop_mount_slot_depth, gearbox_spacer * 2, gearbox_depth]);
                    
                    translate([-endstop_mount_slot_depth, gb_endstop_off, -endstop_pcb_height + endstop_pcb_hole_dist_y + endstop_pcb_hole_dist])
                    cube([endstop_mount_slot_depth, endstop_mount_slot_length, endstop_pcb_height - endstop_pcb_hole_dist_y - endstop_pcb_hole_dist]);
                }
            }
            
            // hole slots for endstop pcb
            translate([-endstop_pcb_depth - endstop_mount_slot_depth, gb_endstop_off, 0])
            rotate([180, 0, 90])
            for (i = [0, 1])
            translate([endstop_pcb_hole_dist_x, 1, endstop_pcb_height - endstop_pcb_hole_dist_y - i * endstop_pcb_hole_dist])
            rotate([-90, 0, 0]) {
                for (j = [-1, 1])
                translate([-j * gb_endstop_slit_len, 0, 0])
                cylinder(d = endstop_pcb_hole, h = endstop_mount_slot_depth + 1);
                
                translate([-gb_endstop_slit_len, -endstop_pcb_hole / 2, 0])
                cube([2 * gb_endstop_slit_len, endstop_pcb_hole, endstop_mount_slot_depth + 1]);
            }
        }
    }
}

module gearbox_assembly() {
    gearbox();
    
    // spacers
    for (i = [0, 1])
    translate([-gearbox_width / 2, gearbox_height / 2 - i * (gearbox_height + gearbox_spacer), -gearbox_wall])
    top_cover(-i + 3);
    
    // top and bottom covers
    for (i = [0, 1])
    translate([-gearbox_width / 2, gearbox_height / 2 - i * (gearbox_height + gearbox_wall) - (i * 2 - 1) * gearbox_spacer, -gearbox_wall])
    top_cover(-i + 1);
    
    %color("grey")
    for (i = [-1, 1])
    translate([0, i * gears_dist / 2, -gearbox_wall + 1])
    cylinder(d = axis_diameter, h = gear_stages * gear_stage_height + gearbox_wall * 2 + gear_stages_dist * (gear_stages - 1) - 2);
}

module bearing() {
    difference() {
        cylinder(d = bearing_outer, h = bearing_height);
        
        translate([0, 0, -1])
        cylinder(d = bearing_inner, h = bearing_height + 2);
    }
}

module extruder_arm() {
    difference() {
        color("blue")
        union() {
            // post for axis
            cylinder(d = extruder_arm_axis_dia, h = extruder_arm_axis_h);
            
            // lever body
            translate([-extruder_arm_width / 2, 0, 0])
            cube([extruder_arm_width, extruder_arm_dia / 2, extruder_arm_axis_h]);
            
            translate([0, extruder_arm_dia / 2, 0]) {
                // lever body
                cylinder(d = extruder_arm_width, h = extruder_arm_axis_h);
                
                // post for bearing
                translate([0, 0, extruder_arm_axis_h])
                cylinder(d1 = extruder_arm_width, d2 = extruder_arm_post_dia, h = extruder_arm_post_h - extruder_arm_axis_h - extruder_arm_flare_off);
                
                translate([0, 0, extruder_arm_axis_h + (extruder_arm_post_h - extruder_arm_axis_h - extruder_arm_flare_off)])
                cylinder(d = extruder_arm_post_dia, h = extruder_arm_flare_off);
            }
        }
        
        // holes for axis, bearing post
        for (i = [0, 1])
        translate([0, i * extruder_arm_dia / 2, -1])
        cylinder(d = axis_hole_diameter, h = extruder_arm_post_h + 2);
        
        // holes for grub screws
        for(i = [-90, 90])
        translate([0, 0, extruder_arm_axis_h / 2])
        rotate([90, 0, i])
        cylinder(d = belt_pulley_fix_dia, h = extruder_arm_axis_dia);
    }
            
    // bearing
    %color("yellow")
    translate([0, extruder_arm_dia / 2, extruder_arm_post_h + 1])
    bearing();
    
    // axis
    %color("grey")
    translate([0, 0, -extruder_arm_off])
    cylinder(d = axis_diameter, h = extruder_arm_off + extruder_arm_axis_h);
}

module extruder_actuator() {
    difference() {
        color("orange")
        union() {
            cube([actuator_width, actuator_wall, actuator_height]);
            
            for (i = [0, 1])
            for (j = [1, -1])
            translate([i * actuator_width, 0, i * actuator_height])
            rotate([0, i * 180, 0])
            hull() {
            //union() {
                cube([actuator_width, actuator_wall, (actuator_height - actuator_slot_h) / 2]);
                    
                translate([(actuator_width - actuator_rod_width) / 2 + i * gearbox_width / 4 * j, actuator_wall - actuator_rod_width, -actuator_rod_h])
                cube([actuator_rod_width, actuator_rod_width, actuator_rod_h]);
            }
        }
        
        // slot for bearing
        translate([(actuator_width - actuator_slot_w) / 2, -1, (actuator_height - actuator_slot_h) / 2])
        cube([actuator_slot_w, actuator_wall + actuator_rod_width + 2, actuator_slot_h]);
        
        // holes for rod
        for (i = [0, 1])
        for (j = [1, -1])
        translate([actuator_width / 2 + i * gearbox_width / 4 * j, actuator_wall - actuator_rod_width / 2, -actuator_rod_h - 1 + i * (actuator_height + actuator_rod_h / 2 + 1)])
        cylinder(d = actuator_rod, h = actuator_rod_h + actuator_rod_inset + 1);
        
        // holes for rod grub screws
        for (i = [0, 1])
        for (j = [1, -1])
        for (r = [-45, 45, 180])
        translate([actuator_width / 2 + i * gearbox_width / 4 * j, actuator_wall - actuator_rod_width / 2, -actuator_rod_h / 2 + i * (actuator_height + actuator_rod_h)])
        rotate([90, 0, r])
        cylinder(d = belt_pulley_fix_dia, h = actuator_rod_width);
    }
    
    // rods
    %color("yellow")
    for (i = [0, 1])
    for (j = [1, -1])
    translate([actuator_width / 2 + (-i + 1) * gearbox_width / 4 * j, actuator_rod_width / 2 + actuator_wall - actuator_rod_width, actuator_height + i * (-actuator_height - actuator_rod_len - actuator_rod_len_add_bottom) + (i - 1) * actuator_rod_inset])
    cylinder(d = actuator_rod, h = actuator_rod_len + i * actuator_rod_len_add_bottom + actuator_rod_inset);
}

module extruder() {
    translate([0, gearbox_depth - gearbox_wall, gearbox_height / 2 + gearbox_wall])
    rotate([90, 0, 0])
    translate([0, 0, gearbox_depth - gearbox_wall * 2])
    rotate([0, 180, 0])
    gearbox_assembly();
    
    translate([0, -extruder_arm_off, gearbox_wall + gearbox_height / 2 + gears_dist / 2])
    rotate([90, 0, 0])
    if (show_extruder_maximum_positions) {
        for (i = [0 : 360 / extruder_maximum_positions : 360])
        rotate([0, 0, i])
        extruder_arm();
    } else {
        rotate([0, 0, use_anim ? ($t * -360) : (extruder_axis_position * -180)])
        extruder_arm();
    }
    
    translate([-actuator_width / 2, -actuator_wall - extruder_arm_post_h - extruder_arm_off + 1, -actuator_height / 2 + gearbox_wall + gearbox_height / 2 + gears_dist / 2 + extruder_arm_dia / 2])
    if (show_extruder_maximum_positions) {
        for (i = [0 : 2 / extruder_maximum_positions : 1])
        translate([0, 0, -i * extruder_arm_dia])
        extruder_actuator();
    } else {
        translate([0, 0, -anim_pos_extruder * extruder_arm_dia])
        extruder_actuator();
    }
}

//gb_back_wall();
//gb_front_wall();
//center_plate();
//top_cover(0);
//top_cover(1);
//top_cover(2);
//top_cover(3);
//gearbox_assembly();

//extruder_arm();
//extruder_actuator();

extruder();