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Diffstat (limited to 'carriage4.scad')
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1 files changed, 398 insertions, 0 deletions
diff --git a/carriage4.scad b/carriage4.scad new file mode 100644 index 0000000..cffebcd --- /dev/null +++ b/carriage4.scad @@ -0,0 +1,398 @@ +// Carriage for 2020 aluminum extrusions and four ~24mm diameter wheels riding +// on the diagonals, with GT2 belt tightener. This works nicely with the +// ball studs and carbon fiber, magnetic, zero-backlash printer arms which +// I have for sale, and with my flying extruder. +// +// They are on my website at: http://www.MagBallArms.com +// +// Here is a link to the wheel, eccentric spacers and round spacers at +// RobotDigg.com: +// http://www.robotdigg.com/product/521/Delrin-or-SUS-Via-S-Bearing +// http://www.robotdigg.com/product/626/Openbuilds-decentration-post +// +// Alternatively you can get them from OpenBuidsPartsStore.com: +// http://openbuildspartstore.com/delrin-v-wheel-kit/ +// http://openbuildspartstore.com/eccentric-spacer/ (choose 1/4") +// +// Per carriage, you'll need: +// 4 of the above V- or W-wheels. +// 4 of the above 1/4" eccentric spacers. +// 4 M5x50 bolts. +// 4 M5 nylock nuts to secure the four axles. +// 2 3/8" ball studs. +// 2 M3 nylock nuts to secure the ball studs. +// 2 M3x35 SHCS for the tightener. +// 2 M3 nuts for the tightener. +// 1 M3x35 SHCS for the vertical post for the upper G2 belt attachment. +// 1 M3 nylock nut to secure the vertical post. +// +// Haydn Huntley +// haydn.huntley@gmail.com + + +$fn = 360/4; + +include <configuration.scad>; +include <roundedBox.scad>; + + +// All measurements in mm. +eccentricSpacerRadius = (7.1 + 0.3)/2; +eccentricSpacerHeight = 0.25 * mmPerInch; +xAxleSpacing = extrusionWidth * sqrt(2) + 19.1 - 0.35; +yAxleSpacing = 30.0; +xBody = max(xAxleSpacing + 2 * 7, ballJointSeparation + 2 * 5); +yBody = yAxleSpacing + 2 * 7; +yBodyExtra = 15.0; +zBody = 10.0; +yBallStudOffset = yAxleSpacing/2 + yBodyExtra; +xInsideBeltOffset = 5; +actualBeltWidth = 9; +beltWidth = actualBeltWidth + 1.0; +singleBeltThickness = 1.5; +doubleBeltThickness = 2.5+0.8; +beltLockHeight = 2*m3NutHeight; +m3BeltLockOffset = 4.5; +rBeltLock = 4.6; +debug = true; + +wheelWidth = 11.0; +gapBetweenCarriageAndExtrusion = 2; +gapBetweenBeltAndExtrusion = 17; +spacerRadius = 10.0/2; +tallSpacerHeight = extrusionWidth * sin(45) + gapBetweenCarriageAndExtrusion - wheelWidth/2 - 1.0; +shortSpacerHeight = tallSpacerHeight - eccentricSpacerHeight; + + +module carriage() +{ + // Draw the belts. + // The is a gap of 17mm between the belts and the aluminum extrusions. + // There should be a gap of 2mm between the carriage and extrusions. + if (debug) + for (x = [1, -1]) + translate([x*(singleBeltThickness/2+5), + 0, + 6/2 + gapBetweenBeltAndExtrusion + - gapBetweenCarriageAndExtrusion]) + %cube([singleBeltThickness, 100, actualBeltWidth], true); + + difference() + { + union() + { + // The round-cornered rectangle body. + translate([0, 0.5*yBodyExtra/2, zBody/2]) + roundedBox([xBody, yBody+0.5*yBodyExtra, zBody], 5, true); + + // Bases for the ball studs. + for (x = [1, -1]) + translate([x*ballJointSeparation/2, yBallStudOffset, 0]) + hull() + { + translate([0, 0, zBody]) + rotate([45, 0, 0]) + translate([0, 5, 2]) + translate([0, 0, 9]) + cylinder(r=10/2, h=1); + + translate([0, 0, (zBody+8)/2]) + roundedBox([10, 15, zBody+8], 5, true); + } + } + + // Place a hole in the center to lighten it. + translate([0, -7/2, zBody/2]) + roundedBox([xBody-4*7, yBody-3*7, zBody+smidge], 5, true); + + // Gracefully remove material between the round-cornered rectangle + // and the ball studs. + translate([0, yBody/2+20/2, zBody/2]) + roundedBox([min(xBody-2*10, ballJointSeparation-10), + 20, + zBody+smidge], 5, true); + + // Four holes for the M5x50 bolts for the axles for the rollers. + // Upper right. + translate([xAxleSpacing/2, yAxleSpacing/2, -smidge/2]) + m5x50(zBody+smidge); + + // Lower right. + translate([xAxleSpacing/2, -yAxleSpacing/2, -smidge/2]) + m5x50(zBody+smidge); + + // Upper left, with room for the eccentric spacer. + translate([-xAxleSpacing/2, yAxleSpacing/2, -smidge/2]) + { + m5x50(zBody+smidge); + cylinder(r=eccentricSpacerRadius, h=zBody+smidge); + } + + // Lower left, with room for the eccentric spacer. + translate([-xAxleSpacing/2, -yAxleSpacing/2, -smidge/2]) + { + m5x50(zBody+smidge); + cylinder(r=eccentricSpacerRadius, h=zBody+smidge); + } + + // Two holes for the ball studs with nut traps. + for (x = [1, -1]) + translate([x*ballJointSeparation/2, yBallStudOffset, zBody]) + rotate([45, 0, 0]) + translate([0, 5, 2]) + { + ballStud(); + if (debug) + %ballStud(); + } + + // A hole for the M3x20 vertical post, for the belt attachment. + translate([xInsideBeltOffset+singleBeltThickness/2, + yAxleSpacing/2, + -smidge/2]) + { + m3x20(20); + if (debug) + %m3x20(20); + } + } +} + + +module m5x50(h=0) +{ + cylinder(r=m5Radius, h=h); +} + + +module m3x20(h=0) +{ + // The head of the M3 SHCS. + cylinder(r=m3LooseHeadRadius, h=m3HeadHeight+1); + + // A domed vault above the head in order to print the overhang better. + translate([0, 0, m3HeadHeight+1-smidge/2]) + cylinder(r1=m3LooseHeadRadius, + r2=m3LooseRadius, + h=m3LooseHeadRadius-m3LooseRadius); + + // The SHCS's threaded shaft. + translate([0, 0, m3HeadHeight+1]) + cylinder(r=m3LooseRadius, h=h); +} + + +module ballStud() +{ + // The M3x10 threaded part. + cylinder(r=m3LooseRadius, h=10+smidge); + + // The nut to hold it. + translate([0, 0, -m3NutHeight*5]) + rotate([0, 0, 30]) + cylinder(r1=m3NutRadius+0.1, r2=m3NutRadius-0.2, h=m3NutHeight*7, $fn=6); + + // The M10 hexagonal base. + hull() + { + translate([0, 0, 10+3]) + cylinder(r=5/2, h=1, $fn=6); + translate([0, 0, 10]) + cylinder(r=11.3/2, h=1, $fn=6); + } + + // The ball at the top. + translate([0, 0, 22.2-3/8*mmPerInch/2]) + sphere(r=3/8*mmPerInch/2, $fn=24); +} + + +module upperBeltLock() +{ + difference() + { + union() + { + // Two circles joined by the area connecting them. + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, 0]) + cylinder(r=rBeltLock, h=beltLockHeight); + + // Plus an oval to widen amd strengthen the middle. + scale([2.0, 1.5, 1]) + cylinder(r=rBeltLock, h=beltLockHeight); + } + + // A hole to capture the doubled GT2 belt. + translate([0, 0, beltLockHeight/2]) + cube([doubleBeltThickness, beltWidth, beltLockHeight+smidge], true); + + // Two holes for capturing M3 nuts. + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, -smidge/2]) + { + cylinder(r=m3LooseRadius, + h=beltLockHeight+smidge); + + // M3 nut traps. + translate([0, 0, beltLockHeight-m3NutHeight]) + rotate([0, 0, 30]) + cylinder(r1=m3TightNutRadius-1.5*smidge, + r2=m3NutRadius-smidge, + h=m3NutHeight+smidge, + $fn=6); + } + } +} + + +module lowerBeltLock() +{ + difference() + { + // Two circles joined by the area connecting them. + union() + { + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, 0]) + cylinder(r=rBeltLock, h=beltLockHeight); + + // Plus an oval to widen amd strengthen the middle. + scale([2.0, 1.5, 1]) + cylinder(r=rBeltLock, h=beltLockHeight); + } + + // A hole to capture the doubled GT2 belt. + translate([0, 0, beltLockHeight/2]) + cube([doubleBeltThickness, beltWidth, beltLockHeight+smidge], true); + + // Two holes for the M3x35 SHCS. + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, -smidge/2]) + cylinder(r=m3LooseRadius, h=beltLockHeight+smidge); + } +} + + +module upperBeltLock6mm() +{ + actualBeltWidth = 6; + + difference() + { + union() + { + // Two circles joined by the area connecting them. + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, 0]) + cylinder(r=rBeltLock, h=beltLockHeight); + + // Plus an oval to widen amd strengthen the middle. + scale([2.0, 1.25, 1]) + cylinder(r=rBeltLock, h=beltLockHeight); + } + + // A hole to capture the doubled GT2 belt. + translate([0, 0, beltLockHeight/2]) + cube([doubleBeltThickness, beltWidth, beltLockHeight+smidge], true); + + // Two holes for capturing M3 nuts. + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, -smidge/2]) + { + cylinder(r1=m3LooseRadius+0.2, + r2=m3LooseRadius, + h=beltLockHeight+smidge); + + // M3 nut traps. + translate([0, 0, beltLockHeight-m3NutHeight]) + rotate([0, 0, 30]) + cylinder(r1=m3TightNutRadius-smidge, + r2=m3NutRadius, + h=m3NutHeight+smidge, + $fn=6); + } + } +} + + +module lowerBeltLock6mm() +{ + actualBeltWidth = 6; + + difference() + { + // Two circles joined by the area connecting them. + union() + { + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, 0]) + cylinder(r=rBeltLock, h=beltLockHeight); + + // Plus an oval to widen amd strengthen the middle. + scale([2.0, 1.25, 1]) + cylinder(r=rBeltLock, h=beltLockHeight); + } + + // A hole to capture the doubled GT2 belt. + translate([0, 0, beltLockHeight/2]) + cube([doubleBeltThickness, beltWidth, beltLockHeight+smidge], true); + + // Two slightly tapering holes for the M3x35 SHCS. + for (x = [1, -1]) + translate([x*m3BeltLockOffset, 0, -smidge/2]) + cylinder(r1=m3LooseRadius+0.2, + r2=m3LooseRadius, + h=beltLockHeight+smidge); + } +} + + + +module shortSpacer() +{ + difference() + { + cylinder(r=spacerRadius, h=shortSpacerHeight); + + translate([0, 0, -smidge/2]) + cylinder(r=m5LooseRadius, h=shortSpacerHeight+smidge); + } +} + + +module tallSpacer() +{ + difference() + { + cylinder(r=spacerRadius, h=tallSpacerHeight); + + translate([0, 0, -smidge/2]) + cylinder(r=m5LooseRadius, h=tallSpacerHeight+smidge); + } +} + + +carriage(); + +color("green") +translate([-8, -3, 0]) +rotate([0, 0, 90]) +upperBeltLock(); + +color("red") +translate([8, -3, 0]) +rotate([0, 0, 90]) +lowerBeltLock(); + +for (x = [1:2]) + for (y = [0:1]) + color("blue") + translate([x*-12+5, -(yBody/2+8+y*12), 0]) + shortSpacer(); + +for (x = [1:2]) + for (y = [0:1]) + color("purple") + translate([x*12-5, -(yBody/2+8+y*12), 0]) + tallSpacer(); |