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45 degree integrated top and motor frames. #5

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01e6a65
Integrated versions of frame_motor/corner piece and frame_cheek,
drogge Mar 24, 2013
e816f81
Socket for ball and socket diagonal rod connection
drogge Apr 10, 2013
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130 changes: 130 additions & 0 deletions frame_integrated_45.scad
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// 2013-02-22 This file is still somewhat experimental
// and may go through more changes in the near future.

include <configuration.scad>;

$fn=24;
extrusion = 15;
height = 43;
roundness=6;

corner_rad = 43.5;
corner_off = 22;

wedge_rad = 64;
motor_offset = 40;
motor_length = 56;

module extrusion_cutout(h, extra) {
difference() {
cube([extrusion+extra, extrusion+extra, h], center=true);
for (a = [0:90:359]) rotate([0, 0, a]) {
translate([extrusion/2, 0, 0])
cube([6, 2.5, h+1], center=true);
}
}
}

module screw_socket() {
cylinder(r=1.65, h=20, center=true);
translate([0, 0, 3.6]) cylinder(r=3.5, h=20);
scale([1, 1, -1]) cylinder(r1=4, r2=8, h=4);
// translate([0, 10, 3.6]) cube([3.3, 20, 20], center=true);
// translate([0, 10, 13.6]) cube([8, 20, 20], center=true);
}

module frame_integrated() {
union() {
translate([-45, 55, -height/2]) cylinder(r=8, h=0.5);
translate([45, 55, -height/2]) cylinder(r=8, h=0.5);
translate([-22, -17, -height/2]) cylinder(r=8, h=0.5);
translate([22, -17, -height/2]) cylinder(r=8, h=0.5);
difference() {
union() {
intersection() {
translate([0, corner_off, 0])
cylinder(r=corner_rad, h=height, center=true, $fn=60);
translate([0, -50, 0]) rotate([0, 0, 30])
cylinder(r=50, h=height+1, center=true, $fn=6);
}
translate([0, 38, 0]) intersection() {
rotate([0, 0, -90])
cylinder(r=wedge_rad, h=height, center=true, $fn=3);
translate([0, 0, 0])
cube([150, 100, 2*height], center=true);
translate([0, -10, 0]) rotate([0, 0, 30])
cylinder(r=55, h=height+1, center=true, $fn=6);
}
}
translate([0, 58, 0]) minkowski() {
intersection() {
rotate([0, 0, -90])
cylinder(r=wedge_rad, h=height, center=true, $fn=3);
translate([0, -32, 0])
cube([100, 16, 2*height], center=true);
}
cylinder(r=roundness, h=1, center=true);
}
translate([0, 58, 0]) minkowski() {
intersection() {
rotate([0, 0, -90])
cylinder(r=wedge_rad, h=height, center=true, $fn=3);
translate([0, 7, 0])
cube([100, 30, 2*height], center=true);
}
cylinder(r=roundness, h=1, center=true);
}
rotate([0, 0, 45]) {
for (z = [-1, 1]) scale([1, 1, z]) {
translate([0, -7.5-extra_radius, 15]) rotate([90, 0, 0])
screw_socket();
}
extrusion_cutout(height+10, 2*extra_radius);
}
translate([0, motor_offset, 0]) {
rotate([90, 0, 0])
# cylinder(r=12, h=20, center=true, $fn=60);
for (a = [0:90:359]) rotate([0, a, 0]) {
translate([15.5, 0, 15.5]) rotate([90, 0, 0])
# cylinder(r=1.65, h=20, center=true);
}
}
for (a = [-1, 1]) rotate([0, 0, 30*a]) {
for (z = [-15, 15]) translate([0, 0, z]) {
%rotate([90, 0, 0])
translate([a*-20.5, 0, -.50])
extrusion_cutout(1, 0);
// Nut tunnels.
for (y = [0:3]) {
rotate([0, 0, a*-60])
translate([a*20.5, -y, -4*z/15])
scale([1, 1, -z/15])
rotate([0, 0, a*30])
cylinder(r=4, h=16, $fn=6);
rotate([0, 0, a*-60])
scale([1, 1, z/15])
translate([a*20.5, -y, 4])
rotate([0, 0, a*30])
#cylinder(r=4, h=8, $fn=6);
}
// Screw sockets.
for (y = [23, 67]) {
translate([a*-13, y, 0])
rotate([0, a*90, 0])
#screw_socket();
}
}
}
}
}
*% translate([0, motor_offset + motor_length/2, 0]) intersection() {
cube([42.2, motor_length, 42.2], center=true);
rotate([0, 45, 0]) cube([52, motor_length, 52], center=true);
}
}

translate([0, 0, height/2]) frame_integrated();
///use <frame_motor.scad>;
//use <corner.scad>;
//%frame_motor();
//%corner(15);
92 changes: 92 additions & 0 deletions socket.scad
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socket_extra=2;

module socket(ball_dia, screw_dia, adisp) {

assign(ball_rad=ball_dia/2){
assign(screw_rad=screw_dia/2){
assign(body_height = ball_dia+socket_extra){
assign(cone_min=screw_rad/cos(adisp)){
assign(cone_max=body_height*tan(adisp)+cone_min){

%if (1) {
// Show ball and attachment screw
sphere(r=ball_rad, center=true, $fn=30);
for (a = [adisp, 0, -adisp]) {
rotate([0, a, 0])
cylinder(r=screw_rad, h=ball_dia, $fn=30);
}
}
difference() {
union() {
translate([0, -body_height*.5, 0])
cube([body_height, body_height, body_height], true);
rotate([0, 90, 0])
cylinder(r=body_height/2, h=body_height, center=true, $fn=30);
}

cube([screw_dia, 1000, 1000], true);
sphere(r=ball_rad, center=true, $fn=30);

// relieve center of socketball_dia*tan(adisp)+
rotate([0, 90, 0]) {
cylinder(r=ball_dia*.25, h=body_height+2,
center=true, $fn=30);
cylinder(r=ball_rad, h=ball_rad*cos(adisp)+screw_dia-2,
center=true, $fn=30);
}

// create clearance for screw attaching ball to rod
intersection() {
rotate([0, 90, 0]) rotate_extrude($fn=30)
polygon(points=[[0, -cone_min],
[0, cone_min],
[body_height, cone_max],
[body_height, -cone_max]],
paths=[[0, 1, 2, 3]]);
translate([0, 50, 50]) cube(100, center=true);
}

for (r = [0,-90]) {
rotate([r, 0, 0])
cylinder(r1=cone_min, r2=cone_max, h=body_height, $fn=30);
}
translate([0, -(ball_rad+1.5+1), 0])
rotate([0, 90, 0])
cylinder(r=1.5, h=body_height+1, center=true, $fn=30);

}
}}}}}}


ball_dia = .5*25.4;
screw_dia = .112*25.4;
adisp = 30; // Max angular displacement of rod to socket

union() {
cube([ball_dia+socket_extra,
ball_dia+socket_extra,
ball_dia+socket_extra], center=true);
translate([0, (ball_dia+socket_extra)*1.5, 0])
socket(ball_dia, screw_dia, adisp);
}




















163 changes: 163 additions & 0 deletions top_integrated_45.scad
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// 2013-02-22 This file is still somewhat experimental
// and may go through more changes in the near future.

include <configuration.scad>;

$fn=24;
extrusion = 15;
height = 43;
roundness=6;
corner_rad = 43.5;
corner_off = 22;

wedge_rad = 64;

motor_offset = 40;
motor_length = 56;

module extrusion_cutout(h, extra) {
difference() {
cube([extrusion+extra, extrusion+extra, h], center=true);
for (a = [0:90:359]) rotate([0, 0, a]) {
translate([extrusion/2, 0, 0])
cube([6, 2.5, h+1], center=true);
}
}
}

module screw_socket() {
cylinder(r=1.65, h=20, center=true);
translate([0, 0, 3.6]) cylinder(r=3.5, h=20);
scale([1, 1, -1]) cylinder(r1=4, r2=8, h=4);
// translate([0, 10, 3.6]) cube([3.3, 20, 20], center=true);
// translate([0, 10, 13.6]) cube([8, 20, 20], center=true);
}


module top_integrated() {
union() {
translate([-45, 55, -height/2]) cylinder(r=8, h=0.5);
translate([44, 55, -height/2]) cylinder(r=8, h=0.5);
translate([-22, -17, -height/2]) cylinder(r=8, h=0.5);
translate([22, -17, -height/2]) cylinder(r=8, h=0.5); difference() {
union() {
intersection() {
translate([0, corner_off, 0])
cylinder(r=corner_rad, h=height, center=true, $fn=60);
translate([0, -50, 0]) rotate([0, 0, 30])
cylinder(r=50, h=height+1, center=true, $fn=6);
}
translate([0, 38, 0]) intersection() {
rotate([0, 0, -90])
cylinder(r=wedge_rad, h=height, center=true, $fn=3);
translate([0, 0, 0])
cube([150, 100, 2*height], center=true);
translate([0, -10, 0]) rotate([0, 0, 30])
cylinder(r=55, h=height+1, center=true, $fn=6);
}
}

translate([0, 58, 0]) minkowski() {
intersection() {
rotate([0, 0, -90])
cylinder(r=wedge_rad, h=height, center=true, $fn=3);
translate([0, -36, 0])
cube([100, 25, 2*height], center=true);
}
cylinder(r=roundness, h=1, center=true);
}
translate([0, 58, 0]) minkowski() {
intersection() {
rotate([0, 0, -90])
cylinder(r=wedge_rad, h=height, center=true, $fn=3);
translate([0, 7, 0])
cube([100, 30, 2*height], center=true);
}
cylinder(r=roundness, h=1, center=true);
}

// Just a bit of clearance for 608 tensioner.
translate([0, 5, 0]) cube([12, 10, height*2], center=true);

rotate([0, 0, -45]) {
for (z = [-1, 1]) scale([1, 1, z]) {
translate([0, -7.5-extra_radius, 15]) rotate([90, 0, 0])
screw_socket();
}
extrusion_cutout(height+10, 2*extra_radius);
}

translate([-50, 60, 52])
rotate([90, 0, 90])
cylinder(r=60, h=100, $fn=60);

for (a = [-1, 1]) rotate([0, 0, 30*a]) {
translate([a*-20.5, 0, -15]) {
%rotate([90, 0, 0])
translate([0, 0, -.50])
extrusion_cutout(1, 0);
// Nut tunnels.
for (y = [0:3]) {
translate([0, -y, 4])
rotate([0, 0, -a*30])
#cylinder(r=4, h=16, $fn=6);
translate([0, -y, -20])
rotate([0, 0, -a*30])
#cylinder(r=4, h=16, $fn=6);

}
}
// Screw sockets.
for (y = [23, 67]) {
translate([a*-13, y, -15])
rotate([0, a*90, 0])
screw_socket();
} }
// Clearance for HoneyWell ZM micro switch.
rotate([0, 0, -30]) translate([16, 2.5, height/2-5]) {
translate([(17-6.)/2, 0, 2-5])
cube([17, 22, 20.6], center=true);
translate([0, 9.5/2, 0]) rotate([0, 90, 0])
cylinder(r=1.25, h=30, center=true, $fn=12);
translate([0, -9.5/2, 0]) rotate([0, 90, 0])
cylinder(r=1.25, h=30, center=true, $fn=12);
}
}

}

// Plate for tensioning screw of 608 tensioner.
translate([0, 0, -height/2+1.5]) {
difference() {
translate([0, 38, 0])
rotate([0, 0, 30])
cylinder(r=wedge_rad, h=3, center=true, $fn=3);
translate([0, 67, 0])
cube([150, 100, 4], center=true);
translate([-5, 12.7, 0])
cylinder(r=1.6, h=4, center=true, $fn=12);
translate([0, corner_off, 0]) {
difference() {
cylinder(r=corner_rad+10, h=height, center=true, $fn=60);
cylinder(r=corner_rad, h=height, center=true, $fn=60);
}
}
rotate([0, 0, 45]) extrusion_cutout(100, 2*extra_radius);
}
}
}

translate([0, 0, height/2])
top_integrated();
%rotate([0, 0, 45])
translate([0, 0, 30])
extrusion_cutout(100, 2*extra_radius);

//use <frame_integrated_45.scad>; %frame_integrated();

use <tensioner_608.scad>;
*%translate([0, 24.8, 10]) rotate([180, 0, 22.5]) tensioner_608();
//use <frame_motor.scad>;
//use <corner.scad>;
//%frame_motor();
//%corner(15);