cyclone-pcb-factory/Hardware/Development/main_frame/frame.scad

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// Cyclone PCB Factory: a 3D printable CNC machine for PCB manufacture
// Created by Carlosgs (http://carlosgs.es)
// License: Attribution - Share Alike - Creative Commons (http://creativecommons.org/licenses/by-sa/3.0/)
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include <MCAD/stepper.scad>
include <MCAD/bearing.scad>
include <MCAD/metric_fastners.scad>
include <MCAD/nuts_and_bolts.scad>
use <../Gears/rod_gear.scad>
use <../Gears/motor_gear.scad>
use <../libs/obiscad/bcube.scad>
use <../libs/obiscad/bevel.scad>
use <../libs/build_plate.scad>
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use <../smooth_rod_fix/smooth_rod_fix.scad>
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use <../libs/End_Stop_Holder.scad>
use <../libs/micro_switch.scad>
layer_thickness = 0.4;
motor_width = 43+1;
motor_length = 49; // not used
motor_screw_distance = 31.3;
motor_center_diameter = 23;
motor_screw_diameter = 4;
motor_screw_head_diameter = 8;
motor_stand_thickness = 5;
bearing_diameter = 22.4;
M8_rod_diam = 8.2;
X_smooth_rods_sep = 50;
X_smooth_rods_sep_projected = sqrt((X_smooth_rods_sep*X_smooth_rods_sep)/2); // Be careful with this measure, it is not properly named since it is used with the following offset:
smooth_rod_margin = 1;
smooth_rod_screw_sep = 8;
smooth_rod_screw_diam = 3;
smooth_rod_screw_len = 7;
X_rods_corner_shaft_size = X_smooth_rods_sep*0.65;
frame_thickness = 10;
frame_width = 90;
frame_height = 135;
frame_corner_radius = 5;
X_threaded_rod_posX = X_smooth_rods_sep_projected;
X_threaded_rod_posY = X_smooth_rods_sep_projected;
motor_axis_distance = 32;
motor_axis_angle = 15;
X_motor_gear_margin = 35;
frame_hole_height = 80;
bottom_thickness = 5;
wall_thickness = 5;
base_screw_diameter = 5;
base_screw_distance = 33;
Y_rod_height = 40;
Y_rod_dist_from_wall = 15;
Y_rod_support_lenght = Y_rod_dist_from_wall+smooth_rod_screw_sep+smooth_rod_screw_diam+3;
motor_adjust_margin = 3;
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Cyclone_Nema17 = [
[NemaModel, 17],
[NemaLengthShort, 33*mm],
[NemaLengthMedium, 39*mm],
[NemaLengthLong, 48*mm],
[NemaSideSize, 42.30*mm],
[NemaDistanceBetweenMountingHoles, 31.0*mm],
[NemaMountingHoleDiameter, 4*mm],
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[NemaMountingHoleDepth, 5.5*mm], //actual is 4.5mm, motor() module is generating 1mm shorter
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[NemaMountingHoleLip, -1*mm],
[NemaMountingHoleCutoutRadius, 0*mm],
[NemaEdgeRoundingRadius, 7*mm],
[NemaRoundExtrusionDiameter, 22*mm],
[NemaRoundExtrusionHeight, 1.9*mm],
[NemaAxleDiameter, 5*mm],
[NemaFrontAxleLength, 24*mm],
[NemaBackAxleLength, 15*mm],
[NemaAxleFlatDepth, 0.5*mm],
[NemaAxleFlatLengthFront, 15*mm],
[NemaAxleFlatLengthBack, 14*mm]
];
module frame(with_motor = 1, show_printbed = 0, with_extra_parts=false, exploded=false) {
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if(show_printbed) {
//for display only, doesn't contribute to final object
translate([frame_width/2,frame_height/2,0]) build_plate(3,110,140);
}
union() {
difference() {
// --------- Main frame --------- //
translate([frame_width/2,frame_height/2,frame_thickness/2])
cube([frame_width,frame_height,frame_thickness],center=true);
// --------- Smooth Y rods --------- //
translate([X_smooth_rods_sep_projected,-smooth_rod_margin,0]) {
cylinder(r=M8_rod_diam/2,h=10*frame_thickness,center=true,$fn=40);
// Screws
rotate([90,0,0]) translate([0,frame_thickness/2,0]) {
translate([-smooth_rod_screw_sep,0,0])
cylinder(r=smooth_rod_screw_diam/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
translate([smooth_rod_screw_sep,0,0])
cylinder(r=smooth_rod_screw_diam/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
}
}
translate([-smooth_rod_margin,X_smooth_rods_sep_projected,0]) {
cylinder(r=M8_rod_diam/2,h=10*frame_thickness,center=true,$fn=40);
// Screws
rotate([0,90,0]) translate([-frame_thickness/2,0,0]) {
translate([0,-smooth_rod_screw_sep,0])
cylinder(r=smooth_rod_screw_diam/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
translate([0,smooth_rod_screw_sep,0])
cylinder(r=smooth_rod_screw_diam/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
}
}
// --------- Holes to save plastic --------- //
// Corner shaft
rotate([0,0,45])
cube([X_rods_corner_shaft_size,X_rods_corner_shaft_size,frame_thickness*3],center=true);
// Hole next to the corner shaft
rotate([0,0,45]) translate([28,0,0])
bcube([15,25,frame_thickness*3],cr=2,cres=10);
// Hole to remove the motor part
if(with_motor==0)
translate([frame_width,0,0])
bcube([frame_width-10,frame_hole_height+bottom_thickness,frame_thickness*3],cr=2,cres=10);
// --------- Large hole in the frame --------- //
translate([(frame_width-wall_thickness)/2,frame_height-frame_hole_height/2-bottom_thickness,0])
bcube([frame_width-wall_thickness-frame_thickness,frame_hole_height,frame_thickness*3],cr=2,cres=10);
// --------- Screws in the base --------- //
rotate([90,0,0]) translate([frame_width/2,frame_thickness/2,-frame_height]) {
translate([-base_screw_distance,0,0])
cylinder(r=base_screw_diameter/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
translate([base_screw_distance*0.8,0,0])
cylinder(r=base_screw_diameter/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
translate([base_screw_distance*0.2,0,0])
cylinder(r=base_screw_diameter/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
}
// --------- X motor assembly, position relative to X threaded rod --------- //
translate([X_threaded_rod_posX,X_threaded_rod_posY,0]) {
// Threaded Y rod hole
translate([0,0,(motor_stand_thickness/2)+layer_thickness])
cylinder(r=(M8_rod_diam*2)/2,h=10*frame_thickness,center=false,$fn=40);
// Threaded X rod bearing hole
translate([0,0,0])
cylinder(r=bearing_diameter/2,h=motor_stand_thickness,center=true,$fn=40);
if(with_motor) {
// ------- BEGIN MOTOR HOLES --------
// Center is the motor shaft, and we apply the rotation keeping the motor horizontal
// Screws for holding the motor
rotate([0,0,-motor_axis_angle]) translate([motor_axis_distance,0,0]) rotate([0,0,90+motor_axis_angle]) {
// Hole for the motor shaft
hull() {
translate([0,motor_adjust_margin/2,0])
cylinder(r=motor_center_diameter/2,h=10*wall_thickness,center=true,$fn=40);
translate([0,-motor_adjust_margin/2,0])
cylinder(r=motor_center_diameter/2,h=10*wall_thickness,center=true,$fn=40);
}
// Screws for holding the motor
for(i=[-1,1]) for(j=[-1,1])
translate([i*motor_screw_distance/2,j*motor_screw_distance/2,0]) {
hull() {
translate([0,motor_adjust_margin/2,0])
cylinder(r=motor_screw_diameter/2,h=10*wall_thickness,center=true,$fn=40);
translate([0,-motor_adjust_margin/2,0])
cylinder(r=motor_screw_diameter/2,h=10*wall_thickness,center=true,$fn=40);
}
}
// Level the motor area
hull() {
translate([0,motor_adjust_margin/2-10,motor_stand_thickness*2])
bcube([motor_width,motor_width+20,frame_thickness],cr=5,cres=10);
translate([0,-motor_adjust_margin/2,motor_stand_thickness*2])
bcube([motor_width,motor_width,frame_thickness],cr=5,cres=10);
}
// ------- END MOTOR HOLES --------
} // End of centering over motor shaft
} // End of if(with_motor)
} // End of centering over X threaded rod
} // End of difference() command
// --------- Support column for the triangular structure --------- //
translate([frame_width/4,frame_height-frame_hole_height/2-bottom_thickness,frame_thickness/2])
rotate([0,0,-23])
cube([wall_thickness,sqrt((frame_width*frame_width)/4+(frame_hole_height*frame_hole_height)),frame_thickness],center=true);
// --------- Bevel base supports --------- //
translate([wall_thickness/2,frame_height,frame_thickness-0.5])
rotate([90,0,-90])
bconcave_corner(cr=Y_rod_support_lenght-0.5, cres=0, l=wall_thickness, th=0.5, ext_corner=true);
translate([frame_width-frame_thickness/2,frame_height,frame_thickness-0.5])
rotate([90,0,-90])
bconcave_corner(cr=Y_rod_support_lenght-0.5, cres=0, l=frame_thickness, th=0.5, ext_corner=true);
// Long bevel
translate([frame_width/2,frame_height,frame_thickness-0.5])
rotate([90,0,-90])
bconcave_corner(cr=wall_thickness-0.5, cres=0, l=frame_width, th=0.5, ext_corner=true);
// --------- Bevel Y rod support --------- //
translate([frame_width-frame_thickness/2,frame_height,frame_thickness-2])
translate([0,-Y_rod_height+smooth_rod_margin,0]) {
difference() {
rotate([90,0,90]) // Bevel
bconcave_corner(cr=Y_rod_support_lenght-smooth_rod_screw_len, cres=0, l=frame_thickness, th=smooth_rod_screw_len, ext_corner=true);
translate([0,-smooth_rod_margin,Y_rod_dist_from_wall]) rotate([0,90,0]) {
cylinder(r=M8_rod_diam/2,h=10*frame_thickness,center=true,$fn=40);
// Screws
rotate([90,0,0]) {
translate([-smooth_rod_screw_sep,0,-1])
cylinder(r=smooth_rod_screw_diam/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
translate([smooth_rod_screw_sep,0,-1])
cylinder(r=smooth_rod_screw_diam/2,h=2*smooth_rod_screw_len,center=true,$fn=6);
}
}
}
}
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if(with_extra_parts)
frame_extras(with_motor=with_motor, exploded_distance=(exploded?30:0));
} // End of union() command
}
module frame_extras(with_motor=1, exploded_distance=0) {
if(with_motor) {
translate([X_threaded_rod_posX,X_threaded_rod_posY,0]) {
rotate([0,0,-motor_axis_angle]) translate([motor_axis_distance,0,0]) rotate([0,0,90+motor_axis_angle]) {
translate([0,0,wall_thickness-1]) {
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echo("Non-Plastic Parts: 1 x Nema 17 on motor frame");
translate([0,0,exploded_distance]) motor(Cyclone_Nema17, NemaLengthLong);
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// --- Motor gear ---
translate([0,0,-12-5.5+1-0.5*exploded_distance])
cyclone_motor_gear(with_extra_parts=true, exploded=(exploded_distance!=0));
}
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echo("Non-Plastic Parts: 4 x Bolts M3 x 8 mm to attach motor on frame");
for(i=[-1,1]) for(j=[-1,1])
translate([i*motor_screw_distance/2,j*motor_screw_distance/2,0])
translate([0,0,-0.4*exploded_distance]) {
rotate([0,0,0]) color(Steel) boltHole(size=3, length=8);
}
}
}
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translate([X_threaded_rod_posX,X_threaded_rod_posY,0]) {
rotate([0,0,0]) {
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echo("Non-Plastic Parts: 1 x 608 bearing for motor frame");
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translate([0,0,-1.0-7/2-0.2*exploded_distance]) bearing(model=608);
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// --- Rod Gear ---
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translate([0,0,-8-1.0-7/2-1.0*exploded_distance])
rotate([0,0,6])
cyclone_rod_gear(with_extra_parts=true, exploded=(exploded_distance!=0));
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}
}
}
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screw_size = 2.9;
screw_length = 16;
echo("Non-Plastic Parts: 3 x Self tapping screw 2.9 x 16 mm to attach frame on base");
rotate([90,0,0]) translate([frame_width/2,frame_thickness/2,-frame_height+frame_thickness/2+.2+exploded_distance]) color(Steel) {
translate([-base_screw_distance,0,0]) rotate([180,0,0])
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csk_bolt(screw_size, screw_length);
translate([base_screw_distance*0.8,0,0]) rotate([180,0,0])
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csk_bolt(screw_size, screw_length);
translate([base_screw_distance*0.2,0,0]) rotate([180,0,0])
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csk_bolt(screw_size, screw_length);
}
// --- X smooth rod fix ---
translate([X_smooth_rods_sep_projected,-smooth_rod_margin,0])
rotate([90,0,0]) translate([0,frame_thickness/2,8.5+0.5*exploded_distance])
rotate([180,0,0]) smooth_rod_fix(with_extra_parts=true, exploded=(exploded_distance!=0));
translate([-smooth_rod_margin,X_smooth_rods_sep_projected,0])
rotate([0,90,0]) translate([-frame_thickness/2,0,-8.5-0.5*exploded_distance])
rotate([0,0,90]) smooth_rod_fix(with_extra_parts=true, exploded=(exploded_distance!=0));
// --- Y smooth rod fix ---
translate([frame_width-frame_thickness/2,frame_height,frame_thickness-2])
translate([0,-Y_rod_height+smooth_rod_margin,0])
translate([0,-smooth_rod_margin-8.5-0.5*exploded_distance,Y_rod_dist_from_wall]) rotate([90,90,180])
smooth_rod_fix(with_extra_parts=true, exploded=(exploded_distance!=0));
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if(with_motor) {
// this seems to reduce working area of Y axis
if(false) {
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echo("Non-Plastic Parts: 1 x Micro switch on Y smooth rod for Y axis");
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translate([frame_width-frame_thickness/2,frame_height,frame_thickness-2])
translate([0,-Y_rod_height+smooth_rod_margin,0])
translate([0,-smooth_rod_margin,Y_rod_dist_from_wall])
translate([-frame_thickness/2-0.5*exploded_distance, 15, 8]) rotate([180,0,0]) rotate([0,-90,0])
end_stop_holder(with_extra_parts=true, exploded=(exploded_distance!=0));
}
// this seems to reduce working area of X axis
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if(false) {
echo("Non-Plastic Parts: 1 x Micro switch on X smooth rod for X axis");
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translate([X_smooth_rods_sep_projected,-smooth_rod_margin,0])
translate([15+0.5*exploded_distance, -8, frame_thickness])
rotate([180,180,-90])
end_stop_holder(with_extra_parts=true, exploded=(exploded_distance!=0));
}
// this seems to reduce working area of X axis
if(false) {
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echo("Non-Plastic Parts: 1 x Micro switch on motor frame for X axis");
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rotate([90, 0, -45])
translate([X_rods_corner_shaft_size/2-19.8,0,-X_rods_corner_shaft_size/2+0.5*exploded_distance])
micro_switch(with_extra_parts=true, exploded=(exploded_distance!=0));
}
}
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if(!with_motor) {
translate([X_threaded_rod_posX,X_threaded_rod_posY,0]) {
rotate([0,0,0]) {
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echo("Non-Plastic Parts: 1 x 608 bearing for no motor frame");
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translate([0,0,-1.0-7/2-0.2*exploded_distance]) bearing(model=608);
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echo("Non-Plastic Parts: 1 x M8 nut to attach threaded rod on no motor frame");
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translate([0,0,-6.5-1.0-7/2-0.6*exploded_distance]) rotate([0,0,0]) color(Steel) flat_nut(8);
}
}
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echo("Non-Plastic Parts: 1 x Micro switch on no motor frame for X axis");
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rotate([90, 0, -45])
translate([X_rods_corner_shaft_size/2-19.8,0,-X_rods_corner_shaft_size/2+0.5*exploded_distance])
micro_switch(with_extra_parts=true, exploded=(exploded_distance!=0));
if(true) {
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echo("Non-Plastic Parts: 1 x Micro switch on Y smooth rod for Y axis");
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translate([frame_width-frame_thickness/2,frame_height,frame_thickness-2])
translate([0,-Y_rod_height+smooth_rod_margin,0])
translate([0,-smooth_rod_margin,Y_rod_dist_from_wall])
translate([-frame_thickness/2-0.5*exploded_distance, 8, -15]) rotate([90,0,0]) rotate([0,-90,0])
end_stop_holder(with_extra_parts=true, exploded=(exploded_distance!=0));
}
// this seems to reduce working area of Y axis
if(false) {
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echo("Non-Plastic Parts: 1 x Micro switch on no motor frame for Y axis");
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translate([frame_width-frame_thickness/2+10.8/2-0.5,frame_height-19.8-2,frame_thickness])
translate([0,-Y_rod_height+smooth_rod_margin,0])
translate([0,-smooth_rod_margin-8.5-0.5*exploded_distance,0])
rotate([0, 0, 90])
micro_switch(with_extra_parts=true, exploded=(exploded_distance!=0));
}
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}
}
// Toggle parameters and mirror to create the other side part
//frame(with_motor = 1, show_printbed = 1);
scale([-1,1,1]) frame(with_motor = 0, show_printbed = 1);