Improved gears

Hardware/CYCLONE_2/Cyclone.scad

@@ -164,7 +164,7 @@ render_2D_or_3D() {
 			// Draw right Y smooth rod
 			rotate([0,0,180]) standard_rod(diam=axes_Ysmooth_rodD, length=axes_Ysmooth_rodLen, threaded=false, echoPart=true);
 		
-			Cyclone_X_leftFrame();
+			!Cyclone_X_leftFrame();
 		}
 	
 	

Hardware/CYCLONE_2/Cyclone_X_frames.scad

@@ -9,6 +9,7 @@ Xmotor_sideLen = 42.20;
 
 axes_XgearSeparation = 37;
 axes_XgearRatio = 21/21; // Number of tooth (motor/rod)
+axes_XgearThickness = 10;
 
 X_frames_additional_thickness = 5;
 
@@ -39,6 +40,34 @@ module Cyclone_X_leftFrame(isLeft=true) {
 	
 	corner_radius = 10;
 	
+	module Cyclone_XsubPart_gearsAndMotor(renderGears=false, echoPart=false, drawMotor=false, gearMargin=0) {
+		translate([gearWallSeparation,0,0]) rotate([0,90,0])
+			rodGear(r=axes_XgearSeparation/(1+1/axes_XgearRatio)+gearMargin, h=axes_XgearThickness+gearMargin, echoPart=echoPart, renderPart=renderGears);
+		// Translate to motor position
+		rotate([motorRotatedOffset,0,0]) {
+			translate([0,axes_XgearSeparation,0])
+				rotate([-motorRotatedOffset,0,0]) {
+					if(drawMotor)
+						translate([-motorWallSeparation,0,0]) rotate([0,90,0]) stepperMotor(screwHeight=motorWallSeparation, echoPart=echoPart);
+					translate([gearWallSeparation,0,0]) rotate([0,90,0]) motorGear(r=axes_XgearSeparation/(1+axes_XgearRatio)+gearMargin, h=axes_XgearThickness+gearMargin, echoPart=echoPart, renderPart=renderGears);
+				}
+		}
+	}
+	
+	module Cyclone_XsubPart_gearCover() {
+		margin = 4;
+		wallThickness = 2;
+		color("grey")
+		difference() {
+			union()
+				Cyclone_XsubPart_gearsAndMotor(renderGears=true, gearMargin=margin+wallThickness);
+			translate([-0.01,0,0])
+				union()
+					Cyclone_XsubPart_gearsAndMotor(renderGears=true, gearMargin=margin);
+			rotate([0,90,0]) cylinder(r=20/2-1.5, h=30);
+		}
+	}
+	
 	
 	difference() {
 		// Main block
@@ -115,16 +144,8 @@ module Cyclone_X_leftFrame(isLeft=true) {
 			translate([-bearingDepth,0,0]) rotate([0,90,0])
 				radialBearing(echoPart=true);
 			if(isLeft) {
-				translate([gearWallSeparation,0,0]) rotate([0,90,0])
+				Cyclone_XsubPart_gearsAndMotor(echoPart=true, drawMotor=true);
-					rodGear(r=axes_XgearSeparation/(1+1/axes_XgearRatio), echoPart=true);
+				Cyclone_XsubPart_gearCover();
-				// Translate to motor position
-				rotate([motorRotatedOffset,0,0]) {
-					translate([0,axes_XgearSeparation,0])
-						rotate([-motorRotatedOffset,0,0]) {
-							translate([-motorWallSeparation,0,0]) rotate([0,90,0]) stepperMotor(screwHeight=motorWallSeparation, echoPart=true);
-							translate([gearWallSeparation,0,0]) rotate([0,90,0]) motorGear(r=axes_XgearSeparation/(1+axes_XgearRatio), echoPart=true);
-						}
-				}
 			}
 			translate([0,0,axes_Xsmooth_separation])
 				rotate([0,0,-90])

Hardware/CYCLONE_2/INHERITED/XYgears/motor_gear.scad

@@ -37,7 +37,7 @@ include <MCAD/materials.scad>
 include <MCAD/teardrop.scad>
 include <MCAD/involute_gears.scad>
 
-motor_shaft_diameter=5.3;
+motor_shaft_diameter=5.6;
 BigGear_N_Teeth = 21; // 24
 
 nholes = 9; // 7
@@ -73,8 +73,7 @@ module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
 				hub_diameter=1,
 				bore_diameter=shaft,
 				circles=circles,
-				twist=twist/teeth,
+				twist=twist/teeth
-				$fn=15*2
 			);
 			mirror([0,0,1]) translate([0,0,-height/2-0.01]) {
 				difference() {
@@ -101,32 +100,28 @@ union() difference() {
 
 		translate( [0, 0, 12] ) mirror( [0, 0, 1] ) difference() {
 			//shaft
-			cylinder( r=9, h=15, $fn=40 );
+			cylinder( r=9, h=15);
-	//adapted to include 3 captive nuts for symmetrical positioning
-	//adpted bij HJ Binnema on August 26 2013.
-	for (i= [0:2]){
-		rotate([0,0,i*120]){
 			//captive nut and grub holes
-			translate( [0, 20, 3.5] ) rotate( [90, 0, 0] ) union() {
+			translate( [0, 19.5, 3.5] ) rotate( [90, 0, 0] ) union() {
 				//enterance
-				translate( [0, -3, 14.5] ) cube( [6, 6, 2.6], center=true );
+				translate( [0, -3, 14.5] ) cube( [6, 6, 2.8], center=true );
 				//nut
-				translate( [0, 0, 13.3] ) rotate( [0, 0, 30] )
+				translate( [0, 0, 14.5] ) rotate( [0, 0, 30] )
-					cylinder( r=6/2+0.5, h=2.6, $fn=6 );
+					cylinder( r=6/2+0.5, h=2.8, $fn=6, center=true);
 				//grub hole
-				translate( [0, 0, 9] ) cylinder( r=3.2/2, h=10, $fn=6 );
+				translate( [0, 0, 9] ) cylinder( r=3.2/2, h=10);
-			}}}
+			}
 		}
 	}
 
 	//holes to save plastic
-	for(i=[0:nholes-1])
+	//for(i=[0:nholes-1])
-		rotate( [0, 0, i*360/(nholes)+45], $fn=20 )
+	//	rotate( [0, 0, i*360/(nholes)+45])
-			translate( [hole_distance_from_center, 0] )
+	//		translate( [hole_distance_from_center, 0] )
-				cylinder( r=holes_diam/2, h=11, center=true, $fn=30 );
+	//			cylinder( r=holes_diam/2, h=11, center=true);
 
 	//shaft hole
-	translate( [0, 0, -6] ) cylinder( r=motor_shaft_diameter/2, h=20, $fn=30 );
+	translate( [0, 0, -6] ) cylinder( r=motor_shaft_diameter/2, h=20);
 }
 }
 

Hardware/CYCLONE_2/INHERITED/XYgears/rod_gear.scad

@@ -30,39 +30,31 @@
  * -- 
  *		 DeuxVis - device@ymail.com */
 
-include <MCAD/metric_fastners.scad>
-include <MCAD/materials.scad>
-include <MCAD/teardrop.scad>
 include <MCAD/involute_gears.scad>
 
 M8_nut_diameter = 15.3;
-nut_separation = 3;
+nut_separation = 5;
 
-SmallGear_N_Teeth = 21;//17; // 12
+SmallGear_N_Teeth = 21;
 M8_rod_diam = 8.4;
 
+// Increase the resolution of default shapes
+$fa = 5; // Minimum angle for fragments [degrees]
+$fs = 0.5; // Minimum fragment size [mm]
+
 /* Herringbone gear module, adapted from MCAD/involute_gears */
 module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
-  twist=200;
+	twist=100;
 	height=10;
 	pressure_angle=30;
 
-  gear(
+	diam = teeth*2;
-    number_of_teeth=teeth,
-    circular_pitch=320,
-		pressure_angle=pressure_angle,
-		clearance = 0.2,
-		gear_thickness = height/2,
-		rim_thickness = height/2,
-		rim_width = 1,
-		hub_thickness = height/2,
-		hub_diameter=1,
-		bore_diameter=shaft,
-		circles=circles,
-		twist=twist/teeth
-  );
 	
-	mirror( [0,0,1] )
+	truncation_length = 3;
+	truncation_height = height/3;
+
+	module myGear() {
+		difference() {
 			gear(
 				number_of_teeth=teeth,
 				circular_pitch=320,
@@ -77,6 +69,19 @@ module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
 				circles=circles,
 				twist=twist/teeth
 			);
+			mirror([0,0,1]) translate([0,0,-height/2-0.01]) {
+				difference() {
+					cylinder(r=diam/2+1, h=truncation_height);
+					translate([0,0,-0.01])
+						cylinder(r1=diam/2-truncation_length, r2=diam/2, h=truncation_height+0.02);
+				}
+			}
+		}
+	}
+	
+	myGear();
+	mirror( [0,0,1] )
+		myGear();
 }
 
 module cyclone_rod_gear(with_extra_parts=false, exploded=false) {
@@ -84,31 +89,11 @@ module cyclone_rod_gear(with_extra_parts=false, exploded=false) {
 difference() {
 	union() {
 		//gear
-    rotate([180,0,0]) herringbone_gear( teeth=SmallGear_N_Teeth, circles=0, shaft=M8_rod_diam, $fn=40 );
+		rotate([180,0,0]) herringbone_gear( teeth=SmallGear_N_Teeth, circles=0, shaft=M8_rod_diam);
-
-    //M8 hobbed bolt head fit washer
-    /*difference() {
-      translate( [0, 0, 5] ) cylinder( r=8, h=3, $fn=60 );
-      translate( [0, 0, 5-0.01] ) cylinder( r=M8_nut_diameter/2, h=7, $fn=6 );
-    }*/
-    /*rotate([180,0,0]) difference() {
-      translate( [0, 0, 5] ) cylinder( r=13, h=3, $fn=60 );
-      translate( [0, 0, 5+0.4] ) cylinder( r=M8_nut_diameter/2, h=7, $fn=6 );
-    }*/
 	}
 
 	translate( [0, 0, (nut_separation/2)] ) cylinder( r=M8_nut_diameter/2, h=7, $fn=6 );
 }
-
-  if(with_extra_parts)
-    cyclone_rod_gear_extras(exploded_distance=(exploded?12:0));
-
-  module cyclone_rod_gear_extras(exploded_distance=0) {
-    echo("Non-Plastic Parts, 2, Nut M8 to attach rod_gear on threaded rod");
-    translate([0,0,-10/2-0.8*8-1.0*exploded_distance]) color(Steel) flat_nut(8);
-    translate([0,0,nut_separation/2+0.8*8+1.0*exploded_distance]) rotate([180,0,0]) color(Steel) flat_nut(8);
-  }
-
 }
 
 cyclone_rod_gear();

Hardware/CYCLONE_2/INHERITED/Zgears/motor_gear.scad

@@ -37,18 +37,23 @@ include <MCAD/materials.scad>
 include <MCAD/teardrop.scad>
 include <MCAD/involute_gears.scad>
 
-motor_shaft_diameter=5.4;
+motor_shaft_diameter=5.6;
 pos=15.4-1; //position hole for grubnut
 nholes = 7;
-shaft_diam=10;
+shaft_diam=9;
 shaft_height=7;
 
+// Increase the resolution of default shapes
+$fa = 5; // Minimum angle for fragments [degrees]
+$fs = 0.5; // Minimum fragment size [mm]
+
 /* Herringbone gear module, adapted from MCAD/involute_gears */
 module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
-  twist=200;
+	twist=100;
 	height=10;
 	pressure_angle=30;
 
+	module myGear() {
 		gear(
 			number_of_teeth=teeth,
 			circular_pitch=320,
@@ -63,22 +68,11 @@ module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
 			circles=circles,
 			twist=twist/teeth
 		);
+	}
 	
+	myGear();
 	mirror( [0,0,1] )
-	  gear(
+		myGear();
-      number_of_teeth=teeth,
-		  circular_pitch=320,
-		  pressure_angle=pressure_angle,
-		  clearance = 0.2,
-		  gear_thickness = height/2,
-		  rim_thickness = height/2,
-		  rim_width = 1,
-		  hub_thickness = height/2,
-		  hub_diameter=1,
-		  bore_diameter=shaft,
-		  circles=circles,
-		  twist=twist/teeth
-    );
 }
 
 module cyclone_motor_z_gear(with_extra_parts=false, exploded=false) {
@@ -91,37 +85,23 @@ rotate([180,0,0]) union() difference() {
 
 		translate( [0, 0, 12] ) mirror( [0, 0, 1] ) difference() {
 			//shaft
-      cylinder( r=shaft_diam, h=shaft_height, $fn=40 );
+			cylinder( r=shaft_diam, h=shaft_height);
-
 			//captive nut and grub holes
-	for (i=[0:2]){ //3 symmetric grubscrews
+			translate( [0, 19.5, 3.5] ) rotate( [90, 0, 0] ) union() {
-
+				//enterance
- 	rotate([0,0,i*120]){     
+				translate( [0, -3, 14.5] ) cube( [6, 6, 2.8], center=true );
- 		translate( [0, 20, 3.5] ) rotate( [90, 0, 0] ) union() {
+				//nut
-        //entrance for nut
+				translate( [0, 0, 14.5] ) rotate( [0, 0, 30] )
-          translate( [0, -4.4, pos] ) cube( [5.9, 5.8, 2.45], center=true );
+					cylinder( r=6/2+0.5, h=2.8, $fn=6, center=true);
-        //nut hole
+				//grub hole
-        translate( [0, 0, pos-1.2] ) rotate( [0, 0, 30] )
+				translate( [0, 0, 9] ) cylinder( r=3.2/2, h=10);
-          cylinder( r=6/2+0.2, h=2.6, $fn=6 );
-        //grub screw hole
-        translate( [0, 0, 9] ) cylinder( r=1.5, h=10, $fn=20 );
-      				}
-				}
 			}
 		}
 	}
 
 	//shaft hole
-  translate( [0, 0, -6] ) cylinder( r=motor_shaft_diameter/2, h=20, $fn=30 );
+	translate( [0, 0, -6] ) cylinder( r=motor_shaft_diameter/2, h=20);
 }
-
-  if(with_extra_parts)
-    cyclone_motor_z_gear_extras(exploded_distance = (exploded?24:0));
-
-  module cyclone_motor_z_gear_extras(exploded_distance=0) {
-    echo("Non-Plastic Parts, 1, Grub Screw M3 x 8 mm to attach Z motor gear to motor shaft");
-    translate([0,-2.5-exploded_distance,-(12-3.5)]) rotate([90, 0, 0]) color(Steel) cylinder(r=1.5, h=8, $fn=30);
-  }
 }
 
 cyclone_motor_z_gear();

Hardware/CYCLONE_2/INHERITED/Zgears/rod_gear.scad

@@ -30,39 +30,31 @@
  * -- 
  *		 DeuxVis - device@ymail.com */
 
-include <MCAD/metric_fastners.scad>
-include <MCAD/nuts_and_bolts.scad>
-include <MCAD/materials.scad>
-include <MCAD/teardrop.scad>
 include <MCAD/involute_gears.scad>
 
-module cyclone_rod_z_gear(with_extra_parts=false, exploded=false) {
-
 M8_nut_diameter = 15.3;
-nut_separation = 3;
+nut_separation = 5;
+
+SmallGear_N_Teeth = 15;
+M8_rod_diam = 8.4;
+
+// Increase the resolution of default shapes
+$fa = 5; // Minimum angle for fragments [degrees]
+$fs = 0.5; // Minimum fragment size [mm]
 
 /* Herringbone gear module, adapted from MCAD/involute_gears */
 module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
-  twist=200;
+	twist=100;
 	height=10;
 	pressure_angle=30;
 
-  gear(
+	diam = teeth*2;
-    number_of_teeth=teeth,
-    circular_pitch=320,
-		pressure_angle=pressure_angle,
-		clearance = 0.2,
-		gear_thickness = height/2,
-		rim_thickness = height/2,
-		rim_width = 1,
-		hub_thickness = height/2,
-		hub_diameter=1,
-		bore_diameter=shaft,
-		circles=circles,
-		twist=twist/teeth
-  );
 	
-	mirror( [0,0,1] )
+	truncation_length = 3;
+	truncation_height = height/3;
+
+	module myGear() {
+		difference() {
 			gear(
 				number_of_teeth=teeth,
 				circular_pitch=320,
@@ -77,37 +69,31 @@ module herringbone_gear( teeth=12, circles=0, shaft=5 ) {
 				circles=circles,
 				twist=twist/teeth
 			);
+			mirror([0,0,1]) translate([0,0,-height/2-0.01]) {
+				difference() {
+					cylinder(r=diam/2+1, h=truncation_height);
+					translate([0,0,-0.01])
+						cylinder(r1=diam/2-truncation_length, r2=diam/2, h=truncation_height+0.02);
+				}
+			}
+		}
+	}
+	
+	myGear();
+	mirror( [0,0,1] )
+		myGear();
 }
 
+module cyclone_rod_gear(with_extra_parts=false, exploded=false) {
 // Extruder Gear
 difference() {
 	union() {
 		//gear
-    rotate([180,0,0]) herringbone_gear( teeth=15, circles=0, shaft=8.5, $fn=40 );
+		rotate([180,0,0]) herringbone_gear( teeth=SmallGear_N_Teeth, circles=0, shaft=M8_rod_diam);
-
-    //M8 hobbed bolt head fit washer
-    /*difference() {
-      translate( [0, 0, 5] ) cylinder( r=8, h=3, $fn=60 );
-      translate( [0, 0, 5-0.01] ) cylinder( r=M8_nut_diameter/2, h=7, $fn=6 );
-    }*/
-    /*rotate([180,0,0]) difference() {
-      translate( [0, 0, 5] ) cylinder( r=13, h=3, $fn=60 );
-      translate( [0, 0, 5+0.4] ) cylinder( r=M8_nut_diameter/2, h=7, $fn=6 );
-    }*/
 	}
 
 	translate( [0, 0, (nut_separation/2)] ) cylinder( r=M8_nut_diameter/2, h=7, $fn=6 );
 }
-
-  if(with_extra_parts)
-    cyclone_rod_z_gear_extras(exploded_distance = (exploded ?8:0));
-
-  module cyclone_rod_z_gear_extras(exploded_distance=false) {
-    echo("Non-Plastic Parts, 2, Nut M8 for rod_gear");
-    translate([0,0,0.8*8+nut_separation/2+exploded_distance]) rotate([180,0,0]) color(Steel) flat_nut(8);
-    translate([0,0,-0.8*8-10/2-exploded_distance]) rotate([0,0,0]) color(Steel) flat_nut(8);
-  }
-
 }
 
-cyclone_rod_z_gear();
+cyclone_rod_gear();

Hardware/CYCLONE_2/libs/standard_parts.scad

@@ -178,15 +178,15 @@ module stepperMotor(screwHeight=10, renderPart=false, echoPart=false) {
 
 
 
-module motorGear(r=30,renderPart=false, echoPart=false) {
+module motorGear(r=30,h=10,renderPart=false, echoPart=false) {
 	renderStandardPart(renderPart)
-		color("lightgreen") cylinder(r=r,h=10)
+		color("lightgreen") cylinder(r=r,h=h)
 	if(echoPart) echo(str("BOM: Gear. Motor."));
 }
 
-module rodGear(r=30,renderPart=false, echoPart=false) {
+module rodGear(r=30,h=10,renderPart=false, echoPart=false) {
 	renderStandardPart(renderPart)
-		color("lightgreen") cylinder(r=r,h=10)
+		color("lightgreen") cylinder(r=r,h=h)
 	if(echoPart) echo(str("BOM: Gear. Rod."));
 }