// 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/)
 /*
 * August 2013 changes to design top-part mounting screw at same side as bottom-part.
 * also started introduced 2nd spindle diameter for a-symmetrical spindles. this is not working yet.
 * by Harry Binnema. 
 */

use <../libs/obiscad/bcube.scad>
use <../libs/build_plate.scad>
use <../libs/Write/Write.scad>

spindle_motor_diam_top = 26*2;
spindle_motor_diam = 26*2;
spindle_holder_thickness = 8;
spindle_holder_distance = 46;
spindle_motor_length = 100;

bottom_thickness = 4;
base_width = 20;
base_length = 25;
base_screw_diameter = 5;

motor_width = 43;
motor_length = 49; // not used
motor_screw_distance = 31.3;
motor_center_diameter = 23;

motor_adjust_margin = 3;

motor_screw_diameter = 3.7;
motor_screw_head_diameter = 8;

bearing_diameter = 22.4;
M8_rod_diameter = 8.2;

axis_distance = 21;

wall_thickness = 9;
wall_height = motor_width;
wall_width = 54;

idler_width = 25;

lbearing_holder_length = 23*2;

Z_threaded_pos = motor_width/2+axis_distance;

Z_smooth_rods_sep = 55;

textHscale = 0.8;
textThickness = 1;

LM8UU_dia = 15.4;

module dummySpindle() {
	translate([0,0,-length]) {
		translate([0,0,spindle_motor_length-5]) color([0.95,0.95,0.95]) cylinder(r=26,h=30,$fn=60);
		translate([0,0,spindle_motor_length-10]) color([0.95,0.95,0.95]) cylinder(r=10/2,h=5,$fn=60);
		translate([0,0,-10]) color([0.6,0.6,0.6]) cylinder(r=26,h=spindle_motor_length,$fn=60);
		translate([0,0,-40]) color([0.9,0.9,0.9]) cylinder(r=15/2,h=40,$fn=60);
		translate([0,0,-50]) color([0.4,0.4,0.4]) cylinder(r=20/2,h=10,$fn=60);
		translate([0,0,-50-20]) color([0.9,0.9,0.9]) cylinder(r1=1/2,r2=3/2,h=20,$fn=60);
	}
}

// Derived from Spindle mount for ShapeOko by Misan (http://www.thingiverse.com/thing:26740)
module spindle_holder_holes(length,spindiam, basediam,top_part) {
	$fn=6;

	translate([20,8,-0.05]) cylinder(r=basediam/2,h=length+2,$fn=60);
	translate([-20,8,-0.05]) cylinder(r=basediam/2,h=length+2,$fn=60);
	if (top_part){
		translate([0,38,0]) rotate([0,0,0]) {
		translate([0,0,-0.05]) cylinder(r=spindiam/2,h=length+2,$fn=60);
		translate([0,-3,-0.01]) cube([90,3,length+2]);
		translate ([spindiam/2+15,15,length/2]) rotate([90,0,0]) cylinder(r=2,h=30);
		translate ([spindiam/2+15,-10.5,length/2]) rotate([90,0,0]) cylinder(r=3.5,h=4,$fn=6);
		}		
		}
	else
		{
		translate([0,38,0]) rotate([0,0,180]) {
		translate([0,0,-0.05]) cylinder(r=spindiam/2,h=length+2,$fn=60);
		translate([0,0,-0.01]) cube([90,3,length+2]);
		translate ([spindiam/2+15,20,length/2]) rotate([90,0,0]) cylinder(r=2,h=30);
		translate ([spindiam/2+15,15,length/2]) rotate([90,0,0]) cylinder(r=3.5,h=4,$fn=6);
		}
		}
}



module motorHolesZ() {
    // 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);
    }

    // Hole for the screwdriver
    translate([0,-wall_width/2,wall_thickness/2]) rotate([0,90,90]) bcube([2*(wall_thickness-5),5,wall_height],cr=1);

    // Screws for holding the motor
    for(i=[-1,1]) for(j=[-1,1])
    translate([i*motor_screw_distance/2,j*motor_screw_distance/2,2.5-wall_thickness/2]) {
      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);
      }
      hull() {
        translate([0,motor_adjust_margin/2,0])
          cylinder(r=motor_screw_head_diameter/2,h=10*wall_thickness,center=false,$fn=40);
        translate([0,-motor_adjust_margin/2,0])
          cylinder(r=motor_screw_head_diameter/2,h=10*wall_thickness,center=false,$fn=40);
      }
    }
}


module motor_stand_holes_Z() {
//difference() {
//  translate([wall_height/2,wall_width/2,wall_thickness/2])
//    bcube([wall_height,wall_width,wall_thickness],cr=4,cres=10);

  // Position relative to motor shaft
  translate([motor_width/2,motor_width/2,wall_thickness/2]) {
    motorHolesZ();

    // Bearing holes
    rotate([0,0,0]) translate([0,axis_distance,0]) {
		hull() {
      	cylinder(r=(M8_rod_diameter*2)/2,h=10*wall_thickness,center=true,$fn=40);
			translate([0,-axis_distance,0])
				cylinder(r=(M8_rod_diameter*2)/2,h=10*wall_thickness,center=true,$fn=40);
		}
      cylinder(r=bearing_diameter/2,h=10*wall_thickness,center=false,$fn=60);

    }

  } // End of translate relative to motor shaft
//} // End of difference
}


module linearBearingHolderZ(h=10) {
	translate([0,0,1.5]) cylinder(r=LM8UU_dia/2,h=h,$fn=50);
	cylinder(r=LM8UU_dia/2.5,h=10*h,center=true,$fn=50);
}


module Z_solid_body(top_part=true) {
	hull() {
		if(top_part)
			translate([wall_height/2,wall_width/2,wall_thickness/2])
				bcube([wall_height,wall_width,wall_thickness],cr=4,cres=10);
		else
			translate([wall_height/2,wall_width,wall_thickness/2])
				bcube([wall_height,wall_width/2,wall_thickness],cr=4,cres=10);
		translate([wall_height/2,wall_width-4,0])
			translate([0,38,0])
				cylinder(r=spindle_motor_diam/2+spindle_holder_thickness,h=wall_thickness,$fn=60);
	}

	// For the linear bearing holders
	hull() {
		translate([wall_height/2-Z_smooth_rods_sep/2,Z_threaded_pos,0])
			cylinder(r=3+LM8UU_dia/2,h=wall_thickness,$fn=50);
		translate([wall_height/2+Z_smooth_rods_sep/2,Z_threaded_pos,0])
			cylinder(r=3+LM8UU_dia/2,h=wall_thickness,$fn=50);
	}

	// For the claw of the spindle holder
if(top_part){
	translate([wall_height/2,wall_width-4,0])
		translate([0,38,0]) {
			rotate([0,0,0]) {
				translate([spindle_motor_diam/2,-12.5,0]) cube([25,20,wall_thickness]);
				
	// Write text in the front
	color([0.5,0.5,0.5])
			rotate([0,0,180]) scale([-1,1,-textHscale])
				writecylinder("CYCLONE",[0,0,-wall_thickness/(2*textHscale)],spindle_motor_diam/2+spindle_holder_thickness,0,font="orbitron.dxf",space=1.1,h=wall_thickness,t=textThickness,center=true,ccw=true);
			}
		}
}
else
translate([wall_height/2,wall_width-4,0])
		translate([0,38,0]) {
			
			rotate([0,0,180]) {
			translate([spindle_motor_diam/2,-7,0]) cube([25,20,wall_thickness]);
			color([0.2,0.2,0.5])
			scale([1,1,textHscale])
				writecylinder("PCB Factory",[0,0,wall_thickness/(2*textHscale)+1],spindle_motor_diam/2+spindle_holder_thickness,0,font="orbitron.dxf",space=1.1,h=wall_thickness-2,t=textThickness,center=true,ccw=true);
			}
		}
}

//for display only, doesn't contribute to final object
//build_plate(3,200,200);

module Z_carriage(showSpindle=false,top_part=true) {

	difference() {
		rotate([0,0,-90]) translate([-wall_height/2,-Z_threaded_pos,0]) {
			difference () {
				Z_solid_body(top_part);
				if(top_part) motor_stand_holes_Z();
				translate([wall_height/2,wall_width-4,0])
					spindle_holder_holes(wall_thickness,spindle_motor_diam,base_screw_diameter,top_part);
				translate([wall_height/2-Z_smooth_rods_sep/2,Z_threaded_pos,0])
					linearBearingHolderZ(wall_thickness);
				translate([wall_height/2+Z_smooth_rods_sep/2,Z_threaded_pos,0])
					linearBearingHolderZ(wall_thickness);
			}
		}

		// Hole for the threaded rod
		if(!top_part) {
			hull() {
				cylinder(r=2+M8_rod_diameter/2,h=wall_thickness*10,center=true,$fn=30);
				translate([-15,0,0])
					cylinder(r=2+M8_rod_diameter/2,h=wall_thickness*10,center=true,$fn=30);
			}
		}

		// Truncation in the base for avoiding collision with the X axis
		if(!top_part) translate([-15,0,0]) rotate([0,45,0]) cube([20,100,10],center=true);
	}
	if(showSpindle) rotate([0,0,-90]) translate([0,wall_width-4-Z_threaded_pos,0])
			translate([0,38,-20+8]) dummySpindle();
}

module Z_carriage_assembled() {
	Z_carriage(showSpindle=true,top_part=false);
	translate([0,0,3+spindle_holder_distance]) rotate([180,0,0]) Z_carriage(showSpindle=false,top_part=true);
}

//Z_carriage(top_part=true);
//Z_carriage(top_part=false);


Z_carriage_assembled();