wip - remove heat set inserts

helper/screws.scad

@@ -137,20 +137,27 @@ module heatSetInsert(screwType) {
 
 }
 
-module hexNutPocket_N(screwType, openSide=true) {
+module hexNutPocket_N(screwType, openSide=true, backSpace=inf10, bridgeFront=false, bridgeBack=false ) {
+
+  heightSlack = bridgeFront || bridgeBack ? overhangSlack: xySlack;
+
   if (screwType == "m3") {
-    hexNutPocketHelper_N(m3RadiusSlacked, m3HexNutWidthAcrossCorners / 2 + 0.3, m3HexNutThickness + 0.3, openSide=openSide);
+    hexNutPocketHelper_N(m3RadiusSlacked, m3HexNutWidthAcrossCorners / 2 + 0.3, m3HexNutThickness + heightSlack, openSide=openSide, backSpace=backSpace, bridgeFront=bridgeFront, bridgeBack=bridgeBack);
   } else if (screwType == "m4") {
-    hexNutPocketHelper_N(m4RadiusSlacked, m4HexNutWidthAcrossCorners / 2 + 0.1, m4HexNutThickness + 0.2, openSide=openSide);
+    hexNutPocketHelper_N(m4RadiusSlacked, m4HexNutWidthAcrossCorners / 2 + 0.1, m4HexNutThickness + heightSlack, openSide=openSide, backSpace=backSpace, bridgeFront=bridgeFront, bridgeBack=bridgeBack);
   } else {
     error("Unsupported screw type");
   }
 }
 
-module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness, openSide=true) {
+module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness, openSide=true, backSpace=inf10, bridgeFront=false, bridgeBack=false) {
+
+  assert (!(bridgeFront && bridgeBack));
+  assert (!(openSide && bridgeFront));
+
   union() {
     hull() {
-      // hexagonal cylinder representing where the nut should fit
+      // hexagonal prism representing where the nut should fit
       cylinder(r = widthAcrossCorners, h = thickness, center = true, $fn = 6);
 
       // negative volume for sliding in the nut
@@ -158,9 +165,36 @@ module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness, openSide
       cylinder(r = widthAcrossCorners, h = thickness, center = true, $fn = 6);
     }
 
-    // negative volume for screw lead
-    translate(v = [0, 0, - 10])
-    cylinder(r = innerRadius, h = inf50, $fn = 32);
+    // negative volume for screw
+    union() {
+      // screw lead spacing
+      translate(v = [0, 0, -backSpace])
+      cylinder(r = innerRadius, h = backSpace, $fn = 32);
+
+      cylinder(r=innerRadius, h=inf50, $fn=32);
+
+      if (bridgeFront) {
+        union() {
+          // first bridge layer
+          translate(v=[0,0,thickness/2 + 0.2/2])
+          cube(size=[2*innerRadius, GtoF(widthAcrossCorners)*2, 0.2], center=true);
+
+          translate(v=[0,0,thickness/2+ 0.3])
+          cube(size=[2*innerRadius, 2*innerRadius, 0.2], center=true);
+        }
+      }
+
+      if (bridgeBack) {
+        union() {
+          // first bridge layer
+          translate(v=[0,0,-(thickness/2 + 0.2/2)])
+          cube(size=[2*innerRadius, GtoF(widthAcrossCorners)*2, 0.2], center=true);
+
+          translate(v=[0,0,-(thickness/2+ 0.3)])
+          cube(size=[2*innerRadius, 2*innerRadius, 0.2], center=true);
+        }
+      }
+    }
 
     if (openSide) {
       hull() {

helper/slack.scad

@@ -19,9 +19,9 @@ radiusXYSlack = xySlack/2;
 
 zSlack = 0.0; // TODO figure out nice default value for this. keep in mind z shrinkage
 
-overhangSlack = 0.6;
+overhangSlack = 0.4;
 
-supportedOverhangSlack = 0.5;
+supportedOverhangSlack = 0.4;
 
 
 // special slack cases, change if neccessary

rack/assemblyGuide.scad

@@ -17,7 +17,7 @@ assemblyInstructions();
 module assemblyInstructions () {
 
   screwMask = false;
-  plasticMask = true;
+  plasticMask = false;
   sideSupportRailMask = true;
 
   // Instruction List (in order)
@@ -28,7 +28,7 @@ module assemblyInstructions () {
   // attachXBarWithYBar(at=$t);
   // screwXBarAndYBar(at=$t);
   // attachSideConnectorModulesToYBars(at=$t);
-  // connectXYTrayWithMainRails(at=$t);
+  // connectXYTrayWithMainRails(at=1);
   // insertDowelsIntoSideWall(at=$t);
   // propUpBottomXYTraywithSideWalls(at=$t);
   // attachXYTrays(at=$t);
@@ -40,7 +40,7 @@ module assemblyInstructions () {
 
   // Final builds:
   // render()
-   finalSingle();
+  // finalSingle();
   // finalDouble();
 
   // Features:

rack/config.scad

@@ -8,10 +8,10 @@
 */
 include <./profiles.scad>
 
-profileName = "default";
+profileName = "micro";
 profile = getProfile(profileName);
 
-// echo("Profile:", profile);
+defaultLayerHeight = 0.3;
 
 function getConfig(name) = getConfigValue(profile, name);
 

rack/connector/basePlateYBarConnectors.scad

@@ -41,9 +41,9 @@ module onYBarBasePlateConnectorPositive() {
 
 module onYBarBasePlateConnectorNegative() {
 
-  translate(v=[_heatSetX, _heatSetY, m3HeatSetInsertSlotHeightSlacked + _baseConnRecession])
+  translate(v=[_heatSetX, _heatSetY, 4 + _baseConnRecession])
   mirror(v=[0,0,1])
-  heatSetInsertSlot_N(rackFrameScrewType, topExtension=inf10);
+  hexNutPocket_N("m3", openSide=false, backSpace=5, bridgeBack=true);
 
   hull() {
     translate(v = [_heatSetX, _heatSetY, _baseConnRecession+overhangSlack])

rack/connector/connectors.scad

@@ -15,9 +15,6 @@ include <./sideModuleYBarConnectors.scad>
 include <./stackYBarConnectors.scad>
 include <./basePlateYBarConnectors.scad>
 
-// WIP
-partList = ["yBar", "xBar", "mainRail", "xyPlate", "sideModule"];
-
 mirror(v=[1,0,0])
 *connectorDebug(on="xBar", to="yBar", trans=identity);
 

rack/connector/mainRailYBarConnectors.scad

@@ -1,6 +1,7 @@
 include <../../helper/screws.scad>
 include <../../helper/common.scad>
 include <../../helper/matrix.scad>
+include <../../helper/halfspace.scad>
 include <../../helper/slack.scad>
 include <../../helper/dovetail.scad>
 include <../../helper/halfspace.scad>
@@ -10,7 +11,8 @@ include <../sharedVariables.scad>
 include <../config.scad>
 
 mainRailHeatSetOnYBarDx = railSideMountThickness + 5;
-mainRailHeatSetOnYBarDy = railFrontThickness + 4;
+mainRailHeatSetOnYBarDy = railFrontThickness + 2;
+
 module onYBarToMainRailNegative() {
 
   slotSlack = xySlack;
@@ -20,20 +22,30 @@ module onYBarToMainRailNegative() {
     translate(v=[-slotZSlack/2, -slotSlack/2,0])
     cube(size = [railTotalWidth+slotZSlack, railTotalDepth + slotSlack, railFootThickness]);
 
-    translate(v = [mainRailHeatSetOnYBarDx, mainRailHeatSetOnYBarDy, -m3HeatSetInsertSlotHeightSlacked])
-    heatSetInsertSlot_N(rackFrameScrewType);
+    translate(v = [mainRailHeatSetOnYBarDx, mainRailHeatSetOnYBarDy, -5])
+    rotate(a=[-45,0,0])
+    hexNutPocket_N("m3", openSide=false, backSpace=5);
   }
 }
 
-
 module onMainRailYBarConnectorPositive() {
-
   cube(size = [frontFaceWidth, sideSupportDepth+railFrontThickness, railFootThickness]);
+
+  // TODO magic numbers
+  hull() {
+    cube(size = [frontFaceWidth, railFrontThickness+8, railFootThickness+4]);
+    translate(v = [0, railFrontThickness+14, 0])
+    cube(size = [frontFaceWidth, 1, railFootThickness]);
+  }
 }
 
 
 module onMainRailYBarConnectorNegative() {
 
-  translate(v = [mainRailHeatSetOnYBarDx, mainRailHeatSetOnYBarDy, railFootThickness])
-  counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
+screwOffset = 9;
+
+  translate(v = [mainRailHeatSetOnYBarDx, mainRailHeatSetOnYBarDy + screwOffset, -5 + screwOffset])
+  rotate(a=[-45,0,0])
+  counterSunkHead_N(rackFrameScrewType, screwExtension=inf50, headExtension=inf50);
+
 }

rack/connector/sideModuleYBarConnectors.scad

@@ -13,6 +13,7 @@ module onYBarSideModuleNegative() {
   translate(v = [-xySlack/2, -xySlack/2, -sideWallConnLugDepression])
   cube(size = [sideWallConnW+xySlack, sideWallConnD+xySlack, sideWallConnLugDepression]);
 
-  translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, -(m3HeatSetInsertSlotHeightSlacked+sideWallConnLugDepression)])
-  heatSetInsertSlot_N(rackFrameScrewType);
+  translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, -(4+sideWallConnLugDepression)])
+  rotate(a=[0,0,90])
+  hexNutPocket_N("m3", openSide=false, backSpace=5, bridgeFront=true);
 }

rack/connector/xBarYBarConnectors.scad

@@ -42,9 +42,10 @@ module onXBarToYBarNegative() {
 module onYBarToXBarNegative() {
   y = 27;
   z = 6;
-  translate(v = [-m3HeatSetInsertSlotHeightSlacked, y, z])
+  translate(v = [-5, y, z])
+  rotate(a = [180, 0, 0])
   rotate(a = [0, 90, 0])
-  heatSetInsertSlot_N(rackFrameScrewType);
+  hexNutPocket_N("m3", openSide=false, backSpace=5);
 
 }
 

rack/mainRail.scad

@@ -8,7 +8,7 @@ include <../helper/matrix.scad>
 
 include <./connector/connectors.scad>
 
-//mainRail();
+*mainRail();
 
 module mainRail() {
 

rack/print/yBar_P.scad

@@ -7,7 +7,10 @@ include <../xBar.scad>
 yBar();
 
 
-translate(v=[40,0,0])
-mirror(v=[1,0,0])
-rotate(a=[0,0,90])
-*xBar();
+*difference() {
+  translate(v=[2,0,0])
+  cube(size=[16,10,6], center=true);
+  hexNutPocket_N("m3", openSide = false, backSpace = 5, bridgeFront = true);
+}
+
+*hexNutPocket_N("m3", openSide = false, backSpace = 5, bridgeBack = true);

rack/yBar.scad

@@ -50,12 +50,14 @@ yBarStackConnectorTrans = translate(v = [connectorXEdgeToYBarXEdge, connectorYEd
 
 yBarSideModuleConnectorTrans = translate(v = [
     yBarWidth-(railTotalWidth+railSlotToInnerYEdge+railSlotToSideWallSlot+sideWallConnectorSlotWidth),
-  sideWallSlotToXZ,
-  yBarHeight]);
+    sideWallSlotToXZ,
+    yBarHeight
+  ]);
 
 yBarMainRailConnectorTrans = translate(v = [
     yBarWidth-(railTotalWidth+railSlotToInnerYEdge),
-  railSlotToXZ,
-    yBarHeight-railFootThickness]);
+    railSlotToXZ,
+    yBarHeight-railFootThickness
+  ]);
 
 yBarXBarConnectorTrans = translate(v = [yBarWidth+eps, 0, 0]);