More wiring updates.

Makefile

@@ -4,7 +4,7 @@ CONVERT=convert
 PARTFILES=$(sort $(wildcard *_parts.scad))
 TARGETS=$(patsubst %.scad,STLs/%.stl,${PARTFILES})
 ROTFILES=$(shell seq -f 'wiki/snappy_rot%03g.png' 0 10 359.99)
-ASM_MODULES=$(shell grep 'module [a-z0-9_]*_assembly' full_assembly.scad | sed 's/^module //' | sed 's/[^a-z0-9_].*$$//')
+ASM_MODULES=$(shell grep 'module [a-z0-9_]*_assembly' full_assembly.scad | sed 's/^module //' | sed 's/[^a-z0-9_].*$$//' | sed '1!G;h;$$!d')
 ASM_BEFORE_TARGETS=$(patsubst %,docs/assembly/%_before.png,${ASM_MODULES})
 ASM_AFTER_TARGETS=$(patsubst %,docs/assembly/%_after.png,${ASM_MODULES})
 

TODO.md

@@ -1,5 +1,4 @@
 TODO:
 ====
 
-- Screwless mounts for limit switches.
 

config.scad

@@ -15,7 +15,6 @@ platform_thick  =   7.0;  // mm
 rail_length     = 133.3;  // mm
 rail_height     =  50.0;  // mm
 rail_thick      =   7.0;  // mm
-rail_offset     =  12.0;  // mm
 
 motor_rail_length = 133.3; // mm
 
@@ -33,7 +32,7 @@ gear_teeth          =  8;
 set_screw_size      =  3;    // mm size of set screw in drive gears, couplers, etc
 motor_length        = 39.25; // mm length of NEMA17 motor.
 motor_shaft_size    =  5;    // mm diameter of NEMA17 motor shaft.
-motor_shaft_length  = 20;    // mm length of NEMA17 motor shaft.
+motor_shaft_length  = 20;    // mm length of exposed NEMA17 motor shaft.
 motor_shaft_flatted = true;  // Is motor shaft keyed? (RECOMMENDED)
 
 // Currently configured for 3/8" ACME threaded rod.
@@ -124,6 +123,8 @@ gear_backlash = printer_slop/2;
 
 
 // Commonly used derived values.  Don't change these.
+shaft_clear = max(20.0, motor_shaft_length)-20.0;
+rail_offset = shaft_clear+12.0;
 rail_spacing = platform_width - joiner_width*4 - 10;
 rail_width = rail_spacing + joiner_width*2;
 motor_mount_spacing=43+joiner_width+10;

docs/assembly/index.html

@@ -3,43 +3,43 @@
 <title>Snappy Assembly</title>
 <style>
 BODY {
-    margin-bottom: 200px;
+  margin-bottom: 200px;
 }
 TABLE TD {
-    vertical-align: middle;
+  vertical-align: middle;
 }
 H2 {
-    margin-bottom: 5px;
-    margin-top: 24px;
-    font-size: 20pt;
+  margin-bottom: 5px;
+  margin-top: 24px;
+  font-size: 20pt;
 }
 LI.section {
-    font-size: 20pt;
-    font-weight: bold;
+  font-size: 20pt;
+  font-weight: bold;
 }
 H3 {
-    margin-left: -15px;
-    margin-bottom: 5px;
-    margin-top: 18px;
-    font-size: 16pt;
+  margin-left: -15px;
+  margin-bottom: 5px;
+  margin-top: 18px;
+  font-size: 16pt;
 }
 LI.step {
-    padding-left: 15px;
-    margin-left: 0;
-    font-size: 16pt;
-    font-weight: bold;
-    list-style-type: none;
+  padding-left: 15px;
+  margin-left: 0;
+  font-size: 16pt;
+  font-weight: bold;
+  list-style-type: none;
 }
 DIV.desc {
-    margin-bottom: 15px;
-    font-size: 12pt;
-    font-weight: normal;
+  margin-bottom: 15px;
+  font-size: 12pt;
+  font-weight: normal;
 }
 OL {
-    margin-left: 30px;
+  margin-left: 30px;
 }
 UL {
-    padding-left: 5px;
+  padding-left: 5px;
 }
 </style>
 </head>
@@ -54,9 +54,9 @@ UL {
 <div class="desc">Attach a limit micro-switch (with wiring) to one of the side clips, with the lever end towards the center. Do this again for a second switch and mount plate.</div>
 <table><tr><td class="befor"><img src="motor_mount_assembly_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="motor_mount_assembly_after.png"></td></tr></table>
 </li>
-<li class="section"><h2>XY Motor Segment Assembly</h2>
-<div class="desc">Seat the stepper motor with drive gear in the X/Y motor rail segment. Clamp it into place with a motor mount plate with micro-switch. Repeat this to make a second XY motor segment assembly. On one, route the wiring out a side wiring access hole opposite the limit switch, and on the other, route it out one end.</div>
-<table><tr><td class="befor"><img src="xy_motor_segment_assembly_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="xy_motor_segment_assembly_after.png"></td></tr></table>
+<li class="section"><h2>Y Motor Segment Assembly</h2>
+<div class="desc">Seat the stepper motor with drive gear in the X/Y motor rail segment. Clamp it into place with a motor mount plate with micro-switch. Route the wiring out a side wiring access hole opposite the limit switch.</div>
+<table><tr><td class="befor"><img src="y_motor_segment_assembly_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="y_motor_segment_assembly_after.png"></td></tr></table>
 </li>
 <li class="section"><h2>Y Axis Assembly</h2>
 <ul>
@@ -90,6 +90,10 @@ UL {
 </li>
 </ul>
 </li>
+<li class="section"><h2>X Motor Segment Assembly</h2>
+<div class="desc">Seat the stepper motor with drive gear in the X/Y motor rail segment. Clamp it into place with a motor mount plate with micro-switch. Route the wiring out one end.</div>
+<table><tr><td class="befor"><img src="x_motor_segment_assembly_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_motor_segment_assembly_after.png"></td></tr></table>
+</li>
 <li class="section"><h2>X Axis Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
@@ -101,27 +105,39 @@ UL {
 <table><tr><td class="befor"><img src="x_axis_assembly_2_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_2_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 3</h3>
-<div class="desc">Join an X sled endcap assembly to one end of the X sled central assembly.</div>
+<div class="desc">Join the X sled cable-chain mount to the front/left side of the X sled endstop.</div>
 <table><tr><td class="befor"><img src="x_axis_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_3_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 4</h3>
-<div class="desc">Slide the X sled partial assembly onto the X axis rails assembly, so that it is centered.</div>
+<div class="desc">Join an X sled endcap assembly to one end of the X sled central assembly.</div>
 <table><tr><td class="befor"><img src="x_axis_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_4_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 5</h3>
-<div class="desc">Connect the Y axis assembly to the XY joiner on the X axis partial assembly. Route the Y axis wiring through the front hole in the XY joiner.</div>
+<div class="desc">Slide the X sled partial assembly onto the X axis rails assembly, so that it is centered.</div>
 <table><tr><td class="befor"><img src="x_axis_assembly_5_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_5_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 6</h3>
-<div class="desc">Join the other X sled endcap assembly to the end of the X sled assembly, fixing the Y sled assembly in place.</div>
+<div class="desc">Connect the Y axis assembly to the XY joiner on the X axis partial assembly. Route the Y axis wiring through the front hole in the XY joiner.</div>
 <table><tr><td class="befor"><img src="x_axis_assembly_6_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_6_after.png"></td></tr></table>
 </li>
+<li class="step"><h3>Step 7</h3>
+<div class="desc">Join the other X sled endcap assembly to the end of the X sled assembly, fixing the Y sled assembly in place.</div>
+<table><tr><td class="befor"><img src="x_axis_assembly_7_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_7_after.png"></td></tr></table>
+</li>
+<li class="step"><h3>Step 8</h3>
+<div class="desc">Attach the cable chain joiner mount to the X motor segment, on the same side as the X sled cable chain joiner and Y axis wiring.</div>
+<table><tr><td class="befor"><img src="x_axis_assembly_8_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_8_after.png"></td></tr></table>
+</li>
+<li class="step"><h3>Step 9</h3>
+<div class="desc">Attach the cable-chain assembly (with 13 or 14 links) to the cable chain mounts on the X axis assembly, making sure to feed the Y-axis wiring through the cable chain.  Route the wiring in through the wiring access hole beside the cable chain mount, then out through the end of the X axis assembly.</div>
+<table><tr><td class="befor"><img src="x_axis_assembly_9_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="x_axis_assembly_9_after.png"></td></tr></table>
+</li>
 </ul>
 </li>
 <li class="section"><h2>Z Tower Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
-<div class="desc">Seat the stepper motor in the Z motor rail segment. Clamp it into place with a motor mount plate without micro-switch.</div>
+<div class="desc">Seat the stepper motor in the Z motor rail segment.  Clamp it into place with a motor mount plate without micro-switch.  Route the motor wiring out the bottom of the rail.</div>
 <table><tr><td class="befor"><img src="z_tower_assembly_1_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_1_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 2</h3>
@@ -144,12 +160,16 @@ UL {
 <div class="desc">Attach support legs to each side of the yz_joiner part.</div>
 <table><tr><td class="befor"><img src="z_tower_assembly_6_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_6_after.png"></td></tr></table>
 </li>
-<li class="step"><h3>Step 7</h3>
-<div class="desc">Attach the Z rail assembly to the top of the YZ joiner assembly. Repeat steps 1 through 7 to make a second Z tower.</div>
-<table><tr><td class="befor"><img src="z_tower_assembly_7_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="z_tower_assembly_7_after.png"></td></tr></table>
-</li>
 </ul>
 </li>
+<li class="section"><h2>Left Z Tower Assembly</h2>
+<div class="desc">Attach the Z rail assembly to the top of a YZ joiner assembly. Route the wires through the back of the YZ joiner.</div>
+<table><tr><td class="befor"><img src="left_z_tower_assembly_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="left_z_tower_assembly_after.png"></td></tr></table>
+</li>
+<li class="section"><h2>Right Z Tower Assembly</h2>
+<div class="desc">Attach the Z rail assembly to the top of the YZ joiner assembly. Route the wires through the front of the YZ joiner.</div>
+<table><tr><td class="befor"><img src="right_z_tower_assembly_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="right_z_tower_assembly_after.png"></td></tr></table>
+</li>
 <li class="section"><h2>Extruder Bridge Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
@@ -165,7 +185,7 @@ UL {
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_3_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 4</h3>
-<div class="desc">Slide the JHead extruder hot end into the slot in the bottom of the JHead platform.</div>
+<div class="desc">Slide the JHead extruder hot end into the slot in the bottom of the JHead platform.  Route the wiring up through the wiring access slot, and along the back of the extruder platform.</div>
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_4_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 5</h3>
@@ -185,7 +205,7 @@ UL {
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_8_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_8_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 9</h3>
-<div class="desc">Clip a cooling fan to the top of the extruder fan shroud using the extruder fan clip part.</div>
+<div class="desc">Clip a cooling fan to the top of the extruder fan shroud using the extruder fan clip part.  Route the wiring along the back side of the extruder platform.</div>
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_9_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_9_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 10</h3>
@@ -193,53 +213,61 @@ UL {
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_10_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_10_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 11</h3>
-<div class="desc">Attach the cooling fan shroud assembly to the bottom of the extruder fan shroud.</div>
+<div class="desc">Attach the cooling fan shroud assembly to the bottom of the extruder fan shroud.  Route the wiring up through the wiring access slot, and along the back side of the extruder platform.</div>
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_11_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_11_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 12</h3>
-<div class="desc">Attach rail segments to either end of the extruder platform assembly.</div>
+<div class="desc">Attach rail segments to either end of the extruder platform assembly.  Route the wiring through the left side rail segment, and out the front-left wiring access hole.</div>
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_12_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_12_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 13</h3>
-<div class="desc">Attach rail segments to either end of the extruder platform assembly.</div>
+<div class="desc">Attach a vertical cable-chain mount to the front left side of the extruder bridge.</div>
 <table><tr><td class="befor"><img src="extruder_bridge_assembly_13_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_13_after.png"></td></tr></table>
 </li>
+<li class="step"><h3>Step 14</h3>
+<div class="desc">Attach Z sled segments to either end of the extruder bridge assembly.</div>
+<table><tr><td class="befor"><img src="extruder_bridge_assembly_14_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="extruder_bridge_assembly_14_after.png"></td></tr></table>
+</li>
 </ul>
 </li>
 <li class="section"><h2>Final Assembly</h2>
 <ul>
 <li class="step"><h3>Step 1</h3>
-<div class="desc">Attach the two Z tower assemblies to either end of the XY axes assembly.</div>
+<div class="desc">Attach the right Z tower assembly to the right end of the XY axes assembly.  Route the right tower wiring through the rear X axis wiring access holes.</div>
 <table><tr><td class="befor"><img src="final_assembly_1_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_1_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 2</h3>
-<div class="desc">Lower the extruder bridge down into the Z tower grooves, screwing the lifter rods into the Z sleds evenly.</div>
+<div class="desc">Attach the left Z tower assembly to the left end of the XY axes assembly.  Route all wiring out the back of the left Z tower base.</div>
 <table><tr><td class="befor"><img src="final_assembly_2_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_2_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 3</h3>
-<div class="desc">Attach a limit microswitch, with wiring, to the Z rail endcap.</div>
+<div class="desc">Lower the extruder bridge down into the Z tower grooves, screwing the lifter rods into the Z sleds evenly.</div>
 <table><tr><td class="befor"><img src="final_assembly_3_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_3_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 4</h3>
-<div class="desc">Attach the Z tower endcap.</div>
+<div class="desc">Attach a limit microswitch, with wiring, to the Z rail endcap.</div>
 <table><tr><td class="befor"><img src="final_assembly_4_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_4_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 5</h3>
-<div class="desc">Attach the spool holder to the top of the other Z tower.</div>
+<div class="desc">Attach the Z tower endcap to the left Z tower.  Route the limit switch wiring down through the wiring access holes in the left Z tower, and out the back of the base with the other wiring.</div>
 <table><tr><td class="befor"><img src="final_assembly_5_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_5_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 6</h3>
-<div class="desc">Attach the RAMPS motherboard mount to the end of the printer base.</div>
+<div class="desc">Attach the spool holder to the top of the other Z tower.</div>
 <table><tr><td class="befor"><img src="final_assembly_6_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_6_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 7</h3>
-<div class="desc">Clip the glass build platform to the build platform supports using four binder clips.</div>
+<div class="desc">Attach the RAMPS motherboard mount to the end of the printer base.</div>
 <table><tr><td class="befor"><img src="final_assembly_7_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_7_after.png"></td></tr></table>
 </li>
 <li class="step"><h3>Step 8</h3>
-<div class="desc">Cradle the spool axle in the spool holder top.</div>
+<div class="desc">Clip the glass build platform to the build platform supports using four binder clips.</div>
 <table><tr><td class="befor"><img src="final_assembly_8_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_8_after.png"></td></tr></table>
 </li>
+<li class="step"><h3>Step 9</h3>
+<div class="desc">Cradle the spool axle in the spool holder top.</div>
+<table><tr><td class="befor"><img src="final_assembly_9_before.png"></td><td class="arrow"><img src="arrow.png"></td><td class="after"><img src="final_assembly_9_after.png"></td></tr></table>
+</li>
 </ul>
 </li>
 </ol>