Centralized slop setting, and improved slop calibration model.

Makefile

@@ -16,12 +16,31 @@ include $(wildcard *.deps)
 	${OPENSCAD} -m make -o $@ -d $@.deps $<
 
 clean:
-	rm -f ${TARGETS} *.deps
+	rm -f ${TARGETS} *.deps snappy_rot*.png
 
 rendering:
-	${OPENSCAD} -o wiki/snappy_full.png --imgsize=3200,3200 --projection=p --csglimit=100000 --camera=-100,200,150,65,0,120,3500 full_assembly.scad
+	${OPENSCAD} -o wiki/snappy_full.png --imgsize=3200,3200 --projection=p --csglimit=100000 \
+	    --camera=0,0,160,65,0,120,3500 full_assembly.scad
 	cp wiki/snappy_full.png wiki/snappy_small.png
 	sips -Z 800 wiki/snappy_full.png
 	sips -Z 200 wiki/snappy_small.png
 
 
+ROTFILES=$(shell seq -f 'snappy_rot%03g.png' 0 15 359.99)
+
+${ROTFILES}: full_assembly.scad
+	${OPENSCAD} -o $@ --imgsize=1280,1280 --projection=p --csglimit=100000 \
+	    --camera=0,0,160,65,0,$(subst snappy_rot,,$(subst .png,,$@)),3500 \
+	    full_assembly.scad
+	sips --deleteColorManagementProperties -Z 640 $@
+
+wiki/snappy_animated.gif: ${ROTFILES}
+	convert -delay 33 -loop 0 ${ROTFILES} wiki/snappy_animated.gif
+
+wiki/snappy_anim_small.gif: ${ROTFILES}
+	convert -resize 200x200 -delay 33 -loop 0 ${ROTFILES} wiki/snappy_anim_small.gif
+
+animation: wiki/snappy_animated.gif wiki/snappy_anim_small.gif
+
+
+

acme_screw.scad

@@ -1,3 +1,4 @@
+include <config.scad>
 use <GDMUtils.scad>
 
 
@@ -35,7 +36,7 @@ module acme_threaded_nut(
 	h=10,
 	threading=3.175,
 	thread_depth=1,
-	slop=0.25
+	slop=printer_slop
 ) {
 	difference() {
 		cylinder(r=od/2/cos(30), h=h, center=true, $fn=6);

config.scad

@@ -5,7 +5,6 @@ platform_length = 110; // mm.  Must be a multiple of rack_tooth_size.
 platform_width  = 150; // mm
 platform_height =  40; // mm
 platform_thick  =   7; // mm
-rack_tooth_size =   5; // mm per tooth.
 
 rail_length  = 150;    // mm
 rail_height  =  50;    // mm
@@ -21,7 +20,11 @@ roller_angle =  30;    // degrees
 
 joiner_angle =  30;    // degrees
 joiner_width =  10;    // mm
-joiner_slop  =   0.5;  // mm
+
+rack_tooth_size  =  5; // mm per tooth.
+set_screw_size   =  3; // mm size of set screw in drive gears, couplers, etc
+motor_shaft_size =  5; // mm
+motor_shaft_flatted = false;  // boolean
 
 // Currently configured for 3/8" ACME threaded rod and matching 11/16" nut
 lifter_rod_diam   =   9.5; // mm
@@ -30,6 +33,10 @@ lifter_nut_size   =  17.4; // mm
 lifter_nut_thick  =   9.3; // mm
 lifter_thread_size =  3.175; // mm lift per revolution
 
+// This is the slop needed to make parts fit more exactly, and may be
+// printer dependant.  Printing a slop calibration plate should help
+// dial this setting in for your printer.
+printer_slop =   0.25; // mm
 
 
 

drive_gear_parts.scad

@@ -5,14 +5,15 @@ use <publicDomainGearV1.1.scad>
 
 module drive_gear() {
 	h = 10;
-	shaft = 5.4;
+	shaft = motor_shaft_size + 2 * printer_slop;
+
 	color("Salmon") render(convexity=10) union() {
 		difference() {
 			// Herringbone gear
 			mirror_copy([0, 0, 1]) {
 				translate([0, 0, h/4]) {
 					gear (
-						mm_per_tooth    = 5,
+						mm_per_tooth    = rack_tooth_size,
 						number_of_teeth = 9,
 						thickness       = h/2,
 						hole_diameter   = shaft,
@@ -29,7 +30,7 @@ module drive_gear() {
 		difference() {
 			union() {
 				// Fix up gear weirdness with solid center.
-				cylinder(h=h, r=5.5, center=true);
+				cylinder(h=h, r=shaft, center=true);
 
 				// Base
 				translate([0, 0, -(h+11)/2])
@@ -40,23 +41,25 @@ module drive_gear() {
 				// Shaft hole
 				cylinder(h=(h+5)*3, r=shaft/2, center=true, $fn=16);
 
-				// Shaft flat side.
-				translate([1.4*shaft, 0, 0])
-					cube(size=[shaft*2, shaft*2, (h+6)*3], center=true);
+				if (motor_shaft_flatted) {
+					// Shaft flat side.
+					translate([1.4*shaft, 0, 0])
+						cube(size=[shaft*2, shaft*2, (h+6)*3], center=true);
+				}
 			}
 
-			translate([5/2+1, 0, -(h/2+5+11)/2]) {
+			translate([motor_shaft_size/2+1.5, 0, -(h/2+5+11)/2]) {
 				yrot(90) {
 					// Nut Slot
 					scale([1.1, 1.1, 1.1]) hull() {
-						metric_nut(size=3, hole=false);
+						metric_nut(size=set_screw_size, hole=false);
 						translate([5, 0, 0])
-							metric_nut(size=3, hole=false);
+							metric_nut(size=set_screw_size, hole=false);
 					}
 
 					// Set screw hole.
 					translate([0, 0, 2])
-						cylinder(r=3.2/2, h=9, center=true, $fn=8);
+						cylinder(r=(set_screw_size+printer_slop)/2, h=9, center=true, $fn=8);
 				}
 			}
 		}

full_assembly.scad

@@ -188,7 +188,7 @@ module full_assembly()
 
 
 
-full_assembly();
+translate([0,-1.5*rail_length,0]) full_assembly();
 
 
 

joiners.scad

@@ -2,7 +2,7 @@ include <config.scad>
 use <GDMUtils.scad>
 
 
-module joiner(h=40, w=10, l=10, a=30, screwsize=3, guides=true)
+module joiner(h=40, w=10, l=10, a=30, screwsize=3, guides=true, slop=printer_slop)
 {
 	dmnd_height = h/2;
 	dmnd_width = dmnd_height*tan(a);
@@ -28,15 +28,15 @@ module joiner(h=40, w=10, l=10, a=30, screwsize=3, guides=true)
 				// Make tab
 				translate([0,0,dmnd_height/2]) {
 					translate([0, -dmnd_width/4, 0])
-						cube(size=[w/3-joiner_slop, dmnd_width/2, dmnd_height], center=true);
-					scale([w/3-joiner_slop, dmnd_width/2, dmnd_height/2]) xrot(45)
+						cube(size=[w/3-slop*2, dmnd_width/2, dmnd_height], center=true);
+					scale([w/3-slop*2, dmnd_width/2, dmnd_height/2]) xrot(45)
 						cube(size=[1,sqrt(2),sqrt(2)], center=true);
 				}
 
 				// Guide ridges.
 				if (guides == true) {
 					translate([0,0,dmnd_height/2]) {
-						grid_of(xa=[-(w/6-joiner_slop/2), (w/6-joiner_slop/2)]) {
+						grid_of(xa=[-(w/6-slop), (w/6-slop)]) {
 							// Guide ridge.
 							scale([0.75, 1, 2]) yrot(45)
 								cube(size=[guide_size/sqrt(2), dmnd_width, guide_size/sqrt(2)], center=true);

lifter_rod_coupler_part.scad

@@ -6,8 +6,8 @@ use <joiners.scad>
 module lifter_rod_coupler()
 {
 	h = 50;
-	shaft = 5.2;
-	setscrew = 3.2;
+	set_screw_rad = set_screw_size/2 + printer_slop;
+	shaft = motor_shaft_size + printer_slop;
 
 	color("Lavender") difference() {
 		// Coupler cylinder.
@@ -18,9 +18,11 @@ module lifter_rod_coupler()
 				// Stepper shaft hole
 				cylinder(h=h/2, r=shaft/2, center=true, $fn=16);
 
-				// Shaft flat side.
-				translate([1.4*shaft, 0, 0])
-					cube(size=[shaft*2, shaft*2, h/2+1], center=true);
+				if (motor_shaft_flatted == true) {
+					// Shaft flat side.
+					translate([1.4*shaft, 0, 0])
+						cube(size=[shaft*2, shaft*2, h/2+1], center=true);
+				}
 			}
 
 			//Stepper set screw
@@ -28,14 +30,14 @@ module lifter_rod_coupler()
 				yrot(90) {
 					// Nut Slot
 					translate([0, 0, 1]) scale([1.1, 1.1, 1.1]) hull() {
-						metric_nut(size=3, hole=false);
+						metric_nut(size=set_screw_size, hole=false);
 						translate([10, 0, 0])
-							metric_nut(size=3, hole=false);
+							metric_nut(size=set_screw_size, hole=false);
 					}
 
 					// Set screw hole.
 					translate([0, 0, 2.5])
-						cylinder(r=setscrew/2, h=12, center=true, $fn=8);
+						cylinder(r=set_screw_rad, h=12, center=true, $fn=8);
 				}
 			}
 		}
@@ -49,14 +51,14 @@ module lifter_rod_coupler()
 				yrot(90) {
 					// Nut Slot
 					translate([0, 0, 1]) scale([1.1, 1.1, 1.1]) hull() {
-						metric_nut(size=3, hole=false);
+						metric_nut(size=set_screw_size, hole=false);
 						translate([-10, 0, 0])
-							metric_nut(size=3, hole=false);
+							metric_nut(size=set_screw_size, hole=false);
 					}
 
 					// Set screw hole.
 					translate([0, 0, 2.5])
-						cylinder(r=setscrew/2, h=10, center=true, $fn=8);
+						cylinder(r=set_screw_rad, h=10, center=true, $fn=8);
 				}
 			}
 		}

nut_capture.scad

@@ -1,6 +1,7 @@
+include <config.scad>
 use <GDMUtils.scad>
 
-module nut_capture(nut_size=17.4, nut_thick=9.5, offset=18, slop=0.25, wall=3)
+module nut_capture(nut_size=17.4, nut_thick=9.5, offset=18, slop=printer_slop, wall=3)
 {
 	nut_rad = nut_size/cos(30)/2;
 	base = (offset - nut_rad);

roller_cap_parts.scad

@@ -3,7 +3,7 @@ use <GDMUtils.scad>
 
 
 
-module roller_cap(r=5.0, h=10, wall=3, cap=2, lip=1.5, shelf=2.4, slop=0.25)
+module roller_cap(r=5.0, h=10, wall=3, cap=2, lip=1.5, shelf=2.4, slop=printer_slop)
 {
 	$fn = 16;
 	color("Pink") difference() {

slop_calibration_parts.scad

@@ -43,7 +43,7 @@ module float_seven_segment(val=0.0, decim=2, size=10, h=1, suppress=false)
 	}
 	for (p = [mag:-1:-decim]) {
 		translate([-0.8*size*(p+0.5), 0, 0]) {
-			assign(d = floor(abs(val)/pow(10, p)) % 10) {
+			assign(d = floor(abs(val)/pow(10, p)+0.000001) % 10) {
 				if (p == -1) {
 					translate([-0.8*size/2, -size/2, 0])
 						cube(size=[size*0.1, size*0.1, h], center=true);
@@ -57,29 +57,39 @@ module float_seven_segment(val=0.0, decim=2, size=10, h=1, suppress=false)
 
 
 
-module tolerances_test_part() { // make me
-	for (i = [0:5]) {
-		translate([-20*i, 0, 0])
-			zrot(90)
-				difference() {
-					nut_capture(
-						nut_size=lifter_nut_size,
-						nut_thick=lifter_nut_thick,
-						offset=lifter_nut_size/2+5,
-						wall=3,
-						slop=0.05*i
-					);
-					translate([lifter_nut_size/2+3, -6, 10]) {
-						zrot(90) xrot(90) float_seven_segment(val=0.05*i, decim=2, size=8, h=1, suppress=true);
+module slop_calibration_parts() { // make me
+	rows = 5;
+	cols = 2;
+	r = 10;
+	h = 15;
+	step = 0.05;
+	spacing = r*2+10;
+	for (col = [0:cols-1]) {
+		translate([-col*spacing*1.25+(cols-1)*spacing*1.25/2, 0, h/2]) {
+			difference() {
+				cube(size=[spacing, rows*spacing, h], center=true);
+				for (row = [0:rows-1]) {
+					assign(slop = (step*rows*col)+step*row) {
+						translate([0, spacing*row-(rows-1)*spacing/2, 0]) {
+							cylinder(r=r+slop, h=h+1, center=true);
+							translate([spacing/2, -7, 0]) {
+								zrot(90) xrot(90) float_seven_segment(val=slop, decim=2, size=8, h=1, suppress=true);
+							}
+						}
 					}
 				}
+			}
+		}
+	}
+	translate([(cols+1)*1.25*spacing/2, 0, h/2]) {
+		cylinder(r=r, h=h, center=true);
+		translate([0,0,-h/4]) cylinder(r=r+2, h=h/2, center=true);
 	}
-	translate([ 20, 0, 2]) yrot(180) zrot(90) lifter_nut_cap();
 }
 
 
 
-tolerances_test_part();
+slop_calibration_parts();
 
 
 

tslot.scad

@@ -25,7 +25,7 @@ module lock_tab(h=30, wall=3, slop=0.0)
 
 
 
-module lock_slot(h=30, wall=3, backing=0, slop=0.3)
+module lock_slot(h=30, wall=3, backing=0, slop=printer_slop)
 {
 	s1 = 2*wall+slop/2;
 	s2 = wall+slop/2;