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// Outside Carriage piece for 2020 aluminum extrusions and ~24mm diameter
// wheels riding on the diagonals, with GT2 belt tightener. This works
// nicely with the ball studs and carbon fiber, magnetic, zero-backlash
// printer arms which I have for sale.
//
// This provides extra stiffening for the carriages.
//
// Haydn Huntley
// haydn.huntley@gmail.com
$fn = 360/4;
include <configuration.scad>;
include <roundedBox.scad>;
// All measurements in mm.
m5Radius = (5.0 + 0.3) / 2;
eccentricSpacerRadius = (7.1 + 0.3)/2;
xAxleSpacing = extrusionWidth * sqrt(2) + 19.1 - 0.35;
yAxleSpacing = 30.0;
xBody = max(xAxleSpacing + 2 * 7, ballJointSeparation + 2 * 5);
yBody = yAxleSpacing + 2 * 7;
zBody = 5.0;
yBallStudOffset = yAxleSpacing/2;
xInsideBeltOffset = 5;
wheelWidth = 11.0;
gapBetweenCarriageAndExtrusion = 2;
gapBetweenBeltAndExtrusion = 17;
aluminumSpacerRadius = 10.0/2;
aluminumSpacerHeight = 0.25 * mmPerInch;
spacerHeight = extrusionWidth * sin(45) + gapBetweenCarriageAndExtrusion - wheelWidth/2 - aluminumSpacerHeight - 2.0;
module outsideCarriage()
{
difference()
{
union()
{
// The round-cornered rectangle body.
translate([0, 0, zBody/2])
roundedBox([xBody, yBody, zBody], 5, true);
}
// Place a hole in the center to lighten it.
translate([0, 0, zBody/2])
roundedBox([xBody-4*7, yBody-3*7, zBody+smidge], 5, true);
// Three holes for the M5x50 bolts for the axles for the rollers.
// Upper right.
translate([xAxleSpacing/2, yAxleSpacing/2, -smidge/2])
m5x50(zBody+smidge);
// Lower right.
translate([xAxleSpacing/2, -yAxleSpacing/2, -smidge/2])
m5x50(zBody+smidge);
// Left, with room for the eccentric spacer.
translate([-xAxleSpacing/2, 0, -smidge/2])
{
m5x50(zBody+smidge);
cylinder(r=eccentricSpacerRadius, h=zBody+smidge);
}
}
}
module m5x50(h=0)
{
cylinder(r=m5Radius, h=h);
}
module spacer()
{
difference()
{
cylinder(r=aluminumSpacerRadius, h=spacerHeight);
translate([0, 0, -smidge/2])
cylinder(r=m5LooseRadius, h=spacerHeight+smidge);
}
}
outsideCarriage();
for (x = [-1, 0, 1])
translate([x*12, 30, 0])
spacer();