def lasershim(height):
"""lasershim
This is a shim which can be used to pad. The base of the shim is in the
XY plane at quadrant 1. One corner is at the origin. The width is parallel
to the x-axis.
The shim can be used if the laserbase is not correctly alligned.
The laser was provided by Odic Force, productid OFL510-1.
param: height: defines height shim [mm]
"""
# PARAMETER
xdisp = 48.5 # [mm], x-displacement screw
ydisp = 16 # [mm], y-displacement screws
r_shaft = 2 + 0.5 # [mm], shaft radius screws
length = 75 # [mm], x-direction length laser
width = 30 # [mm], y-direction width laser
screw_offst = 7 # [mm], screw offset +x-edge
# MAXIMAL MATERIAL BASE
base = cube([length, width, height])
# screw holes
screws = cylinder(h=height, r=r_shaft) + right(xdisp)(cylinder(h=height,
r=r_shaft))
spiegel = forward(ydisp / 2)(mirror([0, 1, 0])(back(ydisp / 2)(screws)))
screws += spiegel
# create holes
base -= translate([length - xdisp - screw_offst, (width - ydisp) / 2,
0])(screws)
return base
def createlogo():
"""createlogo
Openscad cannot handle the Storm font. To mitigate, a vector image of the
storm font is converted to PNG via Inkscape. The PNG image is linearly
extruded and converted to a STL.
This STL is imported by this function, to create the logo.
"""
# TODO: move Python converter for logo to here
# LOGO bounding box x = 234 , y = 26, z = 1
# scaled to x = 120, y = 13
x_bound = 120 + THICK_WALL * 2
y_bound = 13 + THICK_WALL * 2
# TODO: should throw error !! you removed logo
logo = scale([0.5, 0.5, 1])(import_stl('hexastorm.stl'))
logo = None
# openscad cannot handle minkowski on hexastorm logo
# logo_mink = up(1)(minkowski()(cylinder(r=0.5, h=1), logo))
result = translate([-0.5 * x_bound, -0.5 * y_bound, 0])(cube(
[x_bound, y_bound, 1])) - hole()(mirror([0, 1, 0])(logo))
result = scale([1, 1, HEIGHT_TOP - THICK_WALL
])(translate([0.5 * x_bound, 0.5 * y_bound, 0])(result))
result = up(HEIGHT_TOP - THICK_WALL)(cube([x_bound, y_bound, 1]))
# TODO: Openscad can create a preview but does not render the logo,
# at the moment we resort to
# modiefs in blender
return result
def laserbase(laserheight):
"""laserabase
creates the basis for the laser with ventilation wall
The laserbase is in the XY plane at quadrant 1.
One corner is at the origin. The width is parallel to the x-axis.
The laser was provided by Odic Force, productid OFL510-1.
The padheight is laser height- 16.5 The laserbundle travels in
the +x direction and departs from the center, that is 15 mm.
param: laserheight: the desired height of the laser
"""
# The laser tube is at 8 mm from bottom.
# The laser tube has a diameter of 17 mm
# The laser is at 8 + 17 * 0.5 - 1 = 16.5 mm (shim of 1 mm needed)
# The laser base is 30x60 mm, which was made
# 30x75 mm to make room for the ventilator
# PARAMETERS
height = laserheight - 15.5 # [mm],
xdisp = 48.5 # [mm], x-displacement screws
ydisp = 16 # [mm], y-displacement screws
r_shaft = 2 # [mm], shaft radius screws
h_head = 5 # [mm], height shaft head
r_head = 3.5 # [mm], top radius screws
tspile = 4 # [mm], y-thickness ventilation spile
hspile = 25 # [mm], height ventilation spile
length = 75 # [mm], x-direction length laser
width = 30 # [mm], y-direction width laser
screw_offst = 7 # [mm], screw offset +x-edge
# MINIMAL MATERIAL BASE
screws = screw(r_head, h_head, r_shaft, height) + right(xdisp)(screw(
r_head, h_head, r_shaft, height))
spiegel = forward(ydisp / 2)(mirror([0, 1, 0])(back(ydisp / 2)(screws)))
screws += spiegel
base = translate([length - xdisp - screw_offst, (width - ydisp) / 2,
0])(screws)
# ventilation wall
# spile
spile = up(height)(cube([THICK_WALL, tspile, hspile]))
nofspiles = ceil((width) / (tspile * 2))
# shift base
base = right(THICK_WALL)(base)
# add wall
base += cube([THICK_WALL, width, HEIGHT_WALL])
# create pockets
for i in range(0, nofspiles):
base -= hole()(forward(i * 2 * tspile + THICK_WALL)(spile))
return base
def topbox(down, logo):
"""topbox
constructs the top part of the box
:param down: if true downward ray box created
:param logo: if true logo is generated, logo slows rendering
"""
top = cube([LENGTH_TOP, WIDTH_TOP, THICK_WALL])
# 4 screws used, 2 was insufficient
screw_fixout = 3.5 # mm (radius)
screw_fixin = 2 # TODO: connect to holesize threaded inserti
screw_toph = 5
cyl = screw(screw_fixout, screw_toph, screw_fixin, HEIGHT_TOP)
top += translate([SCREW_FIXOFFST, SCREW_FIXOFFST, 0])(cyl)
top += translate([LENGTH_TOP - SCREW_FIXOFFST, SCREW_FIXOFFST, 0])(cyl)
top += translate(
[LENGTH_TOP - SCREW_FIXOFFST, WIDTH_TOP - SCREW_FIXOFFST, 0])(cyl)
top += translate([SCREW_FIXOFFST, WIDTH_TOP - SCREW_FIXOFFST, 0])(cyl)
# sliding should be prevented with 4 protrusion,
# 1 is logo and 3 other are knobs
x_knob = cube([THICK_WALL, THICK_WALL * 3, HEIGHT_TOP - THICK_WALL])
x_knobs = translate(
[THICK_WALL, WIDTH_TOP / 2 - 1, THICK_WALL])(x_knob) + translate([
LENGTH_TOP - 2 * THICK_WALL, WIDTH_TOP / 2 - 1, THICK_WALL
])(x_knob)
y_knob = cube([THICK_WALL * 3, THICK_WALL, HEIGHT_TOP - THICK_WALL])
y_knobs = translate([LENGTH_TOP * 0.25, 0, THICK_WALL
])(forward(THICK_WALL)(y_knob) +
forward(WIDTH_TOP - 2 * THICK_WALL)(y_knob))
top += y_knobs + x_knobs
# LOGO slows down render, should be turned off when developing
if logo:
top += translate([
0.5 * (LENGTH_TOP - (120 + THICK_WALL * 2)),
WIDTH_TOP - THICK_WALL - (13 + THICK_WALL * 2), 0
])(createlogo())
if not down:
laser_y = 24 + 2 * THICK_WALL
top -= translate(
[75 + 10 + 48 + THICK_WALL + 10, laser_y - 0.5 * 8,
0])(cube([20, 8, THICK_WALL]))
# FIX FOR BOX orientation
top = rotate([0, 0, 180])(mirror([0, 1, 0])(rotate([0, 180, 0])(top)))
return top
def polygonshim(height):
"""polygonshim
The polygon shim is located in first quadrant of the XY plane.
A corner is at the origin. The width is parallel to the y-axis.
The shim can be used to align the polygon.
The shim was designed for polygon mirror Motor aficio 1018 G029-196.
:param height: height shim
"""
# BASE:
length = 68 # mm [y-direction]
width = 48 # mm [x-direction]
r_shaft = 2 # mm shaft radius
slot_width = 2 # width slot
base = cube([width / 2, length, height])
def slot(radius, height, width):
"""slot
openscad styled vertically oriented printable slot
origin formed by the center of the left circle
:param radius: the radius of the top of the screw
:param height: the height of the slot
:param width: the width of the slot, i.e. distance between radii
"""
cyl = cylinder(h=height, r=radius)
outer = hull()(cyl, right(width)(cyl))
return outer
# create 2 screw slots
simple_slot = slot(r_shaft, height, slot_width)
base -= translate([3.1, length - 4, 0])(simple_slot)
base -= translate([3.2, 4 + 1.29, 0])(rotate([0, 0, -50])(simple_slot))
# create hole for polygon rotation axis
base -= translate([24, 24, 0])(cylinder(h=height, r=10))
# create hole for polygon lock
base -= translate([24 - 7.5, 0, 0])(cube([15, 10, height]))
# mirror and add to original
spiegelold = right(width)(mirror([1, 0, 0])(base))
base += spiegelold
return base
def onderkantbox(down):
"""onderkantbox
constructs the bottom part of the box
:param down: if true ray will be directed downward
"""
# construct a base
# height wall ; earlier experiments ; 40 (bottom) + 25 (top)
height = 65
base = cube([LENGTH_TOP, WIDTH_TOP, THICK_WALL + height])
base -= translate([THICK_WALL, THICK_WALL, THICK_WALL])(cube(
[LENGTH_TOP - 2 * THICK_WALL, WIDTH_TOP - 2 * THICK_WALL, height]))
# NOTE the order in which objects are placed is important
# there can be coflicts between the stickit/panel mount and the
# mirror mount
# most likely this is due to the inner workings of the hole function
# the polygon is the lowest part, for certainty its offset is set at
# THICK_WALL laser_y = 24 (polygon) + 2 * THICK_WALL
# as a result y-offset laserbase is laser_y - 0.5 * 30 (width laserbase)
# the y-offset mirror base=laser_y-0.5*light_hole-THICK_WALL-INSERT_MIRROR
# the x-offset of the laserbase is 0,
# it comes with an integrated ventilation
# the x-offset of the polygon is 75 (length_base) + 10 (laserlens)
# the x-offset mirror is 75 + 10 + 48 (width polygon) + THICK WALL (safety
# margin) TODO: for an unknown reason the stickit nead to be added first
# other wise the photodiode mount will be effected
# add stick
base += translate([THICK_WALL + 90, WIDTH_TOP, 0])(xulaconnector())
# add laser base
laser_y = 24 + 2 * THICK_WALL
base += translate([0, laser_y - 0.5 * 30, 0])(laserbase(LASER_HEIGHT))
# add polygon 4 is space for square
base += translate([75 + 10 + 4, 2 * THICK_WALL,
0])(polygonbase(LASER_HEIGHT))
# add mirror; y position is corrected for mirror_insert,
# thick wall +8 (square) and light hole
base += translate([75 + 10 + 48 + THICK_WALL + 8, laser_y,
0])(mirrormount(down, LASER_HEIGHT))
# add exits DC barrels
r_barrel = 6.6
dcbarrel = rotate([90, 0, 0])(cylinder(r=r_barrel,
h=2 * THICK_WALL,
segments=30))
# NOTE: offset between DC barrels should
# be larger than radius due to extent
base -= translate([
THICK_WALL + r_barrel + 10, WIDTH_TOP, THICK_WALL + r_barrel * 2
])(dcbarrel + up(2 * r_barrel + 4 + THICK_WALL)(dcbarrel))
# add exit for microusb (also has width of DC barrel)
base -= translate(
[LENGTH_TOP - THICK_WALL, WIDTH_TOP - 23.2,
THICK_WALL + 11 + 23])(rotate([0, 0, 90])(dcbarrel))
# add mount belt
mount_box = cube([10, 30, 50])
base -= translate(
[LENGTH_TOP - THICK_WALL, WIDTH_TOP - 60, THICK_WALL + 15])(mount_box)
base += translate(
[LENGTH_TOP - THICK_WALL, WIDTH_TOP - 60, THICK_WALL + 15])(boxmount())
# you need to create room mirror
if down:
# TODO: remove manual fixed parameters
# manual fix parameters; x 10 shift and y extent 20
base -= translate(
[75 + 10 + 48 + THICK_WALL + 10, laser_y - 0.5 * light_hole,
0])(cube([20, light_hole, THICK_WALL]))
# add two cable ties;
# corner
# base += translate([LENGTH_TOP - 18, WIDTH_TOP - 10, THICK_WALL])
# (cable_fasten(TIE_HEIGHT, TIE_WIDTH, THICK_WALL, True))
# laserbase
base += translate([75 - 10, WIDTH_TOP - 20,
THICK_WALL])(cable_fasten(TIE_HEIGHT, TIE_WIDTH,
THICK_WALL, False))
# add fasteners at corners
# bottom left and upper right corner
upshift = THICK_WALL + height - HEIGHT_TOP + THICK_WALL
base += translate([SCREW_FIXOFFST, SCREW_FIXOFFST,
upshift])(threadedinsert(True, THICK_WALL, 4.0, 5.8))
base += translate(
[LENGTH_TOP - SCREW_FIXOFFST, WIDTH_TOP - SCREW_FIXOFFST,
upshift])(threadedinsert(False, THICK_WALL, 4.0, 5.8))
base += translate([LENGTH_TOP - SCREW_FIXOFFST, SCREW_FIXOFFST,
upshift])(threadedinsert(True, THICK_WALL, 4.0, 5.8))
base += translate([SCREW_FIXOFFST, WIDTH_TOP - SCREW_FIXOFFST,
upshift])(threadedinsert(False, THICK_WALL, 4.0, 5.8))
base = mirror([0, 1, 0])(base)
return base
def mirrormount(down, laserheight):
"""mirrormount
A 25 mm x 25 mm square and 2 mm thick first sided mirror is used to refract
the ray downward or upward. The thickness is in the +x-direction.
This mirror is tilted at a 45 degrees and is positioned by a holder.
The holder is put in place via two pillars.
A photodiode mount is placed into these pillars to detect the laser motion.
It is important that the photodiode is at the correct height
The photodiode_height is LASER_HEIGHT-2.5, to ensure the laser hits the
photodiode at its center.
:param down: if true downward refraction, if false upward refraction
:param laserheight: height laser bundle, [mm]
"""
width_mirror = 25 # [mm]
# thickness y+ pillar, y- pillar is insert+THICK_wall
tpillar_left = 14 # [mm]
insert_mirror = 5 # [mm]
thick_mirror = 2 # [mm]
# height_mirror < photodiode_height
height_mirror = laserheight - 6 # [mm]
# 4.5 determined via felix printed box
photodiode_height = laserheight - 4.5 # [mm]
cable_guide = 2 # [mm]
# sensor width with cables is 5.6 (measurement @diode)
sensor_width = 2 # [mm]
# sensor height is 4 (measurement @ photodiode)
sensor_height = 4.5 # [mm]
sensor_insert = 2 # [mm] diode thickness i 2 @ measured
# margin is needed for FFF printer
margin = 0.5 # [mm]
# defines the thickness of the holder
thick = 1.3 # [mm]
# offset constraint set by upward proj. due to cable collision possibility
offset = 19 # [mm] offset sensor pole
x_width = 0.5 * sqrt(2) * (thick_mirror + margin + 2 * thick)
# TODO: xbound seems to be an y_bound
x_bound = 0.5 * sqrt(2) * (2 * thick + width_mirror + margin) + x_width
y_bound = offset + THICK_WALL + sensor_insert
holder = cube([
thick_mirror + margin + 2 * thick,
light_hole + THICK_WALL + insert_mirror + tpillar_left,
width_mirror + margin + 2 * thick
])
holder_inner = translate([thick, 0, thick])(cube([
thick_mirror + margin, light_hole + tpillar_left + insert_mirror,
width_mirror + margin
]))
# the holder can contain left over of filament.
# To remove these left over a cleaning hole is needed.
holder_inner += translate([thick, 0, thick + width_mirror + margin])(cube(
[thick_mirror + margin, tpillar_left - THICK_WALL, thick]))
holder -= hole()(holder_inner)
# up mirror
holder = up(height_mirror)(rotate([0, 45, 0])(holder))
# pillars
# light exit has a width of light_hole
# pillars are next to this exit point and have a width of tpillar_left,
# and THICK_WALL + insert_mirror
mount_mirror = cube([
x_width, light_hole + tpillar_left + THICK_WALL + insert_mirror,
height_mirror
])
mount_mirror += holder
# create pocket for light 2x is for certainty
mount_mirror -= forward(tpillar_left)(cube(
[2 * width_mirror, light_hole, 2 * width_mirror]))
if not down:
mount_mirror = right(x_bound)(mirror([1, 0, 0])(mount_mirror))
# add mount photodiode
# the photodiode is at height photodiode_height mm
# the cable guides are cable_guide mm thick, the pins of the photodiode
# are sensor width displaced, the photodiode is sensor height tall
# the photodiode sensor insert is sensor_insert, the wall between light
# exit and sensor is fixed at 1 mm, kept small to get maximum out of light
# path. The top has a three time thickness, to create a connection between
# mirror and pole
enclosure = cube([
THICK_WALL + sensor_insert,
cable_guide * 2 + sensor_width + THICK_WALL + 1,
sensor_height + photodiode_height + 2 * THICK_WALL
])
photodiode = cube([
sensor_insert + THICK_WALL, cable_guide * 2 + sensor_width,
sensor_height
])
# substract central pillar
photodiode -= translate([0, cable_guide, 0
])(cube([THICK_WALL, sensor_width,
sensor_height]))
# combine pole with photodiode housing
pole = enclosure - hole()(translate([0, 1, photodiode_height])(photodiode))
combined = mount_mirror + translate([offset, tpillar_left + light_hole, 0
])(pole)
# a trafo is executed to simplify positioning;
# light should be centered at y=0
combined = translate([y_bound, tpillar_left + 0.5 * light_hole,
0])(mirror([1, 0, 0])(mirror([0, 1, 0])(combined)))
# add tie-wrap
# TODO: remove custom parameters
fasten = translate([9, tpillar_left + 9,
0])(cable_fasten(TIE_HEIGHT, TIE_WIDTH, THICK_WALL,
True))
combined += fasten
return combined
def polygonbase(laserheight):
"""polygonbase
defines the base of a polygon
The polygon base is located in the first quadrant of the XY plane.
A corner is at the origin. The width is parallel the y-axis.
The laser bundle is at 24 mm in the y-direction and the laser bundle
should be between [10.65, 13.65] mm in the z-direction.
The height of the base is laserheight - 12.15 mm.
The height of the base should be at least 7.2 mm. The polygon motor result
in a protrusion.
The laser is directed in the +x-direction. The length is oriented along
y-axis, 21000 RPM polygon
base could be rotated if laserbase is made smaller. New polygon base at
24000 RPM seems to be harder to rotate.
The polygon rotates clockwise.
:param laserheight: the desired height of the laser, [mm]
"""
# TODO: the polygon is larger than its, it has a negative x- and y-extent
# BASE:
length = 68 # [mm], y-direction
width = 48 # [mm], x-direction
height = laserheight - 12.5 # [mm]
r_shaft = 2 # [mm], shaft radius
r_head = 3.5 # [mm], head radius
h_head = 5 # [mm], head insert
slot_width = 2 # [mm], width slot
def slot(r_head, h_head, r_shaft, width, height):
"""slot
openscad styled vertically oriented printable slot
origin formed by the center of left circle
:param r_head: the radius of the top of the screw, [mm]
:param h_head: the height of the top of the screw, [mm]
:param r_shaft: the radius of the shaft of the screw, [mm]
:param width: the width of the slot, [mm]
:param height: the height of the slot, [mm]
"""
h_shaft = height - h_head - (r_head - r_shaft)
head = cylinder(h=h_head, r=r_head, segments=30)
# 45 degrees cone for printability
cone = up(h_head)(cylinder(h=r_head - r_shaft,
r1=r_head,
r2=r_shaft,
segments=30))
shaft = up(h_head + (r_head - r_shaft))(cylinder(h=h_shaft,
r=r_shaft,
segments=30))
cyl = head + cone + shaft
inner = hull()(cyl, right(width)(cyl))
cyl = cylinder(h=height, r=r_head + THICK_WALL)
outer = hull()(cyl, right(width)(cyl))
slot = outer - hole()(inner)
return slot
wall_slot = slot(r_head, h_head, r_shaft, slot_width, height)
base = translate([3.1, length - 4, 0])(wall_slot)
base += translate([3.2, 4 + 1.29, 0])(rotate([0, 0, -50])(wall_slot))
spiegel = right(width)(mirror([1, 0, 0])(base))
base += spiegel
return base