initial design

.gitmodules

+[submodule "MCAD"]
+	path = MCAD
+	url = https://github.com/SolidCode/MCAD.git
+[submodule "gearCreator"]
+	path = gearCreator
+	url = https://github.com/VladAlpha/gearCreator.git

MCAD @ 9a958fd1

+Subproject commit 9a958fd11b0a6b5f8becd37c4f8a42f585abfcd8

gearCreator @ c1e9da4d

+Subproject commit c1e9da4d2745294f08f41699aee3ca49204904e9

magnet holder.scad

+include <rack_herringbone.scad>;
+include <MCAD/motors.scad>;
+include <MCAD/nuts_and_bolts.scad>;
+include <MCAD/involute_gears.scad>;
+
+// gear parameters
+innerRadius=3.1;//shaft radius, in mm
+borders=2.5;//how thick should the borders around the central "shaft" be, in mm
+diametralPitch=12;
+numberOfTeeth=14;
+pressureAngle=20*pi/180;
+centerAngle=25;//angle at center of teeth
+
+// magnet
+magnetWidth=25.42;
+magnetLength=76.14;
+magnetHeight=19.02;
+
+// guide rods
+rodRad=3;
+linearBearingOD=12;
+linearBearingHeight=19;
+
+//rack(innerRadius,borders,diametralPitch,numberOfTeeth,pressureAngle,centerAngle);
+
+union(){
+    translate([-80,0,0]){
+        color("blue") magnetPlate();
+        color("red") pillar(30);
+        
+        translate([40,0,-15])
+            motorSide();
+        
+        color("orange")
+        translate([40,0, 5])
+        rotate([0,180,0])
+            pinion(7);
+        
+//        color("green")
+//        translate([40,0,1])
+//        for (y = [-1,1]){
+//            translate([0, y*(magnetLength+5+2*(rodRad+3))/2, 0])
+//            bearingClamp();
+//        }
+    }
+//    color("Purple") endPlate(30);
+}
+
+// Magnet plate
+module magnetPlate(){
+    thickness = 10;
+    $fn=50;
+    union(){
+        difference(){// rod holders
+            for (y = [-1,1]){ 
+                translate([-thickness/2, y*(magnetLength+5+2*(rodRad+3))/2, 0])
+                rotate([0,-90,0])
+                    cube(size = [2*(rodRad+3),2*(rodRad+3), thickness], center = true);
+            };
+            
+            for (y = [-1,1]){ // rod insert---halfway through holder + 1mm so face doesn't line up
+                translate([1, y*(magnetLength+5+2*(rodRad+3))/2, 0])
+                rotate([0,-90,0])
+                    cylinder(h=thickness/2+1, r=rodRad);
+            };
+        }
+
+        difference(){  //magnet trough
+            translate([0, -(magnetLength+5)/2, -(magnetWidth+5)/2])
+            rotate([0,-90,0]) 
+                cube([magnetWidth+5, magnetLength+5, thickness]);
+            
+            translate([-5, -(magnetLength)/2, -(magnetWidth)/2]) // 5mm under magnet
+            rotate([0,-90,0])
+                cube([magnetWidth, magnetLength, magnetHeight]);
+            }
+    }
+}
+module pillar(spacing = 30){
+    thickness = 10;
+    width = 50;
+    length = 80;
+    cavitySideThickness = 10;
+    cavityEndThickness = 10; // shouldn't be smaller than 10 or nut hole is too far in
+    
+    translate([0, -width/2, -thickness/2])
+    difference(){
+        cube([length,width,thickness]);
+        for (y = [width/2-spacing/2, width/2+spacing/2]){ // M3 nut/bolt holes
+            translate([length-5, y, -1])
+            rotate([0,0,-90])
+            linear_extrude(height=thickness/2+3.2+1)
+                nutHole(size=3, proj=2);
+            
+            $fn=50;
+            translate([length-5, y, thickness/2])
+            rotate([0,90,0])
+                linear_extrude(height=6) boltHole(size=3, proj=1);
+        }
+        translate([cavityEndThickness, cavitySideThickness, -1])
+            cube([length-cavityEndThickness*2, width-cavitySideThickness*2, thickness+2]);
+    }
+
+}
+
+module endPlate(spacing = 30){
+    thickness = 10;
+    length = magnetLength+5;
+    $fn=50;
+    
+    union(){
+        translate([0, -length/2, -thickness/2])
+        difference(){
+                cube([thickness, length, thickness]);
+            for (y = [length/2-spacing/2, length/2+spacing/2]){
+                translate([thickness-6, y, thickness/2]) // cap recessed by 6mm
+                rotate([0,-90,0])
+                    boltHole(size=3, length=thickness, extraCapHeight=10);
+            }
+        }
+        
+        difference(){// rod holders
+            for (y = [-1,1]){ 
+                translate([thickness/2, y*(magnetLength+5+2*(rodRad+3))/2, 0])
+                rotate([0,90,0])
+                    cube(size = [2*(rodRad+3),2*(rodRad+3), thickness], center = true);
+            };
+            
+            for (y = [-1,1]){ // rod insert---halfway through holder + 1mm so face doesn't line up
+                translate([-1, y*(magnetLength+5+2*(rodRad+3))/2, 0])
+                rotate([0,90,0])
+                    cylinder(h=thickness/2+1, r=rodRad);
+            };
+        }
+    }
+}
+
+module motorSide(){
+    $fn=50;
+    thickness = 5;
+    length = 50;
+    width = (magnetLength+5)+(2*(rodRad+3))+(linearBearingOD+3);
+    
+    difference(){
+        union(){
+            difference(){ // main platform
+                translate([0,0,thickness/2])
+                cube([length, width, thickness], center = true);
+                
+                linear_extrude(height = thickness+1)
+                stepper_motor_mount(17);
+            }
+            
+            for (y = [-1, 1]){ // bearing blocks
+                translate([0, y*(magnetLength+5+2*(rodRad+3))/2, 15/2])
+                    cube([linearBearingHeight+5, linearBearingOD+20, 15], center = true);
+            }
+        }
+    
+        for (y = [-1, 1]){ // bolt holes
+                translate([-linearBearingHeight/2, y*(magnetLength+5+2*(rodRad+3))/2, 15])
+                union(){
+                    rotate([0,90,0])
+                        cylinder(h = linearBearingHeight, r = linearBearingOD/2); //bearing
+                    translate([-3.5,0,0])
+                    rotate([0,90,0])
+                        cylinder(h = linearBearingHeight+7, r = rodRad+1); //shaft clearance
+                    for (i = [-1, 1]){
+                        translate([linearBearingHeight/2, i*(linearBearingOD/2+4), -16]) // bolts
+                            linear_extrude(height=15+2) boltHole(size = 3, proj = 1);
+                        translate([linearBearingHeight/2, i*(linearBearingOD/2+4), -(15+12)+10]) // nuts
+                            linear_extrude(height=10+2) nutHole(size = 3, proj = 1);
+                        
+                    }
+                }
+                
+        }
+    }
+    
+}
+
+module bearingClamp(){
+    $fn=50;
+    
+    difference(){
+        translate([0, 0, (linearBearingOD/2+5)/2])
+            cube([linearBearingHeight+5, linearBearingOD+20, linearBearingOD/2+5], center = true);
+        
+        translate([-linearBearingHeight/2, 0, 0])
+        union(){
+            rotate([0,90,0])
+                cylinder(h = linearBearingHeight, r = linearBearingOD/2); //bearing
+            
+            translate([-3.5,0,0])
+            rotate([0,90,0])
+                cylinder(h = linearBearingHeight+7, r = rodRad+1); //shaft clearance
+            
+            for (i = [-1, 1]){
+                translate([linearBearingHeight/2, i*(linearBearingOD/2+4), (linearBearingOD/2+5)-6]) // bolts
+                rotate([0,180,0])
+                    boltHole(size = 3, length = 15+2, proj = -1, extraCapHeight = 8);
+                
+            }
+        }
+    }
+}
+
+module pinion(teeth){
+	//double helical gear
+	{
+        $fn=50;
+		twist=200;
+		height=15;
+		pressure_angle=30;
+
+		gear (number_of_teeth=teeth,
+			circular_pitch=400,
+			pressure_angle=pressure_angle,
+			clearance = 0.2,
+			gear_thickness = height/4,
+			rim_thickness = height/2,
+			rim_width = 10,
+			hub_thickness = height,
+			hub_diameter=15,
+			bore_diameter=5,
+			circles=4,
+			twist=twist/teeth);
+		mirror([0,0,1])
+		gear (number_of_teeth=teeth,
+			circular_pitch=400,
+			pressure_angle=pressure_angle,
+			clearance = 0.2,
+			gear_thickness = height/2,
+			rim_thickness = height/2,
+			rim_width = 10,
+			hub_thickness = height/2,
+			hub_diameter=15,
+			bore_diameter=5,
+			circles=4,
+			twist=twist/teeth);
+	}
+    
+//    gear_with_setscrew(
+//        module_number = 2, 						//standard metric way of specing a gear
+//        shaft_diameter = 5,
+//        trap_width = 6,
+//        hardware_bore = 3.4,
+//        number_of_teeth = teeth,
+//        hub_thickness = 13.5,
+//        rim_thickness = 8,
+//        no_bore = false,
+//    twist=twist/teeth);
+    
+}
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