// https://gitorious.org/ozzloy/challenge-bot
// https://github.com/waynegramlich/challenge-bot
+use <oshw.scad>
+
// use 10 ish for development, 60 or so for printing
$fn = 60;
-standoff_radius = 14.732 / 2; // 0.580 / 2 inches from spec sheet
-standoff_height = 55; // eyeballed
+/* measured with calipers */
+ball_diameter = 12.7 + 0.80; // extra bit added for printing imprecision
+ball_radius = ball_diameter / 2;
+
+standoff_height = 60; // kyle eyeballed
+
+wall_thickness = 1;
+holder_floor = 3;
+holder_arms_length = 20;
+holder_height =
+ holder_floor + holder_arms_length + (11 / 16) * ball_diameter;
+
+holder_radius = ball_radius + wall_thickness;
+holder_diameter = holder_radius * 2;
-nut_short_side = 4.7; // from calipers
-nut_height = 1.6; // from calipers
+standoff_radius = holder_radius; // 0.580 / 2 inches from spec sheet
+standoff_lower_portion_height = standoff_height - holder_height;
// eyeballed caster flange height, (0.580/5) inches, times 2 to be stronger
caster_flange_height = 5;
caster_flange_screw_radius = 2.286 / 2; // 0.090 inches
caster_flange_screw_length = 8; // eyeballed
-deck_grid_width = 25.4; // measured center to center on grid on pegboard
+deck_pitch = 25.4; // measured center to center on grid on pegboard
deck_flange_height = 2.9464;
deck_flange_screw_radius = 3.556 / 2; // For #6 machine screws
-deck_flange_radius = (deck_grid_width) / 2 + deck_flange_screw_radius + 3;
+deck_flange_radius = (deck_pitch) / 2 + deck_flange_screw_radius + 3;
module deck_flange(){
+ deck_pitch_diagonal = sqrt(2 * pow(deck_pitch, 2));
difference(){
- cylinder(h = deck_flange_height, r = deck_flange_radius);
+ scale([0.35, 0.35, 1]){
+ linear_extrude(height = deck_flange_height){
+ oshw();}}
for(ii = [-1, 1]){
- translate([deck_grid_width / 2 * ii, 0, -.1])
+ translate([deck_pitch_diagonal / 2 * ii, 0, -.1])
cylinder(h = deck_flange_height * 1.1,
- r = deck_flange_screw_radius);
- translate([0, deck_grid_width / 2 * ii, -.1])
- cylinder(h = deck_flange_height * 1.1,
- r = deck_flange_screw_radius);}}}
+ r = deck_flange_screw_radius);}
+ translate([0, deck_pitch_diagonal / 2, -.1])
+ cylinder(h = deck_flange_height * 1.1,
+ r = deck_flange_screw_radius);}}
module deck_flange_reinforcement(){
translate([-deck_flange_radius,
deck_flange_height * 1.1, // 1.1 is bigger than 1
deck_flange_radius]);}}}}}
-module caster_flange_screws(){
- translate([standoff_radius, 0, 0])
- cylinder(h = caster_flange_screw_length,
- r = caster_flange_screw_radius);
- translate([-standoff_radius, 0, 0])
- cylinder(h = caster_flange_screw_length,
- r = caster_flange_screw_radius);}
-
-module caster_flange(){
- side_radius = caster_flange_width / 2 - standoff_radius;
- hull(){
- cylinder(h = caster_flange_height, r = standoff_radius);
- translate([standoff_radius, 0, 0])
- cylinder(h = caster_flange_height, r = side_radius);
- translate([-standoff_radius, 0, 0])
- cylinder(h = caster_flange_height, r = side_radius);}}
-
-module nut(size, height){
- width = size/1.75;
- for (r = [-60, 0, 60]) rotate([0,0,r]) cube([width, size, height], true);}
-
-module nuts(){
- translate([standoff_radius, 0, nut_height/2])
- nut(nut_short_side, nut_height + .1);
- translate([-standoff_radius, 0, nut_height/2])
- nut(nut_short_side, nut_height + .1);}
-
-module _2_screw(){
- //measured with calipers
- screw_length = 8;
- thread_radius = 2.17 / 2 - 0.1; // subtract 0.1 to make squeeze fit
- head_height = 1.8;
- head_radius = 4.1 / 2 + 0.2; // add 0.2 to allow head to fit
- cylinder(r = thread_radius, h = screw_length);
- cylinder(r = head_radius, h = head_height);}
-
-module caster_deck_interlock_solid(){
- translate([-1, standoff_radius - 2.1, 0]){
- cube([2, 2, standoff_height]);}
- translate([-1, -standoff_radius + 0.1, 0]){
- cube([2, 2, standoff_height]);}}
-
-module caster_deck_interlock_hole(){
- translate([0, standoff_radius - 1, -0.1]){
- cube([2.5, 2.5, standoff_height], center = true);}
- translate([0, -standoff_radius + 1, -0.1]){
- cube([2.5, 2.5, standoff_height], center = true);}}
-
-module caster_standoff_deck_side(){
- difference(){
- cylinder(h = standoff_height - caster_flange_height,
- r = standoff_radius);
- translate([0, 0, standoff_height - caster_flange_screw_length * 1.1 + 0.1])
- scale([1, 1, 1.1])
- caster_flange_screws();
- translate([0, 0, standoff_height - (caster_flange_height + nut_height)])
- nuts();
- translate([0, 0, standoff_height]){
- // make hole to get to screw head depth
- cylinder(r = 4.1 / 2 + 0.2, h = 3, center = true);
- translate([0, 0, -0.7])
- rotate([180, 0, 0])
- _2_screw(r = 0.5, h = 5);}}
+module ball_holder(){
+ gap = wall_thickness * 4;
+ difference (){
+ cylinder(r = holder_radius, h = holder_height);
+ translate([0, 0, ball_radius + holder_floor + holder_arms_length]){
+ sphere(r = ball_radius);}
+ translate([0, 0, holder_floor + (holder_height - holder_floor) / 2 + 0.5]){
+ cube([holder_diameter + 0.1, gap, holder_height - holder_floor + 0.1],
+ center = true);}}}
+
+module caster_standoff(){
+ cylinder(h = standoff_lower_portion_height,
+ r = standoff_radius);
deck_flange();
for(ii = [0:3]){
rotate([0, 0, 45 + 90 * ii])
deck_flange_reinforcement();}
- caster_deck_interlock_solid();}
-
-module caster_standoff_caster_side(){
- difference(){
- caster_flange();
- translate([0, 0, caster_flange_height - 0.7]){
- rotate([180, 0, 0]){
- _2_screw();}}
- // make hole to get to screw head
- translate([0, 0, caster_flange_height - 0.8]){
- cylinder(r = 4.1 / 2 + 0.2, h = 10);}
- translate([0, 0, -.1]){
- caster_flange_screws();}
- caster_deck_interlock_hole();}}
+ translate([0, 0, standoff_lower_portion_height]){
+ ball_holder();}}
-caster_standoff_deck_side();
-translate([caster_flange_width / 2 + deck_flange_radius + 1, 0, 0]){
- caster_standoff_caster_side();}
+caster_standoff();