compact-z-probe.scad

// Compact Z-Probe
// Author: Reid Linnemann <linnemannr@gmail.com>

$fn = 100;
//units are mm
switch_width = 12.8;
switch_height = 5;
switch_thickness = 5.7;
switch_hole_diameter = 1.5;
switch_hole_spacing = 6.5;
switch_hole_offset = 1.5;
switch_operating_height = 5.5;


armature_diameter = 2;
shaft_length = 4;
shaft_clearance = 1;
armature_thickness = .75;

probe_diameter = 2.8;
probe_clearance = 0.5;

base_thickness = shaft_length;

switch_hole_depth = switch_thickness/2;

guide_padding = 12;
guide_y = switch_width/2 - switch_operating_height - -switch_hole_offset - probe_clearance + guide_padding;

dovetail_width = switch_width/2;

guide_thickness = base_thickness + switch_thickness;

guide_roundness = 5;

module armature(collar_d, collar_h, shoulder_d, shoulder_h, l) {
    union() {
        hull() {
            cylinder(h=10, shoulder_h, r=shoulder_d/2);
            translate([0, -l, 0])
              cylinder(h=shoulder_h, r=2.25);
        };
        translate([0,0,1])
          rotate([180,0,0])
          cylinder(h=collar_h+1, r=collar_d/2);
    }
}

module screwtap(r,d) {
    translate([0,0,0.1])
      cylinder(r=r, h=d+0.1);
}

module screwtaps(r,d,w) {
    for(x=[-2, 2]) {
        translate([w/x, 0, 0])
          screwtap(r,d);
    }
}

module probe_guide() {
    difference() {
        cube([switch_width, guide_y, switch_thickness+base_thickness]);
        translate([4, switch_width/2+guide_padding, switch_thickness/2+base_thickness])
          rotate([90,0,0])
          cylinder(r=probe_diameter/2, h=switch_width+guide_padding);
    }
}
module plate(w,h) {
    hull() {
        cube([w, 2*w+guide_padding, h]);
        cube([w/4, w+guide_padding, h]);

    }
}

module full_plate(w,h) {
    difference() {
        plate(w,h);
        translate([w/2,w/2+guide_padding,h-3])
          rotate([0,0,180])
          scale(v=1.1)
          armature(6,6,6,4,12);
    }
}

module dovetail(w,h,l) {
    hull() {
        cube([l, 2*w/3, .01]);
        translate([0,-w/6,-h])
          cube([l,w,.01]);
    }
}
module switch_captor(w,h) {
    intersection(){
        hull() {
            translate([guide_roundness, guide_roundness, h])
              rotate([180,0,0])
              cylinder(r=guide_roundness, h=2.75*h);
            translate([switch_width - guide_roundness,       guide_roundness, h])
              rotate([180,0,0])
              cylinder(r=guide_roundness, h=2.75*h);
            translate([guide_roundness, w+2+guide_padding-guide_roundness, h])
              rotate([180,0,0])
              cylinder(r=guide_roundness, h=2.75*h);
            translate([switch_width-guide_roundness, w+2+ guide_padding-guide_roundness, h])
              rotate([180,0,0])
              cylinder(r=guide_roundness, h=2.75*h);
        }
        union() {
            cube([w, w+2+guide_padding, h]);
            translate([w-dovetail_width, guide_padding/4-.5, 0])
              dovetail(4, 1.75*h, dovetail_width);
            translate([w-dovetail_width, 3*guide_padding/4-.5, 0])
              dovetail(4, 1.75*h, dovetail_width);
            translate([w/2,(switch_height + w)/2+guide_padding, -switch_hole_depth*2/3])
              screwtaps(switch_hole_diameter/3, 2*switch_hole_depth/3,
                  switch_hole_spacing);
        }
    }
}
module assembled_guide() {
    intersection() {
        hull() {
            translate([guide_roundness, guide_roundness])
              cylinder(r=guide_roundness, h=guide_thickness);
            translate([switch_width - guide_roundness,       guide_roundness])
              cylinder(r=guide_roundness, h=guide_thickness);
            translate([guide_roundness, 12+switch_width+guide_padding-guide_roundness])
              cylinder(r=guide_roundness, h=guide_thickness);
            translate([switch_width-guide_roundness, 12+switch_width+guide_padding-guide_roundness])
              cylinder(r=guide_roundness, h=guide_thickness);
        }
        difference() {
            union() {
                full_plate(switch_width,base_thickness);
                probe_guide();
            }
            translate([.01,0,base_thickness + switch_thickness]) {
                union() {
                    translate([0,.2,0])
                      switch_captor(switch_width,base_thickness);
                    translate([0,-.2,0])
                      switch_captor(switch_width,base_thickness);
                }
            }
        }
    }
}

assembled_guide();
translate([-switch_width,0,base_thickness])
rotate([0,180,0])
switch_captor(switch_width, base_thickness);
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