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throttle-base.scad
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// Throttle handle base that connect the handle to the rails and case bottom
include <throttle-parameters.scad>
// Parameters
bearing_margin_side = 3;
bearing_margin_frontback = 2;
bearing_offset = 60.5 / 2 - 7.5; // 25?
bearing_radius = bearing_height / 2;
bearing_case_margin = 0.17;
bearing_case_radius = bearing_radius + bearing_case_margin;
bearing_case_length = bearing_length + 2 * bearing_case_margin;
base_top_height = 1;
base_width = 60.5 + 2 * bearing_margin_side;
base_length = 45 + 2 * bearing_margin_frontback;
base_height = bearing_height + base_top_height;
base_cavity_width = 25;
shaft_outer_radius = 10;
shaft_bolt_offsets = 20;
shaft_connector_width = 35;
shaft_connector_height = 4;
// Bearing casing for housing standard linear bearings like LM8LUU
module BearingCase()
{
// Bearing case
translate ([-bearing_case_margin,0,bearing_case_radius])
rotate (a=90, v=[0,1,0])
cylinder (r1=bearing_case_radius, r2=bearing_case_radius,
h=bearing_case_length);
// Bearing insert box
translate ([-bearing_case_margin,-bearing_case_radius,-2])
cube ([bearing_case_length, 2 * bearing_case_radius, bearing_case_radius + 2]);
// Rod cavity
translate ([-1 - bearing_margin_frontback, 0, bearing_radius])
rotate (a=90, v=[0,1,0])
cylinder (r1=5, r2=5, h=base_length + 2);
// Rod insert box
translate ([-1 - bearing_margin_frontback, -5, -0.1])
cube ([base_length + 2, 10, bearing_radius]);
}
// The printed part of the base
module BasePrinted(leverDistance=18, leverWidth=8.0, shaftConnectorWidth, shaftConnectorThickness=3.0)
{
difference ()
{
// Main base box
translate ([-base_length/2, -base_width/2,0])
cube([base_length,
base_width,
base_height]);
// Right bearing case
translate ([-base_length/2 + bearing_margin_frontback, bearing_offset,0])
BearingCase();
// Left bearing case
translate ([-base_length/2 + bearing_margin_frontback, -bearing_offset,0])
BearingCase();
// Center cavity
translate ([-0.1-base_length/2, -12.5,-0.1])
cube([base_length + 0.2, base_cavity_width, base_height - base_top_height - 2 + 0.1]);
// Cable hole
cylinder (r1=7.7, r2=7.7, h=26);
// Handle mounting holes (2 x 4mm bolts with washers)
translate ([shaft_bolt_offsets,0,0]) cylinder (r1=2, r2=2, h=bearing_height + base_top_height + 1);
translate ([-shaft_bolt_offsets,0,0]) cylinder (r1=2, r2=2, h=bearing_height + base_top_height + 1);
// Zip tie holes
ziptie_thickness = 1.7;
ziptie_width = 3.2;
translate ([18.5,12,2.5]) cube ([ziptie_width, 22, ziptie_thickness]);
translate ([-21.5,12,2.5]) cube ([ziptie_width, 22, ziptie_thickness]);
translate ([18.5,-34,2.5]) cube ([ziptie_width, 22, ziptie_thickness]);
translate ([-21.5,-34,2.5]) cube ([ziptie_width, 22, ziptie_thickness]);
}
// Lever
lever_rim_width = 2;
lever_outside_width = leverWidth + 2 * lever_rim_width;
lever_height = 3;
translate([-lever_outside_width/2,-(base_width/2 + leverDistance + lever_rim_width),base_height-lever_height])
difference()
{
cube([lever_outside_width,leverDistance + lever_rim_width,lever_height]);
translate([lever_rim_width, lever_rim_width - 1, -0.1])
cube([leverWidth,2,lever_height+0.2]);
}
// Ball Spring Plunger spring case
// moveY(base_width/2 + 6) moveZ(33) flipY() turnZ(-90) BallSpringPlunger(); // center detent actuator
translate([0, 2+base_width/2 + detent_ball_offset + 0.75, 12 - case_bottom + base_height + case_bottom_gap])
flipY() turnZ(-90) BallSpringPlunger2(ballPart=false);
*translate([0, 2+base_width/2 + 0.5, 12 - case_bottom + base_height + case_bottom_gap])
flipY() turnZ(-90) BallSpringPlunger2(springPart=false);
}
// --------------------------
// Handle shaft and its base
// --------------------------
module ShaftAndBase(length, intrusion)
{
difference ()
{
union ()
{
// Base box
translate ([-base_length/2, -shaft_connector_width/2,0])
cube([base_length,
shaft_connector_width,
shaft_connector_height]);
// ???? TODO: Round the cable exit side of the base box
// Shaft tubes
tube (shaft_outer_radius-2, length, 1);
tube (shaft_outer_radius, length, 1);
// Shaft supports
translate ([-1.5,9,0])
rotate ([90,0,0])
cube ([3,length, 18]);
translate ([-9,-1.5,0])
rotate ([90,0,90])
cube ([3,length, 18]);
// Shaft base support cone
translate([0,0,shaft_connector_height])
difference ()
{
cylinder (d1=30, d2=20, h=6);
}
// Handle connector cone
translate ([0,0,length - intrusion - 10 + case_thickness])
cylinder (d1=20, d2=30, h=7);
}
// Handle mounting holes (2 x 4mm bolts with washers)
translate ([shaft_bolt_offsets,0,0]) hole (4, shaft_connector_height);
translate ([-shaft_bolt_offsets,0,0]) hole (4, shaft_connector_height);
// Central cable hole
hole(14, length);
// Side cable exit hole
turnZ(-25) translate ([0,0,7]) rotate([110,0,0])
{
scale([1,1.4,1])
hole(8, 28);
}
}
}