Box for universal motor

Needs updates to make brushes fit properly.

lovejoy.scad

@@ -4,14 +4,13 @@ use <PolyGear/shortcuts.scad>
 
 
 module spider_section(ir=6,or=13, l=6, lt=1, h, die=false) {
-	$fn= ($preview || $fn > 60) ? $fn : 60;
 	a = 360/l;
 	cx=or-ir+.2;
 	for (r=[0,a]) 
 		rotate([0,0,r]) 
 			translate([ir+cx/2-.2,0,0]) cube([cx, die ? lt+.2 : lt, h], center=true);
 	if (die) {
-		RiS(R=or, r=0, h=h, w1=0, w2=60, center=true, D=undef, d=undef);
+		RiS(R=or, r=0, h=h, w1=0, w2=60);
 		Ri(R=ir+.4, r=0, h=h);
 	} else {
 		Ri(R=ir, r=ir-lt, h=h);
@@ -36,7 +35,10 @@ module lovejoy(ph=5, jh=3) {
 	}
 }
 
-$fs= ($preview || $fn > 2) ? $fn : .1;
+if (! $preview) {
+	$fs= .1;
+	$fn= 60;
+}
 color("pink")
 	lovejoy() translate([0,0,-6]) cylinder(r=2, h=12, $fn=4, center=true);
 color("green") 

motor.scad

@@ -0,0 +1,209 @@
+use <inserts.scad>
+
+STATOR_L=30;
+STATOR_H=57.19;
+STATOR_W=56;
+STATOR_ID=4.33;
+
+ARM_AXIS=114;
+ARM_FRONT_BEAR=22.02;
+ARM_FRONT_BEAR_L=6.8;
+ARM_REAR_BEAR=19.09;
+ARM_REAR_BEAR_L=6.6;
+ARM_WIND=55;
+ARM_WIND_L=64;
+ARM_BRUSH_OFF=23;
+ARM_REAR_OFF=23;
+
+
+
+FAN_BAFFLE=37;
+FAN_BAFFLE_L=2;
+FAN=53;
+FAN_L=7;
+
+module rim(d, rw=2.5, rh=2.4, cc=25, rcolor="red", top=false) {
+	// Rim
+	rcol = $incolor ? rcolor : undef;
+	off = top ? rw : 0;
+	
+	difference() {
+		linear_extrude(height=rh)
+			square([d.x-off, d.y-off], center=true);
+		translate([0,0,-.15]) linear_extrude(height=rh+.3)
+			offset(r=-rw) square([ARM_AXIS-.1-off, STATOR_W+8+6+5-off], center=true);
+		translate([0,0,(rw+1)/2]) cube([d.x+1, cc, rh+1], center=true);
+	}
+}
+
+module stator(sl=STATOR_L, sh=STATOR_H, sw=STATOR_W, id=STATOR_ID) {
+	cube([sh+.2,sw+.2,sl+.2], center=true);
+	rotate([0,0,0]) cylinder(d=sw-1,h=sl+7, center=true);
+	for (i=[-1, 1]) {
+		translate([0,i*-(58/2-2.5),0]) cube([36,8,58], center=true);
+	}
+}
+
+module arm_axis(d=0, arm_axis=ARM_AXIS,real=false, acolor="silver") {
+	incolor = is_undef($incolor) ? false : $incolor;
+
+	axis_color = incolor ? acolor : undef;
+	rotate([0,90,0]) {
+		if ($children < 1) {
+			color(axis_color) cylinder(h=arm_axis, d=1, center=true);
+		} else {
+			translate([0,0,d]) children();
+		}
+	}
+}
+
+module brush_posts() {
+	for (ix=[-1, 1])
+		translate([0,ix*(1+22.7/2+13.25/2),0]) {
+			cube([13.25,18+4,13.25], center=true);
+			// side posts
+			translate([3-1.5,0,0]) cube([6.1,5,20], center=true);
+			// Wire Clearance
+			translate([2,ix*12,15]) cube([8,9,22], center=true);
+		}
+}
+
+module armature(
+	aa=ARM_AXIS,
+	afbd=ARM_FRONT_BEAR,
+	afbl=ARM_FRONT_BEAR_L,
+	arbd=ARM_REAR_BEAR,
+	arbl=ARM_REAR_BEAR_L,
+	abo=ARM_BRUSH_OFF,
+	awd=ARM_WIND,
+	awl=ARM_WIND_L,
+	fbcd=FAN_BAFFLE,
+	fl=FAN_L,
+	fd=FAN,
+	fbd=FAN_BAFFLE,
+	fbl=FAN_BAFFLE_L,
+	sl=STATOR_L,
+	spd=16
+) {
+	fo=6;
+	incolor = is_undef($incolor) ? false : $incolor;
+	bearing_color = incolor ? "green" : undef;
+	fan_color = incolor ? "blue" : undef;
+
+	
+	//%arm_axis(d=0, acolor="purple");
+	// front bearing
+	arm_axis(d=aa/2 - afbl) 
+		color(bearing_color) cylinder(d=afbd, h=afbl);
+	// Fan
+	color(fan_color) arm_axis(d=aa/2 - afbl - fl +.5) {
+		cylinder(d=spd+.4, h=fl+.2);
+		translate([0,0,-(fo)]) { 
+			translate([0,0,-2]) cylinder(d=fd+1, h=fl+4);
+			// air outlets
+			for (r=[60:360/12:300])
+					rotate([0,0,270-r])
+						translate([0,fd/2,fl/2]) cube([fl,42,fl/2], center=true);
+				
+	}
+		translate([0,0,-(fo+.5+fbl)-3]) cylinder(d2=fbd, d1=fd-2,h=fbl+2);
+	}
+	
+	// Arm Clearance
+	arm_axis(d=4.5) cylinder(d=awd, h=awl-4, center=true);
+	//arm_axis(d=aa/2 - afbl) cylinder(d=afbd, h=afbl);
+
+	// Rear Clearance
+	arm_axis(d=-(awl/2 + abo +1)) {
+		translate([0,0,abo/2-.1]) cylinder(d=27,h=abo/2+8);
+		translate([0,0,arbl/2]) cylinder(d2=27,d1=arbd-2.5,h=abo/2-1);
+
+		// Air Inlets
+		for (r=[60:360/12:300])
+			if (270-r != 90) // Not straight up
+				rotate([0,0,270-r])
+					translate([0,arbd/2 +12,fl-4])
+						rotate([-30,0,0]) cube([5,45,4], center=true);
+	}
+	arm_axis(d=(aa-sl)/2 -34.5 -3) stator();
+	// Brush Posts
+	arm_axis(d=-(aa/2 - abo)) {
+		// communtator
+		cylinder(d=22.5, h=9.92, center=true);
+		brush_posts();
+	}
+	// rear bearing
+	arm_axis(d=-(aa/2)) 
+		color(bearing_color) cylinder(d=arbd, h=arbl);
+	
+}
+
+module case(top=false) 
+{
+	$incolor=false;
+	ext=1.5;
+	extx=17.5;
+	bx=ARM_AXIS-.1;
+	by=STATOR_W+8+6+5;
+	bz=2+STATOR_H/2;
+	arot=top ? [180,0,0] : [0,0,0];
+
+	difference() {
+		union() {
+			cube([bx, by, bz], center=true);
+			translate([0,0,bz/2]) rim(d=[bx, by], top=top);
+			if (! top)  
+				translate([-(bx/2 - ARM_BRUSH_OFF+extx/2),-by/2,bz/2]) cube([extx,by-1,ext]);
+		}
+
+		translate([0,0,bz/2]) rotate(arot) armature();
+		if (top) {
+			echo("top");
+			translate([-(bx/2 - ARM_BRUSH_OFF+extx/2),-by/2 + 2,bz/2-ext]) 
+				cube([extx,by-5,ext+1]);
+		}
+	
+		// Case screws
+		csrot = top ? [0,180,0] : [0,0,0];
+		for(ix=[1, -1])
+			for(iy=[1, -1])
+				translate([ix*(bx/2 - 8), iy*(by/2 - 8), bz/2 +.01]) 
+					rotate(csrot) thread_insertM3(bl=40, bz=-12.8, $die=true);
+		
+		// Mount Inserts
+		for(ix=[1, -1])
+			for(iy=[1, -1])
+				translate([ix*(bx/2 - 8), iy*(by/2 - 8), -(bz/2 +.01)]) 
+					rotate([0,180,0]) 
+						thread_insertM3(bl=40, bz=-20, $die=true);	
+
+		// Input Wires hole
+		ho = top ? 8/2 : 0 ;
+		hys = top ? 1 : -1; 
+		translate([-20,hys*(by/2-4),bz/2 + ho]) 
+			rotate([90,0,0]) 
+				cylinder(d=8, h=9, center=true);	
+	}
+}
+
+if (! $preview) {
+	$fs=.1;
+}
+by=STATOR_W+8+6+5;
+bz=2+STATOR_H/2;
+
+module place_plate(by, bz) {
+	d = by/2 + 5;
+	translate([0,d,bz/2]) children(0);
+	translate([0,-d,bz/2]) children(1);
+}
+
+module place_final(bz) {
+	translate([0,0,bz/2]) rotate([180,0,0]) children(0) ;
+	translate([0,0,-bz/2]) children(1);
+}
+
+place_plate(by, bz) {
+	case(bz=bz, top=true);
+	case(bz=bz);
+}