From 3ea8a73f40da3d238b248db1a88d0a460d331002 Mon Sep 17 00:00:00 2001
From: Stephen Carpenter <sjc@carpanet.net>
Date: Tue, 7 Jan 2020 15:14:09 -0500
Subject: [PATCH] Second test, bigger, badder

Module is now parametric, as are most values.
Larger leafs
Larger gears
Thicker walls.
---
 gears.scad | 95 +++++++++++++++++++++++++++++++++++-------------------
 1 file changed, 62 insertions(+), 33 deletions(-)

diff --git a/gears.scad b/gears.scad
index 8d0b888..dd00103 100644
--- a/gears.scad
+++ b/gears.scad
@@ -1,39 +1,46 @@
 use <PolyGear/PolyGear.scad>
 use <PolyGear/shortcuts.scad>
 
-width = 5;
-N1 = 9;
-N2 = 9;
-axis_angle = -0;
+width = 8;
+N = 9;
+// Force same number of teeth
+N1=N;
+N2=N;
+axis_angle = 0;
+Module=1.3;
 
-// RefD = M/N ; Default M=1
+ShaftD=4.5;
+MeshD=Module*(N1+N2)/2;
 
-MeshD=(N1+N2)/2;
+SwingAdd = 1;
+Swing = MeshD/2 + Module + SwingAdd;
+
+// RefD = M*N ; Default M=1
+tol=.2;
+BackW=Swing+Module;
+SideW=tol+BackW;
 
 echo("Reference Diameter (MeshD): ", MeshD);
 //rot=360/N1*$t;
-rot=90-5*$t;
-//rot=90;
+//rot=90-90*$t;
+rot=90;
 //axis_angle = -50;
 color("blue") translate([-MeshD/2,0]) rotate([0,0,rot]) {
 	render() intersection() {
-		spur_gear(n=N1, w=width, helix_angle=constant(axis_angle/2));
+		spur_gear(n=N1, w=width, m=Module,helix_angle=constant(axis_angle/2));
 	
 		difference() {	
 			CyS(r=MeshD, h=width, w1=215, w2=20);
 			// Shaft Hole
-			cylinder(d=4, h=12, center=true, $fn=16);
+			cylinder(d=ShaftD, h=12, center=true, $fn=16);
+	
+			// Block limit
+			translate([-BackW+2*tol,-MeshD/2,0]) cube([MeshD,MeshD,width], center=true);
 		}
 	}
 	
 	// leaf arm
-	translate([MeshD/2 - 1.75,4,0]) cube([1.25,8,5], center=true);
-	
-	// Block
-	//difference() {
-	//	translate([-MeshD/2 + 1.75,-3,0]) cube([1.25,3,5], center=true);
-	//	translate([-4.125,-4.5,0]) rotate([0,0,45]) cube([1.5,3,6], center=true);
-	//}
+	translate([MeshD/2 - 2.5,4,0]) cube([2,8,5], center=true);
 
 }
 
@@ -42,12 +49,12 @@ color ("red") translate([MeshD/2,0]) rotate([0,0,-rot]){
 		difference() {
 			union() {
 			intersection() {
-				spur_gear(n=N2, w=width, helix_angle=constant(axis_angle/2));
+				spur_gear(n=N2, w=width, m=Module, helix_angle=constant(axis_angle/2));
 				CyS(r=MeshD, h=width, w1=150, w2=-30);
 			}
 			
 			// leaf arm
-			translate([-MeshD/2 + 1.75,4,0]) cube([1.25,8,5], center=true);
+			translate([-MeshD/2 + 2.5,4,0]) cube([2,8,5], center=true);
 	
 			// Block
 			//translate([+MeshD/2 - 1,-1,0]) cube([1.5,6,5], center=true);
@@ -55,30 +62,52 @@ color ("red") translate([MeshD/2,0]) rotate([0,0,-rot]){
 			CyS(r=MeshD - 3, h=width, w1=-55, w2=-30);
 		}
 		// Shaft Hole
-		cylinder(d=4, h=12, center=true, $fn=16);
+		cylinder(d=ShaftD, h=12, center=true, $fn=16);
 		
 		// Block limit
-		translate([5.75,-3,0]) cube([5,5,5], center=true);
+		translate([BackW-2*tol,-MeshD/2,0]) cube([MeshD,MeshD,width+1], center=true);
 		}
 	}
 }
 
-module box() {
+module box(
+	d=ShaftD,
+	tol=.3,
+	ShaftFN=$fn,
+	MeshD=MeshD,
+	Module=Module,
+	SwingAdd=1,
+	WallD=1.5,
+	full=true)
+{
+	Swing = MeshD/2 + Module + SwingAdd;
+	BackW=WallD/2 + Swing+Module+1;
+	SideW=tol -1 + BackW-MeshD/2;
+	if (full == true) {
+		mirror([1,0,0]) box(d=d, tol=tol, ShaftFN=ShaftFN, full=false);
+	}
+	
 	translate([MeshD/2,0]) {
-		cylinder(d=4-.2, h=width+1,$fn=16, center=true);
-		translate([2,0]) cube([5,1,width+1], center=true);
-		translate([4.5,-3]) cube([1,7,width+1], center=true);
+		// Shaft
+		cylinder(d=d-tol, h=width+1,$fn=ShaftFN, center=true);
+		// Front Wall
+		translate([BackW/2 - SideW +1,0]) cube([SideW+tol,WallD,width+1], center=true);
+		// Side Wall
+		translate([SideW,-Swing/2]) cube([WallD,Swing+WallD,width+1], center=true);
 	}
-	translate([-MeshD/2,0]) { 
-		cylinder(d=4-.2, h=width+1,$fn=16, center=true);
-		translate([-2,0]) cube([5,1,width+1], center=true);
-		translate([-4.5,-3]) cube([1,7,width+1], center=true);
+	// Back Wall
+	translate([BackW/2,-Swing,0]) cube([BackW,WallD,width+1],center=true);
+	// Bottom/Top
+	translate([BackW/2,-(Swing)/2,-width/2 - WallD/2 - tol]) 
+		cube([BackW,Swing+WallD,WallD], center=true);
+	translate([BackW/2,-(Swing)/2,width/2 + WallD/2 + tol]) 
+	difference() {
+		cube([BackW,Swing+WallD,WallD], center=true);
+		translate([-Swing/2,0,0]) cube([BackW/2, Swing/2,4],center=true);
 	}
-	translate([0,-6.5,0]) cube([19,1,width+1],center=true);
-	translate([0,-3.5,-width/2 - .75]) cube([19,6.5,1], center=true);
-	translate([0,-3.5,width/2 + .75]) cube([19,6.5,1], center=true);
+
 }
 
 color("green") {
-	//box();
+	box(full = true, ShaftFN=16);
 }