// PRUSA iteration4
// X carriage
// GNU GPL v3
// Josef Průša <iam@josefprusa.cz> and contributors
// http://www.reprap.org/wiki/Prusa_Mendel
// http://prusamendel.org

use <bearing.scad>

module belt_cut()
{
    rotate([0, 0, 180])
    {
        translate([-20, 0, 0]) cube([39, 0.75, 15]);
        translate([-20, 0, 5]) rotate([-7, 0, 0]) cube([39, 0.75, 10]);
        translate([-20, 0, 5]) rotate([10, 0, 0]) cube([39, 0.75, 10]);
        for (_step = [-20 : 2 : 18])
        {
            translate([_step, 0.5, 0]) cube([1, 1.0, 10]);
        }
        for (_step = [-20 : 2 : 18])
        {
            translate([_step, 0.5, 5]) rotate([-7, 0, 0]) cube([1, 1, 10]);
        }
    }
}


module x_carriage_base()
{

    // Small bearing holder
    translate([-33 / 2, 0, 0]) rotate([0, 0, 90]) horizontal_bearing_base(1);

    // Long bearing holder
    translate([-33 / 2, 45, 0]) rotate([0, 0, 90]) horizontal_bearing_base(2);

    // Base plate
    translate([-34, -14, 0]) cube([34.5, 70.5, 7]);
    translate([-33, -15, 0]) cube([33, 7, 15]);
    translate([-42.5, 53.0, 0]) cube([52, 6.5, 15]);

    difference()
    {
        union()
        {
            translate([-12, 30, 1]) rotate([0, 0, 45]) cube([6, 6, 14]);
            translate([-20, 30, 1]) rotate([0, 0, 45]) cube([6, 6, 14]);
        }
        translate([-25, 38, 11]) rotate([43, 0, 0]) cube([20, 8, 8]);
    }

    // upper motor screw block
    translate([-23, 56.8, 0]) rotate([0, 0, 0]) cube([32.5, 18.2, 8]);

    // Belt holder base
    translate([-42.5, 20, 0]) cube([52, 16, 7]);

    // new belt holder base block
    translate([-42.5, 18, 7]) cube([52, 16.3, 8]);
}

module x_carriage_holes()
{
    // Small bearing holder holes cutter
    translate([-33 / 2, 0, 0]) rotate([0, 0, 90]) horizontal_bearing_holes_nozip(1);

    // Long bearing holder holes cutter
    translate([-33 / 2, 45, 0]) rotate([0, 0, 90]) horizontal_bearing_holes_nozip(2);

    // upper ziptie right
    translate([2, 0, 0])
    difference()
    {
        translate([0.75, 45, 12]) rotate([0, 90, 0]) cylinder(r = 10.8, h = 3.5, $fn = 25);
        translate([0, 45, 12]) rotate([0, 90, 0]) cylinder(r = 9, h = 6, $fn = 25);
    }

    // upper ziptie left
    translate([-38, 0, 0])
    difference()
    {
        translate([0.75, 45, 12]) rotate([0, 90, 0]) cylinder(r = 10.8, h = 3.5, $fn = 25);
        translate([0, 45, 12]) rotate([0, 90, 0]) cylinder(r = 9, h = 6, $fn = 25);
    }

    // upper ziptie head
    translate([0, 52.5, 12]) cube([10, 10, 5]);
    translate([-45, 52.5, 12]) cube([13.5, 10, 5]);

    // Extruder mounting holes
    translate([-17.5 + 12, 24.5, -1]) cylinder(r = 1.65, h = 20, $fn = 25);
    translate([-17.5 + 12, 24.5, -0.1]) cylinder(r1 = 2.1, r2 = 1.65, h = 0.5, $fn = 25);
    translate([-17.5 + 12, 24.5, 12]) cylinder(r = 5.8 / 2, h = 20, $fn = 25);

    translate([-16.5 - 12, 24.5, -1]) cylinder(r = 1.65, h = 20, $fn = 25);
    translate([-16.5 - 12, 24.5, -0.1]) cylinder(r1 = 2.1, r2 = 1.65, h = 0.5, $fn = 25);
    translate([-16.5 - 12, 24.5, 12]) cylinder(r = 5.8 / 2, h = 20, $fn = 25);

    // Carriage slimer
    translate([-55.5 + 3, 19, -1]) cube([10, 40, 30]);
    translate([12.5 - 3, 19, -1]) cube([10, 40, 30]);
    translate([12.5 - 3.5 - 2, 30.8, -1]) rotate([0, 90 - 65, 0]) cube([10, 55, 30]);
    translate([-55.5 + 6.7 + 2, 19, -10]) rotate([0, -90 + 65, 0]) cube([10, 40, 30]);
}

module x_carriage_fancy()
{
    // Top right corner
    translate([11.5, 8, 0]) translate([0, 45 + 11.5, -1]) rotate([0, 0, 45]) translate([0, -15, 0]) cube([30, 30, 20]);

    // Top left corner
    translate([-33 - 13.5, -5, 0]) translate([0, 45 + 11.5, -1]) rotate([0, 0, 135]) translate([0, -15, 0]) cube([30, 30, 20]);

    translate([-27, 74.5, 9]) rotate([0, 45, 0]) translate([0, -15, 0]) cube([5, 25, 5]);
    translate([-23, 86, 16]) rotate([45, 0, 0]) translate([0, -15, 0]) cube([45, 5, 5]);

    // bottom side edges
    translate([-40, -15, -5]) rotate([30, 0, 0]) cube([45, 6, 15]);
    translate([-35, -19.2, 0]) rotate([0, 0, 45]) cube([6, 6, 16]);
    translate([2, -19.2, 0]) rotate([0, 0, 45]) cube([6, 6, 16]);
    translate([2, 55.9, 12]) rotate([0, 0, 45]) cube([6, 6, 16]);
    translate([-33.5, 55.9, 12]) rotate([0, 0, 45]) cube([6, 6, 16]);
}

module cable_tray()
{
    // center screw block
    translate([-21, 23, 0]) cube([9, 12, 15]);

    difference()
    {
        union()
        {
            translate([-20.8, 24.8, 0]) rotate([0, 0, 20]) cube([3, 10, 15]);
            translate([-15.5, 25.8, 0]) rotate([0, 0, -20]) cube([3, 10, 15]);
        }
        translate([-25, 34.2, 0]) cube([20, 10, 15]);
    }

    translate([6.5, 32, 10]) cube([3, 5, 5]);
    translate([-42.5, 32, 10]) cube([4, 5, 5]);

    //Left cable tray
    translate([-39.9, 11, 0]) cube([9, 2, 15]);
    translate([-39.9, 5.5, 0]) cube([9, 2, 15]);

    //Right cable tray
    translate([-2, 5.5, 0]) cube([11.45, 2, 15]);
    translate([-2, 11, 7]) cube([11.45, 2, 8]);

    translate([-31, 11.5, 7]) cube([30, 1.5, 8]);

    difference()
    {
        translate([0, 11, 0]) cube([9.50, 12, 7]);
        translate([0, 6, 1]) rotate([-30, 0, 0]) cube([7.5, 12, 7]);
        translate([0, 3.5, 6]) rotate([-60, 0, 0]) cube([7.5, 12, 7]);
        translate([0, 10 + 3, -1]) cube([7.5, 11, 6]);
    }
}

module final_cutout()
{
    // cable guide edges
    translate([-44, 0, 16]) rotate([0, 45, 0]) cube([5, 15, 5]);
    translate([6, 0, 16]) rotate([0, 45, 0]) cube([5, 15, 5]);

    // motor cable opening
    translate([0.5, 10 + 3, -1]) cube([7, 9.2, 6]);

    // filament hole
    difference()
    {
        union()
        {
            translate([-14.199, 9.05, 0]) rotate([-5, 0, 22.5]) cylinder(r = 1.62, h = 40, $fn = 8);
            translate([-14.5, 9.7, 8]) rotate([-5, 0, 22.5]) cylinder(r = 1.62, r2 = 3, h = 8, $fn = 8);
        }
        //translate([-18, 6.7, 12]) cube([7, 7, 5]);
    }

    // bottom back mounting screws
    translate([-6.5, -11, 4]) cylinder(r = 1.65, h = 20, $fn = 50);
    translate([-26.5, -11, 4]) cylinder(r = 1.65, h = 20, $fn = 50);

    difference()
    {
        union()
        {
            translate([-29.3, -14, 10]) cube([5.6, 7, 2.1]);
            translate([-09.3, -14, 10]) cube([5.6, 7, 2.1]);
        }
        translate([-36, -8.1, 10]) cube([40, 1, 0.5]);
    }

    // better printing bridges
    translate([-29.3, -12.65, 10.35]) cube([5.6, 3.3, 2.1]);
    translate([-09.3, -12.65, 10.35]) cube([5.6, 3.3, 2.1]);
    translate([-28.15, -12.65, 10.7]) cube([3.3, 3.3, 2.1]);
    translate([-8.15, -12.65, 10.7]) cube([3.3, 3.3, 2.1]);

    // x-carriage-back mounting screws
    translate([-4, 56, 0]) cylinder(r = 1.7, h = 40, $fn = 50);
    translate([-27.5, 56, 0]) cylinder(r = 1.7, h = 40, $fn = 50);
    translate([-30.3, 53, 8]) cube([5.6, 8, 2]);
    translate([-6.8, 53, 8]) cube([5.6, 8, 2]);

    // better printing bridges
    translate([-6.8, 54.35, 8.35]) cube([5.6, 3.3, 2]);
    translate([-5.65, 54.35, 8.7]) cube([3.3, 3.3, 2]);
    translate([-30.3, 54.35, 8.35]) cube([5.6, 3.3, 2]);
    translate([-29.15, 54.35, 8.7]) cube([3.3, 3.3, 2]);

    // center mounting screw
    translate([-16, 29, 0]) cylinder(r = 1.65, h = 40, $fn = 50);
    translate([-18.8, 26, 10.5]) cube([5.6, 12, 2.1]);
    translate([-21, 33, 11]) cube([10, 8, 6]);

    // better printing bridges
    translate([-18.8, 27.35, 10.9]) cube([5.6, 3.3, 2.1]);
    translate([-17.65, 27.35, 11.25]) cube([3.3, 3.3, 2.1]);

    // opening for power cables to hotend & termistor cable
    translate([-16.5, -18, -5]) rotate([-5, 0, 0]) cylinder(r = 6, h = 40, $fn = 30);
}

module x_carriage_block()
{
    difference()
    {
        union()
        {
            difference()
            {
                x_carriage_base();
                x_carriage_holes();
                x_carriage_fancy();
            }
            cable_tray();
        }
        final_cutout();
    }
}

module x_carriage()
{
    difference()
    {
        x_carriage_block();

        // upper motor screw
        translate([2.5, 67.5, -50]) cylinder(r = 1.8, h = 100, $fn = 30);
        translate([2.5, 67.5, -0.1]) cylinder(r1 = 2.1, r2 = 1.8, h = 0.5, $fn = 25);
        translate([2.5, 67.5, 5]) cylinder(r = 3.2, h = 8, $fn = 30);
        translate([0.5, 22.5, 0]) rotate([0, 90, 0]) cylinder(r = 5.2, h = 7.0, $fn = 25);

        // cable management cleanup
        difference()
        {
            translate([2.5, 21.5, 0]) rotate([0, 90, 0]) cylinder(r = 5.2, h = 5.0, $fn = 25);
            translate([2, 16, -10]) cube([10, 6, 20]);
        }

        // selective infill
        translate([5, -15.4, -1]) rotate([0, 45, 0]) cube([0.3, 4.6, 8]);
        translate([8.45, 11.5, 1]) cube([0.5, 1.8, 4]);

        translate([5, -16.4, -1]) rotate([0, 45, 0]) cube([0.3, 0.5, 8]);
        translate([5, -10.3, -1]) rotate([0, 45, 0]) cube([0.3, 0.5, 8]);
        translate([6, -16.5, -1]) cube([1, 0.5, 5]);
        translate([3, -16.5, -1]) cube([2, 0.5, 5]);
        translate([6, -10.2, -1]) cube([1, 0.5, 5]);
        translate([3, -10.2, -1]) cube([2, 0.5, 5]);
        translate([6, 7.5, -1]) cube([1, 0.5, 5]);
        translate([6, 10.5, -1]) cube([1, 0.5, 5]);

        translate([-19, 24, 1.5]) cube([6, 0.5, 12.0]);

        //cable openings in guides
        translate([-40.8, 7.5, 0]) rotate([0, 20, 0]) cube([5, 3.5, 20]);
        translate([-2.9, 7.5, 18]) rotate([0, 80, 0]) cube([20, 3.55, 5]);

        // filament sensor connector
        translate([-12.5, 64, -3]) cube([4, 11.2, 14]);
        translate([-12.5, 65.75, -3]) cube([5, 2.5, 14]);
        translate([-12.5, 71.75, -3]) cube([5, 2.5, 14]);
        translate([-14.5, 67, -3]) cube([4, 6, 14]);
        translate([-14.5, 65, 4.7]) cube([4, 10.2, 5]);
        translate([-12.5, 54.5, 8]) cube([3.5, 10.2, 14]);
        translate([-12.5, 57.5, 9.5]) rotate([35, 0, 0]) cube([3.5, 10.2, 14]);
        translate([-12.5, 58, 8]) rotate([0, 0, 45]) cube([3, 3, 14]);
        translate([-10, 58, 8]) rotate([0, 0, 45]) cube([3, 3, 14]);

        translate([0, -0.5, 0]) left_belt_cut();
        translate([0, 0.5, 0]) right_belt_cut();

        //version
        translate([-2, -8, 0.5]) rotate([0, 180, 0]) linear_extrude(height = 0.6)
        { text("R3", font = "helvetica:style = Bold", size = 5, center = true); }
    }
}

module left_belt_cut()
{
    translate([-22.5, 30.2, 7]) cylinder(r = 1.5, h = 100, $fn = 30);
    translate([-23.0, 20, 7]) cube([2, 10, 30]);
    translate([-56.5, 28.5, 7]) belt_cut();
    translate([13.5, 20.5, 0]) rotate([0, 0, 25])
    {
        difference()
        {
            translate([-56.5, 28.5, 7]) belt_cut();
            translate([-80, 25, 7]) cube([37.5, 10, 30]);
        }
    }
    translate([13.2, 2.38, 0]) rotate([0, 0, 0])
    {
        difference()
        {
            translate([-56.5, 28.5, 7]) belt_cut();
            translate([-82.42, 25, 7]) cube([37.5, 10, 30]);
        }
    }
    translate([-45, 17.6, 4]) rotate([0, 0, -15]) cube([10, 3, 30]);
    translate([-31.5, 30.4, 10]) rotate([-10, 0, 15]) cylinder(r = 0.2, h = 100, $fn = 30);
    translate([-31.6, 30.75, 7]) rotate([0, 0, 0]) cylinder(r = 0.2, h = 100, $fn = 30);
}

module right_belt_cut()
{
        // right belt cut
        translate([-9.6, 29.7, 7]) cylinder(r = 1.5, h = 100, $fn = 30);
        translate([-11.1, 19.8, 7]) cube([2, 10, 30]);
        translate([22.5, 25.5, 7]) belt_cut();
        translate([66.65, 1.95, 0]) rotate([0, 0, 0])
        {
            difference()
            {
                translate([-56.5, 28.5, 7]) belt_cut();
                translate([-71.55, 25, 7]) cube([37.5, 10, 30]);
            }
        }
        translate([43.2, -30.25, 0]) rotate([0, 0, -30])
        {
            difference()
            {
                translate([-56.5, 28.5, 7]) belt_cut();
                translate([-82.1, 25, 7]) cube([10, 10, 30]);
                translate([-61.5, 25, 7]) cube([20.5, 10, 30]);
            }
        }
        translate([2, 14.6, 7]) rotate([0, 0, 15]) cube([10, 3, 30]);
        translate([-5.1, 30, 10]) rotate([-10, 0, -15]) cylinder(r = 0.2, h = 100, $fn = 30);
        translate([-5, 30.3, 7]) rotate([0, 0, 0]) cylinder(r = 0.2, h = 100, $fn = 30);
    }

x_carriage();