first beta reading for printing

first beta reading for printing

use <StepMotor_28BYJ-48.scad>;
use <Hub_28BYJ-48.scad>;
include <Bearing_6807-2RS.scad>;

// global rendering parameters
$fn = 24;

// library examples
// translate([100, 100, 10]) { StepMotor28BYJ(); }
// stepperHub(10, 7, 6, 3.1, 1.5, 2.75);
//translate([0, 0, 8]) bearing6807_2RS();
// bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
//shoulderBase(2, 55, 9.1, 3.1);

// interference fit adjustment for 3D printer
iFitAdjust = .4;

// shoulder base parameters
shoulderBaseHeight = 3;
shoulderBaseDiameter = 55;
shaftBossDiameter = 10;
mountScrewDiameter = 3.1;
bearingStep = 2; // size in mm of bearing interface step
// joint parameters
hubHeight = 10;
hubRadius = 7;
shaftHeight = 6;
shaftRadius = 3.1;
setScrewRadius = 1.5;
setScrewHeight = 2.75;
spokeWidth = 3;
spokes = 6;
screwTabs = 4;
screwTabHeight = 4;
armLength = 100;
// misc
baseDeckExtension = 60;
boundingBox = 8;
boundingBoxHalf = boundingBox / 2;
// 8 is distance from shaft center to screw center on x axis
// 35 is screw center to screw center on y axis
shaftCenterToMountHoldCenterXAxis = 8;
mountHoleCenterToMountHoleCenter = 35;
leadScrewDiameter = 8;
// forearm
forearmLength = 75;

/* Pieces in this model
** Shoulder:
*** Base plate
*** Top plate
*** Lower arm
*** Upper arm
** Forearm:
*** ?
** Hand:
*** ?
*/

// shoulder base
color([.7, .7, 1])
    shoulderBase(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// shoulder lower stepper
rotate([0, 180, 0])
    translate([-8, 0, 10])
        StepMotor28BYJ();
// lower shoulder bearing
translate([0, 0, shoulderBaseHeight + bearingStep])
    %bearing6807_2RS();
// shoulder top
color([.6, .6, .9])
    translate([0, 0, 2 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep)])
    rotate([180, 0, 0])
        shoulderBase(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// upper shoulder bearing
translate([0, 0, shoulderBaseHeight + (3 * bearing6807_2RS_B) + (7 * bearingStep)])
    %bearing6807_2RS();
// shoulder upper stepper
rotate([0, 0, 180])
    translate([-8, 0, 10 + 2 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep)])
        StepMotor28BYJ();
// shoulder spacers
color([.7, .6, .2])
shoulderSpacers(bearing6807_2RS_D + iFitAdjust, 0 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep));
color([.7, .6, .2])
translate([baseDeckExtension / 3, 0, 0])
shoulderSpacers(bearing6807_2RS_D + iFitAdjust, 0 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep));
// end shoulder

// lower arm including the shoulder - arm joint
//render()
color([1, .7, .7])
    translate([0, 0, shoulderBaseHeight + bearing6807_2RS_B])
        armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// upper arm
//render()
color([.9, .7, .7])
    translate([0, 0, shoulderBaseHeight + ( 2*bearing6807_2RS_B) + (12 * bearingStep) - (.5 * bearingStep)])
        rotate([180, 0, 0])
            armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// elbow joint pieces
// lower bearing
translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + bearingStep])
    %bearing6807_2RS();
// arm upper stepper
translate([-armLength + 8, 0, shoulderBaseHeight + ( 3*bearing6807_2RS_B) + (16 * bearingStep) - (.5 * bearingStep)])
    rotate([0, 0, 180])
        StepMotor28BYJ();
// arm lower stepper
rotate([0, 180, 0])
    translate([armLength - 8, 0, bearingStep * 2])
        StepMotor28BYJ();
// arm spacers
color([.6, .6, .3])
    armSpacers(bearing6807_2RS_D + iFitAdjust, 0 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep));
// end arm

// forearm pieces
// lower
color([.1, .7, .1])
translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (4 *bearingStep)])
//translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (14 *bearingStep)])
    forearmLower(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight + (bearing6807_2RS_B / 2) + (bearingStep/2), hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox);
// upper
color([.2, .8, .2])
translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (4 *bearingStep)])
    rotate([180, 0, 0])
        forearmLower(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight + (bearing6807_2RS_B / 2) + (bearingStep/2), hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox);
// forearm upper bearing
translate([-armLength, 0, shoulderBaseHeight + (2 * bearing6807_2RS_B) + (7 * bearingStep)])
    %bearing6807_2RS();
// forearm spacers
// none at this time

//bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
module bearingInnerStep(bearingID, stepHeight, stepWidth) {
    difference() {
        union() {
            // this fits inside of the bearing
            cylinder(h = stepHeight * 2, d = bearingID);
            // this rests on the bearing inner lip
            cylinder(h = stepHeight, d = bearingID + stepWidth);
        }
        // remove center
        cylinder(h = stepHeight * 2, d = bearingID - (stepWidth * 2));
    }
}

//translate([0, 0, 12]) bearingOuterStep(bearing6807_2RS_D + iFitAdjust, 2, 2);
module bearingOuterStep(bearingOD, stepHeight, stepWidth) {
    //render(convexivity = 3)
    difference() {
        cylinder(h = stepHeight * 2, d = bearingOD + stepWidth);
        cylinder(h = stepHeight * 2, d = bearingOD - stepWidth);
        cylinder(h = stepHeight, d = bearingOD);
    }
}

module shoulderSpacers(bearingOD, screwSpacerHeight) {
    union() {
        // screw holes for joining to arm
        rotate([0, 0, -30])
        radial_array_partial(vec = [0, 0, 1], n = 6, 2)
            translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight * 1.0])
        difference() {
            union () {
                cylinder(h = screwSpacerHeight, r = setScrewRadius * 2);

                }
            cylinder(h = screwTabHeight, r = setScrewRadius);
        }
    }
}

module armSpacers(bearingOD, screwSpacerHeight) {
    union() {
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = 4)
            translate([bearingOD / 2 + (setScrewRadius * 2), 0, shoulderBaseHeight + bearing6807_2RS_B + 2 * bearingStep])
        difference() {
            union () {
                cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius * 2);

                }
            cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius);
        }
        // TODO: put in spacers along arm, make sure holes exist in arm
        translate([- armLength, 0, 0])
        rotate([0, 0, -30])
        radial_array_partial(vec = [0, 0, 1], n = 6, 2)
            translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight + bearing6807_2RS_B + 2 * bearingStep])
        difference() {
            union () {
                cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius * 2);

                }
            cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius);
        }
    }
}

// armJointSpacer(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
module armJointSpacer(bearingID, bearingOD, bearingStep, shaftBossDiameter, mountScrewDiameter) {
    union() {
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID);
        }
        translate([0, 0, bearingStep * 2])
                bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//shoulderBase(2, 55, 9.1, 3.1);
// WARNING: has some hard-coded non-parametric values in here!
module shoulderBase(bearingID, bearingOD, shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter) {
    mountHoleDepth = shoulderBaseHeight;

    //render(convexivity = 3)
    difference() {
        union () {
            cylinder(h = shoulderBaseHeight, d = shoulderBaseDiameter);
            translate([0, 0, shoulderBaseHeight])
                bearingInnerStep(bearing6807_2RS_d - iFitAdjust, bearingStep, bearingStep);
            // 40 is the length of deck extension from the baseplate in x
            translate([0, -shoulderBaseDiameter / 2, 0])
                cube([baseDeckExtension, shoulderBaseDiameter, shoulderBaseHeight], center = false);
        }
        // motor shaft hole
        cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
        // mounting holes

        translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        // lead screw hole
        translate([baseDeckExtension - (leadScrewDiameter * 1.5), 0, 0])
            cylinder(h = shoulderBaseHeight, d = leadScrewDiameter + (leadScrewDiameter / 2));
        // upper to lower spacer screw holes
        rotate([0, 0, -30])
            radial_array_partial(vec = [0, 0, 1], n = 6, 2)
                translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight * 0])
                    cylinder(h = screwTabHeight, r = setScrewRadius);
           translate([baseDeckExtension / 3, 0, 0])
            rotate([0, 0, -30])
            radial_array_partial(vec = [0, 0, 1], n = 6, 2)
                translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight * 0])
                    cylinder(h = screwTabHeight, r = setScrewRadius);
    }
    // NOTE: need to add LM8UU mounts
}

module armLower(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength) {
    armWidth = bearingOD / 2;
    render(convexivity = 3)
    difference() {
    union() {
        armInnerJoint(bearingOD, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
        translate([-armLength, 0, 0])
            armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight);
        difference() {
            translate([-armLength, -armWidth / 2, 0])
                cube([armLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }
        difference() {
            intersection() {

                translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : armLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

        }
               difference() {
               hull() {
                   translate([- armLength, 0, bearingStep])
                    linear_extrude(height = 2 * bearingStep, center = true, twist = 0)
                        polygon(points=[[0, -bearingOD/2 - setScrewRadius/2], [bearingOD / 2 + (setScrewRadius * 8), -armWidth / 2], [bearingOD / 2 + (setScrewRadius * 8), armWidth / 2], [0, bearingOD/2 + setScrewRadius/2]]);
                translate([- armLength, 0, 0])
                    rotate([0, 0, -30])
                    radial_array_partial(vec = [0, 0, 1], n = 6, 2)
                        translate([bearingOD / 2 + (setScrewRadius * 8), 0, 0])
                            cylinder(h = 2 * bearingStep, r = setScrewRadius * 2);

                    }
                translate([- armLength, 0, 0])
                    rotate([0, 0, -30])
                    radial_array_partial(vec = [0, 0, 1], n = 6, 2)
                        translate([bearingOD / 2 + (setScrewRadius * 8), 0, 0])
                        cylinder(h = 2 * bearingStep, r = setScrewRadius);

                 translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
             translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);

        }
   }
           // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);

   }
}

module armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight) {
    mountHoleDepth = bearingStep * 2;

    union() {
        difference() {
            union() {
                translate([0, 0, -(bearingStep * 2)])
                    cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
                translate([0, 0, bearingStep * 2])
                    rotate([0, 180, 0])
                        bearingOuterStep(bearingOD, bearingStep, bearingStep);
            }
            // motor shaft hole
            translate([0, 0, -(bearingStep * 2)])
                cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
            // mounting holes
            translate([0, 0, -(bearingStep * 2)]) {
                translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
                translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
            }
        }

    }
}

//armInnerJoint(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
module armInnerJoint(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight) {
    //translate([0, 0, hubHeight - (2 * stepHeight)])
    difference() {
        union() {
         difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + (setScrewRadius * 6));
            cylinder(h = bearingStep * 2, d = bearingOD);
//            translate([0, -bearingOD, 0])
//                cube([bearingOD, bearingOD * 2, bearingStep * 2]);
        }
        bearingOuterStep(bearingOD, stepHeight, stepWidth);
        // hub
        translate([0, 0, -(hubHeight - (2 * stepHeight))])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), stepHeight])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, stepHeight], center = false);
        // screw tabs for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])

                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }

                    }
        // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
    }
}

module forearmLower(bearingID, bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox) {
    armWidth = bearingOD / 2;

    rotate([180, 0, 0]) union() {
        boundingBoxHalf = boundingBox / 2;
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID - (2 * bearingStep));
        }
        translate([0, 0, bearingStep * 2])
            bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
        // hub
        translate([0, 0, hubHeight]) rotate([180, 0, 0])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), 0])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, 2 *stepHeight], center = false);
        // forearm extension
             difference() {
            translate([-forearmLength, -armWidth / 2, 0])
                cube([forearmLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-forearmLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD / 2);
                 // 4 on next line comes from dividing the bearingOD on the above line
            translate([-forearmLength + (bearingOD / 4) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([forearmLength - (bearingOD/2) - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }

            intersection() {

                translate([-forearmLength + boundingBox * 2, -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([forearmLength - (bearingOD / 2) - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : forearmLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

    }
}

module copy_mirror(vec=[0,1,0]) {
    children();
    mirror(vec)
        children();
}

module radial_array(vec = [0,0,1], n = 4) {
    for ( i = [0 : n - 1] )
    {
        rotate( i * 360 / n, vec)
            children();
    }
}

module radial_array_partial(vec = [0,0,1], n = 4, j = 2) {
    for ( i = [0 : n - 1] )
    {
        if (i < j)
            rotate( i * 360 / n, vec)
                children();
    }
}

use <StepMotor_28BYJ-48.scad>;
use <Hub_28BYJ-48.scad>;
include <Bearing_6807-2RS.scad>;

// global rendering parameters
$fn = 24;

// library examples
// translate([100, 100, 10]) { StepMotor28BYJ(); }
// stepperHub(10, 7, 6, 3.1, 1.5, 2.75);
//translate([0, 0, 8]) bearing6807_2RS();
// bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
//shoulderBase(2, 55, 9.1, 3.1);

// interference fit adjustment for 3D printer
iFitAdjust = .4;

// shoulder base parameters
shoulderBaseHeight = 3;
shoulderBaseDiameter = 55;
shaftBossDiameter = 10;
mountScrewDiameter = 3.1;
bearingStep = 2; // size in mm of bearing interface step
// joint parameters
hubHeight = 10;
hubRadius = 7;
shaftHeight = 6;
shaftRadius = 3.1;
setScrewRadius = 1.5;
setScrewHeight = 2.75;
spokeWidth = 3;
spokes = 6;
screwTabs = 4;
screwTabHeight = 4;
armLength = 100;
// misc
baseDeckExtension = 60;
boundingBox = 8;
boundingBoxHalf = boundingBox / 2;
// 8 is distance from shaft center to screw center on x axis
// 35 is screw center to screw center on y axis
shaftCenterToMountHoldCenterXAxis = 8;
mountHoleCenterToMountHoleCenter = 35;
leadScrewDiameter = 8;
// forearm
forearmLength = 75;

/* Pieces in this model
** Shoulder:
*** Base plate
*** Top plate
*** Lower arm
*** Upper arm
** Forearm:
*** ?
** Hand:
*** ?
*/

// shoulder base
color([.7, .7, 1])
    shoulderBase(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// shoulder lower stepper
rotate([0, 180, 0])
    translate([-8, 0, 10])
        StepMotor28BYJ();
// lower shoulder bearing
translate([0, 0, shoulderBaseHeight + bearingStep])
    %bearing6807_2RS();
// shoulder top
color([.6, .6, .9])
    translate([0, 0, 2 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep)])
    rotate([180, 0, 0])
        shoulderBase(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// upper shoulder bearing
translate([0, 0, shoulderBaseHeight + (3 * bearing6807_2RS_B) + (7 * bearingStep)])
    %bearing6807_2RS();
// shoulder upper stepper
rotate([0, 0, 180])
    translate([-8, 0, 10 + 2 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep)])
        StepMotor28BYJ();
// shoulder spacers
color([.7, .6, .2])
shoulderSpacers(bearing6807_2RS_D + iFitAdjust, 0 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep));
color([.7, .6, .2])
translate([baseDeckExtension / 3, 0, 0])
shoulderSpacers(bearing6807_2RS_D + iFitAdjust, 0 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep));
// end shoulder

// lower arm including the shoulder - arm joint
//render()
color([1, .7, .7])
    translate([0, 0, shoulderBaseHeight + bearing6807_2RS_B])
        armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// upper arm
//render()
color([.9, .7, .7])
    translate([0, 0, shoulderBaseHeight + ( 2*bearing6807_2RS_B) + (12 * bearingStep) - (.5 * bearingStep)])
        rotate([180, 0, 0])
            armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// elbow joint pieces
// lower bearing
translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + bearingStep])
    %bearing6807_2RS();
// arm upper stepper
translate([-armLength + 8, 0, shoulderBaseHeight + ( 3*bearing6807_2RS_B) + (16 * bearingStep) - (.5 * bearingStep)])
    rotate([0, 0, 180])
        StepMotor28BYJ();
// arm lower stepper
rotate([0, 180, 0])
    translate([armLength - 8, 0, bearingStep * 2])
        StepMotor28BYJ();
// arm spacers
color([.6, .6, .3])
    armSpacers(bearing6807_2RS_D + iFitAdjust, 0 * shoulderBaseHeight + (4 * bearing6807_2RS_B) + (8 * bearingStep));
// end arm

// forearm pieces
// lower
color([.1, .7, .1])
translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (4 *bearingStep)])
//translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (14 *bearingStep)])
    forearmLower(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight + (bearing6807_2RS_B / 2) + (bearingStep/2), hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox);
// upper
color([.2, .8, .2])
translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (4 *bearingStep)])
    rotate([180, 0, 0])
        forearmLower(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight + (bearing6807_2RS_B / 2) + (bearingStep/2), hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox);
// forearm upper bearing
translate([-armLength, 0, shoulderBaseHeight + (2 * bearing6807_2RS_B) + (7 * bearingStep)])
    %bearing6807_2RS();
// forearm spacers

/*
deprecated
render()
    translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + (2* bearingStep)])
        armJointSpacer(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
*/

//bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
module bearingInnerStep(bearingID, stepHeight, stepWidth) {
    difference() {
        union() {
            // this fits inside of the bearing
            cylinder(h = stepHeight * 2, d = bearingID);
            // this rests on the bearing inner lip
            cylinder(h = stepHeight, d = bearingID + stepWidth);
        }
        // remove center
        cylinder(h = stepHeight * 2, d = bearingID - (stepWidth * 2));
    }
}

//translate([0, 0, 12]) bearingOuterStep(bearing6807_2RS_D + iFitAdjust, 2, 2);
module bearingOuterStep(bearingOD, stepHeight, stepWidth) {
    //render(convexivity = 3)
    difference() {
        cylinder(h = stepHeight * 2, d = bearingOD + stepWidth);
        cylinder(h = stepHeight * 2, d = bearingOD - stepWidth);
        cylinder(h = stepHeight, d = bearingOD);
    }
}

module shoulderSpacers(bearingOD, screwSpacerHeight) {
    union() {
        // screw holes for joining to arm
        rotate([0, 0, -30])
        radial_array_partial(vec = [0, 0, 1], n = 6, 2)
            translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight * 1.0])
        difference() {
            union () {
                cylinder(h = screwSpacerHeight, r = setScrewRadius * 2);

                }
            cylinder(h = screwTabHeight, r = setScrewRadius);
        }
    }
}

module armSpacers(bearingOD, screwSpacerHeight) {
    union() {
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = 4)
            translate([bearingOD / 2 + (setScrewRadius * 2), 0, shoulderBaseHeight + bearing6807_2RS_B + 2 * bearingStep])
        difference() {
            union () {
                cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius * 2);

                }
            cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius);
        }
        // TODO: put in spacers along arm, make sure holes exist in arm
        translate([- armLength, 0, 0])
        rotate([0, 0, -30])
        radial_array_partial(vec = [0, 0, 1], n = 4, 2)
            translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight + bearing6807_2RS_B + 2 * bearingStep])
        difference() {
            union () {
                cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius * 2);

                }
            cylinder(h = bearing6807_2RS_B * 2 + 4 * bearingStep, r = setScrewRadius);
        }
    }
}

// armJointSpacer(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
module armJointSpacer(bearingID, bearingOD, bearingStep, shaftBossDiameter, mountScrewDiameter) {
    union() {
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID);
        }
        translate([0, 0, bearingStep * 2])
                bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//shoulderBase(2, 55, 9.1, 3.1);
// WARNING: has some hard-coded non-parametric values in here!
module shoulderBase(bearingID, bearingOD, shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter) {
    mountHoleDepth = shoulderBaseHeight;

    //render(convexivity = 3)
    difference() {
        union () {
            cylinder(h = shoulderBaseHeight, d = shoulderBaseDiameter);
            translate([0, 0, shoulderBaseHeight])
                bearingInnerStep(bearing6807_2RS_d - iFitAdjust, bearingStep, bearingStep);
            // 40 is the length of deck extension from the baseplate in x
            translate([0, -shoulderBaseDiameter / 2, 0])
                cube([baseDeckExtension, shoulderBaseDiameter, shoulderBaseHeight], center = false);
        }
        // motor shaft hole
        cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
        // mounting holes

        translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        // lead screw hole
        translate([baseDeckExtension - (leadScrewDiameter * 1.5), 0, 0])
            cylinder(h = shoulderBaseHeight, d = leadScrewDiameter + (leadScrewDiameter / 2));
        // upper to lower spacer screw holes
        rotate([0, 0, -30])
            radial_array_partial(vec = [0, 0, 1], n = 6, 2)
                translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight * 0])
                    cylinder(h = screwTabHeight, r = setScrewRadius);
           translate([baseDeckExtension / 3, 0, 0])
            rotate([0, 0, -30])
            radial_array_partial(vec = [0, 0, 1], n = 6, 2)
                translate([bearingOD / 2 + (setScrewRadius * 8), 0, shoulderBaseHeight * 0])
                    cylinder(h = screwTabHeight, r = setScrewRadius);
    }
    // NOTE: need to add LM8UU mounts
}

module armLower(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength) {
    armWidth = bearingOD / 2;
    render(convexivity = 3)
    difference() {
    union() {
        armInnerJoint(bearingOD, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
        translate([-armLength, 0, 0])
            armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight);
        difference() {
            translate([-armLength, -armWidth / 2, 0])
                cube([armLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }
        difference() {
            intersection() {

                translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : armLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

        }
   }
           // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
   }
}

module armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight) {
    mountHoleDepth = bearingStep * 2;

    union() {
        difference() {
            union() {
                translate([0, 0, -(bearingStep * 2)])
                    cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
                translate([0, 0, bearingStep * 2])
                    rotate([0, 180, 0])
                        bearingOuterStep(bearingOD, bearingStep, bearingStep);
            }
            // motor shaft hole
            translate([0, 0, -(bearingStep * 2)])
                cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
            // mounting holes
            translate([0, 0, -(bearingStep * 2)]) {
                translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
                translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
            }
        }

    }
}

//armInnerJoint(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
module armInnerJoint(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight) {
    //translate([0, 0, hubHeight - (2 * stepHeight)])
    difference() {
        union() {
         difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + (setScrewRadius * 6));
            cylinder(h = bearingStep * 2, d = bearingOD);
//            translate([0, -bearingOD, 0])
//                cube([bearingOD, bearingOD * 2, bearingStep * 2]);
        }
        bearingOuterStep(bearingOD, stepHeight, stepWidth);
        // hub
        translate([0, 0, -(hubHeight - (2 * stepHeight))])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), stepHeight])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, stepHeight], center = false);
        // screw tabs for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])

                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }

                    }
        // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
    }
}

module forearmLower(bearingID, bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox) {
    armWidth = bearingOD / 2;

    rotate([180, 0, 0]) union() {
        boundingBoxHalf = boundingBox / 2;
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID - (2 * bearingStep));
        }
        translate([0, 0, bearingStep * 2])
            bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
        // hub
        translate([0, 0, hubHeight]) rotate([180, 0, 0])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), 0])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, 2 *stepHeight], center = false);
        // forearm extension
             difference() {
            translate([-forearmLength, -armWidth / 2, 0])
                cube([forearmLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-forearmLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD / 2);
                 // 4 on next line comes from dividing the bearingOD on the above line
            translate([-forearmLength + (bearingOD / 4) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([forearmLength - (bearingOD/2) - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }

            intersection() {

                translate([-forearmLength + boundingBox * 2, -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([forearmLength - (bearingOD / 2) - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : forearmLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

    }
}

module copy_mirror(vec=[0,1,0]) {
    children();
    mirror(vec)
        children();
}

module radial_array(vec = [0,0,1], n = 4) {
    for ( i = [0 : n - 1] )
    {
        rotate( i * 360 / n, vec)
            children();
    }
}

module radial_array_partial(vec = [0,0,1], n = 4, j = 2) {
    for ( i = [0 : n - 1] )
    {
        if (i < j)
            rotate( i * 360 / n, vec)
                children();
    }
}


internal shapre of a pipe is now drafted

eps = 0.01;
phi = 25;
wall = 1.3;
side = 22;

module screw_mount()
{
  s = 10;
  h = 5;
  difference()
  {
    translate([-s/2, -s/2, 0])
      cube([s, s, h]);
    translate([0, 0, -eps])
      #cylinder(d=4, h=h+2*eps, $fn=50);
  }
}

module triangle_2d(side)
{
  dx = -side/2;
  dy = 0;
  translate([dx, 0, 0])
  polygon( points=[
    [0, 0],
    [side, 0],
    [cos(60)*side, sin(60)*side]
  ] );
}

module triangular_prism(side, height)
{
  linear_extrude(height=height)
    triangle_2d(side);
}

module pipe_connector(d, h)
{
  cylinder(d=d, h=h, $fn=200);
}

module inner_pipe()
{
  // rocket side
  ph = 180;
  translate([0, ph, 0])
    rotate([90, 0, 0])
      triangular_prism(side, ph);
  // rubber pipe side
  dz = side * sin(60);
  translate([0, -phi/2, dz])
    pipe_connector(phi, 20);
  // interconenction of both
  hull()
  {
    rotate([90, 0, 0])
      triangular_prism(side, 0.1);
    translate([0, 0, dz])
      for(r=[0:5:40])
        rotate([r, 0, 0])
          translate([0, -phi/2, 0])
            pipe_connector(phi-r/5, 0.1, $fn=50);
  }
}

module launcher()
{
  inner_pipe();
}

launcher();

eps=0.01;
//wall=1;
//hose_phi=6;
//bottle_screw_phi=27.4 + 0.6;
//bottle_screw_h=9;
side = 22;

module screw_mount()
{
  s = 10;
  h = 5;
  difference()
  {
    translate([-s/2, -s/2, 0])
      cube([s, s, h]);
    translate([0, 0, -eps])
      #cylinder(d=4, h=h+2*eps, $fn=50);
  }
}

module triangle_2d(side)
{
  dx = -side/2;
  dy = -side/2 * sin(30);
  translate([dx, dy, 0])
  polygon( points=[
    [0, 0],
    [side, 0],
    [cos(60)*side, sin(60)*side]
  ] );
}

module triangle_pipe(side, height)
{
  linear_extrude(height=height)
    difference()
    {
      triangle_2d(side);
      triangle_2d(side-6);
    }
}

module launcher_core()
{
  dx = 40+22+6;
  module pad_core()
  {
    // pipe mount
    translate([50, 0, 11])
      cylinder(d=6, h=10, $fn=50);
    difference()
    {
      // block
      translate([-side/2, -side/2+0.75, 0])
        cube([dx, side, 11]);
      // triangle cut at the basecut
      translate([0, 0, 2+eps])
        rotate([0, 0, -30])
          linear_extrude(height=9)
            triangle_2d(12);
    }
    // launcher tube
    rotate([0, 0, -30])
      triangle_pipe(side, 180);
  }

  difference()
  {
    pad_core();
    // cut in for pressure to get in
    translate([50, 0, 10-6/3])
      cylinder(d=6-2, h=11+6/3+eps, $fn=50);
    // pipe hole
    translate([1-4, 0, 8/2+1])
      rotate([0, 90, 0])
        cylinder(d=8, h=dx-side/2, $fn=30);
  }
}

module launcher()
{
  launcher_core();
  for(dy=[-15, 16])
    translate([20, dy, 0])
      screw_mount();
}

launcher();


/ ‘Impression 3D/2016 - Trocar/trocar-test1.scad’


fixed bottom part - must be mirrored

fixed bottom part - must be mirrored

eps = 0.01;
N = 4;
M = 4;

module qiagen_logo()
{
  translate([-10.5, -9, 0])
    translate([0,0,1+1])
      linear_extrude(1)
        scale(.42*[1,1])
          import("qiagen_logo.svg");
}

module qiabasz()
{
  difference()
  {
    cylinder(d=30, h=1+1, $fn=100);
    translate([0,0,-eps])
      linear_extrude(1+eps)
        mirror([1, 0, 0])
          text("#!", size=18, halign="center", valign="center");
  }
  qiagen_logo();
}

for(i=[0:N-1])
  for(j=[0:M-1])
    translate([i*32, j*32, 0])
      qiabasz();

eps = 0.01;
N = 4;
M = 4;

module qiagen_logo()
{
  translate([-10.5, -9, 0])
    translate([0,0,1+1])
      linear_extrude(1)
        scale(.42*[1,1])
          import("qiagen_logo.svg");
}

module qiabasz()
{
  difference()
  {
    cylinder(d=30, h=1+1, $fn=100);
    translate([0,0,-eps])
      linear_extrude(1+eps)
        text("#!", size=18, halign="center", valign="center");
  }
  qiagen_logo();
}

for(i=[0:N-1])
  for(j=[0:M-1])
    translate([i*32, j*32, 0])
      qiabasz();


prototype forearm

prototype forearm

use <StepMotor_28BYJ-48.scad>;
use <Hub_28BYJ-48.scad>;
include <Bearing_6807-2RS.scad>;

// global rendering parameters
$fn = 24;

// library examples
// translate([100, 100, 10]) { StepMotor28BYJ(); }
// stepperHub(10, 7, 6, 3.1, 1.5, 2.75);
//translate([0, 0, 8]) bearing6807_2RS();
// bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
//shoulderBase(2, 55, 9.1, 3.1);

// interference fit adjustment for 3D printer
iFitAdjust = .6;

// shoulder base parameters
shoulderBaseHeight = 3;
shoulderBaseDiameter = 55;
shaftBossDiameter = 10;
mountScrewDiameter = 3.1;
bearingStep = 2; // size in mm of bearing interface step
// joint parameters
hubHeight = 10;
hubRadius = 7;
shaftHeight = 6;
shaftRadius = 3.1;
setScrewRadius = 1.5;
setScrewHeight = 2.75;
spokeWidth = 3;
spokes = 6;
screwTabs = 4;
screwTabHeight = 4;
armLength = 200;
// misc
baseDeckExtension = 50;
boundingBox = 8;
boundingBoxHalf = boundingBox / 2;
// 8 is distance from shaft center to screw center on x axis
// 35 is screw center to screw center on y axis
shaftCenterToMountHoldCenterXAxis = 8;
mountHoleCenterToMountHoleCenter = 35;
leadScrewDiameter = 8;
// forearm
forearmLength = 160;

/* Pieces in this model
** Shoulder:
*** Base plate
*** Top plate
*** Lower arm
*** Upper arm
** Forearm:
*** ?
** Hand:
*** ?
*/

// shoulder base
color([.7, .7, 1])
    shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// shoulder stepper
rotate([0, 180, 0])
    translate([-8, 0, 10])
        StepMotor28BYJ();
// lower shoulder bearing
translate([0, 0, shoulderBaseHeight + bearingStep])
    %bearing6807_2RS();
// lower arm including the shoulder - arm joint
//render()
color([1, .7, .7])
    translate([0, 0, shoulderBaseHeight + bearing6807_2RS_B])
        armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// arm joint pieces
translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + bearingStep])
    %bearing6807_2RS();
// arm stepper
rotate([0, 180, 0])
    translate([armLength - 8, 0, bearingStep * 2])
        StepMotor28BYJ();
// forearm pieces
color([.1, .7, .1])
translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (4 *bearingStep)])
//translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (14 *bearingStep)])
render()
    forearmLower(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight + (bearing6807_2RS_B / 2) + (bearingStep/2), hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox);
/*
render()
    translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + (2* bearingStep)])
        armJointSpacer(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
*/

//bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
module bearingInnerStep(bearingID, stepHeight, stepWidth) {
    difference() {
        union() {
            // this fits inside of the bearing
            cylinder(h = stepHeight * 2, d = bearingID);
            // this rests on the bearing inner lip
            cylinder(h = stepHeight, d = bearingID + stepWidth);
        }
        // remove center
        cylinder(h = stepHeight * 2, d = bearingID - (stepWidth * 2));
    }
}

//translate([0, 0, 12]) bearingOuterStep(bearing6807_2RS_D + iFitAdjust, 2, 2);
module bearingOuterStep(bearingOD, stepHeight, stepWidth) {
    //render(convexivity = 3)
    difference() {
        cylinder(h = stepHeight * 2, d = bearingOD + stepWidth);
        cylinder(h = stepHeight * 2, d = bearingOD - stepWidth);
        cylinder(h = stepHeight, d = bearingOD);
    }
}

// armJointSpacer(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
module armJointSpacer(bearingID, bearingOD, bearingStep, shaftBossDiameter, mountScrewDiameter) {
    union() {
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID);
        }
        translate([0, 0, bearingStep * 2])
                bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//shoulderBase(2, 55, 9.1, 3.1);
// WARNING: has some hard-coded non-parametric values in here!
module shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter) {
    mountHoleDepth = shoulderBaseHeight;

    //render(convexivity = 3)
    difference() {
        union () {
            cylinder(h = shoulderBaseHeight, d = shoulderBaseDiameter);
            translate([0, 0, shoulderBaseHeight])
                bearingInnerStep(bearing6807_2RS_d - iFitAdjust, bearingStep, bearingStep);
            // 40 is the length of deck extension from the baseplate in x
            translate([0, -shoulderBaseDiameter / 2, 0])
                cube([baseDeckExtension, shoulderBaseDiameter, shoulderBaseHeight], center = false);
        }
        // motor shaft hole
        cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
        // mounting holes

        translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        // lead screw hole
        translate([baseDeckExtension - (leadScrewDiameter * 1.5), 0, 0])
            cylinder(h = shoulderBaseHeight, d = leadScrewDiameter + (leadScrewDiameter / 2));
    }
    // NOTE: need to add LM8UU mounts
}

module armLower(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength) {
    armWidth = bearingOD / 2;
    //render(convexivity = 3)
    difference() {
    union() {
        armInnerJoint(bearingOD, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
        translate([-armLength, 0, 0])
            armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight);
        difference() {
            translate([-armLength, -armWidth / 2, 0])
                cube([armLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }
        difference() {
            intersection() {

                translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : armLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

        }
   }
           // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
   }
}

module armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight) {
    mountHoleDepth = bearingStep * 2;

    union() {
        difference() {
            union() {
                translate([0, 0, -(bearingStep * 2)])
                    cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
                translate([0, 0, bearingStep * 2])
                    rotate([0, 180, 0])
                        bearingOuterStep(bearingOD, bearingStep, bearingStep);
            }
            // motor shaft hole
            translate([0, 0, -(bearingStep * 2)])
                cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
            // mounting holes
            translate([0, 0, -(bearingStep * 2)]) {
                translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
                translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
            }
        }

    }
}

//armInnerJoint(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
module armInnerJoint(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight) {
    //translate([0, 0, hubHeight - (2 * stepHeight)])
    difference() {
        union() {
         difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + (setScrewRadius * 6));
            cylinder(h = bearingStep * 2, d = bearingOD);
//            translate([0, -bearingOD, 0])
//                cube([bearingOD, bearingOD * 2, bearingStep * 2]);
        }
        bearingOuterStep(bearingOD, stepHeight, stepWidth);
        // hub
        translate([0, 0, -(hubHeight - (2 * stepHeight))])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), stepHeight])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, stepHeight], center = false);
        // screw tabs for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])

                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }

                    }
        // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
    }
}

module forearmLower(bearingID, bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox) {
    armWidth = bearingOD / 2;

    rotate([180, 0, 0]) union() {
        boundingBoxHalf = boundingBox / 2;
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID - (2 * bearingStep));
        }
        translate([0, 0, bearingStep * 2])
            bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
        // hub
        translate([0, 0, hubHeight]) rotate([180, 0, 0])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), 0])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, 2 *stepHeight], center = false);
        // forearm extension
             difference() {
            translate([-forearmLength, -armWidth / 2, 0])
                cube([forearmLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-forearmLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD / 2);
                 // 4 on next line comes from dividing the bearingOD on the above line
            translate([-forearmLength + (bearingOD / 4) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                #cube([forearmLength - (bearingOD/2) - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }

            intersection() {

                translate([-forearmLength + boundingBox * 2, -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([forearmLength - (bearingOD / 2) - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : forearmLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

    }
}

module copy_mirror(vec=[0,1,0]) {
    children();
    mirror(vec)
        children();
}

module radial_array(vec = [0,0,1], n = 4) {
    for ( i = [0 : n - 1] )
    {
        rotate( i * 360 / n, vec)
            children();
    }
}

use <StepMotor_28BYJ-48.scad>;
use <Hub_28BYJ-48.scad>;
include <Bearing_6807-2RS.scad>;

// global rendering parameters
$fn = 24;

// library examples
// translate([100, 100, 10]) { StepMotor28BYJ(); }
// stepperHub(10, 7, 6, 3.1, 1.5, 2.75);
//translate([0, 0, 8]) bearing6807_2RS();
// bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
//shoulderBase(2, 55, 9.1, 3.1);

// interference fit adjustment for 3D printer
iFitAdjust = .6;

// shoulder base parameters
shoulderBaseHeight = 3;
shoulderBaseDiameter = 55;
shaftBossDiameter = 10;
mountScrewDiameter = 3.1;
bearingStep = 2; // size in mm of bearing interface step
// joint parameters
hubHeight = 10;
hubRadius = 7;
shaftHeight = 6;
shaftRadius = 3.1;
setScrewRadius = 1.5;
setScrewHeight = 2.75;
spokeWidth = 3;
spokes = 6;
screwTabs = 4;
screwTabHeight = 4;
armLength = 200;
// misc
baseDeckExtension = 50;
boundingBox = 8;
boundingBoxHalf = boundingBox / 2;
// 8 is distance from shaft center to screw center on x axis
// 35 is screw center to screw center on y axis
shaftCenterToMountHoldCenterXAxis = 8;
mountHoleCenterToMountHoleCenter = 35;
leadScrewDiameter = 8;
// forearm
forearmLength = 160;

/* Pieces in this model
** Shoulder:
*** Base plate
*** Top plate
*** Lower arm
*** Upper arm
** Forearm:
*** ?
** Hand:
*** ?
*/

// shoulder base
color([.7, .7, 1])
    shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// shoulder stepper
rotate([0, 180, 0])
    translate([-8, 0, 10])
        StepMotor28BYJ();
// lower shoulder bearing
translate([0, 0, shoulderBaseHeight + bearingStep])
    %bearing6807_2RS();
// lower arm including the shoulder - arm joint
//render()
color([1, .7, .7])
    translate([0, 0, shoulderBaseHeight + bearing6807_2RS_B])
        armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// arm joint pieces
translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + bearingStep])
    %bearing6807_2RS();
// arm stepper
rotate([0, 180, 0])
    translate([armLength - 8, 0, bearingStep * 2])
        StepMotor28BYJ();
// forearm pieces
color([.1, .7, .1])
translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (4 *bearingStep)])
//translate([-armLength, 0, shoulderBaseHeight + (bearing6807_2RS_B * 2) + (14 *bearingStep)])
render()
    forearmLower(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight + (bearing6807_2RS_B / 2) + (bearingStep/2), hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox);
/*
render()
    translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + (2* bearingStep)])
        armJointSpacer(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
*/

//bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
module bearingInnerStep(bearingID, stepHeight, stepWidth) {
    difference() {
        union() {
            // this fits inside of the bearing
            cylinder(h = stepHeight * 2, d = bearingID);
            // this rests on the bearing inner lip
            cylinder(h = stepHeight, d = bearingID + stepWidth);
        }
        // remove center
        cylinder(h = stepHeight * 2, d = bearingID - (stepWidth * 2));
    }
}

//translate([0, 0, 12]) bearingOuterStep(bearing6807_2RS_D + iFitAdjust, 2, 2);
module bearingOuterStep(bearingOD, stepHeight, stepWidth) {
    //render(convexivity = 3)
    difference() {
        cylinder(h = stepHeight * 2, d = bearingOD + stepWidth);
        cylinder(h = stepHeight * 2, d = bearingOD - stepWidth);
        cylinder(h = stepHeight, d = bearingOD);
    }
}

// armJointSpacer(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
module armJointSpacer(bearingID, bearingOD, bearingStep, shaftBossDiameter, mountScrewDiameter) {
    union() {
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID);
        }
        translate([0, 0, bearingStep * 2])
                bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//shoulderBase(2, 55, 9.1, 3.1);
// WARNING: has some hard-coded non-parametric values in here!
module shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter) {
    mountHoleDepth = shoulderBaseHeight;

    //render(convexivity = 3)
    difference() {
        union () {
            cylinder(h = shoulderBaseHeight, d = shoulderBaseDiameter);
            translate([0, 0, shoulderBaseHeight])
                bearingInnerStep(bearing6807_2RS_d - iFitAdjust, bearingStep, bearingStep);
            // 40 is the length of deck extension from the baseplate in x
            translate([0, -shoulderBaseDiameter / 2, 0])
                cube([baseDeckExtension, shoulderBaseDiameter, shoulderBaseHeight], center = false);
        }
        // motor shaft hole
        cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
        // mounting holes

        translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        // lead screw hole
        translate([baseDeckExtension - (leadScrewDiameter * 1.5), 0, 0])
            cylinder(h = shoulderBaseHeight, d = leadScrewDiameter + (leadScrewDiameter / 2));
    }
    // NOTE: need to add LM8UU mounts
}

module armLower(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength) {
    armWidth = bearingOD / 2;
    //render(convexivity = 3)
    difference() {
    union() {
        armInnerJoint(bearingOD, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
        translate([-armLength, 0, 0])
            armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight);
        difference() {
            translate([-armLength, -armWidth / 2, 0])
                cube([armLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }
        difference() {
            intersection() {

                translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : armLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

        }
   }
           // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
   }
}

module armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight) {
    mountHoleDepth = bearingStep * 2;

    union() {
        difference() {
            union() {
                translate([0, 0, -(bearingStep * 2)])
                    cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
                translate([0, 0, bearingStep * 2])
                    rotate([0, 180, 0])
                        bearingOuterStep(bearingOD, bearingStep, bearingStep);
            }
            // motor shaft hole
            translate([0, 0, -(bearingStep * 2)])
                cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
            // mounting holes
            translate([0, 0, -(bearingStep * 2)]) {
                translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
                translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
            }
        }

    }
}

//armInnerJoint(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
module armInnerJoint(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight) {
    //translate([0, 0, hubHeight - (2 * stepHeight)])
    difference() {
        union() {
         difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + (setScrewRadius * 6));
            cylinder(h = bearingStep * 2, d = bearingOD);
//            translate([0, -bearingOD, 0])
//                cube([bearingOD, bearingOD * 2, bearingStep * 2]);
        }
        bearingOuterStep(bearingOD, stepHeight, stepWidth);
        // hub
        translate([0, 0, -(hubHeight - (2 * stepHeight))])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), stepHeight])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, stepHeight], center = false);
        // screw tabs for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])

                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }

                    }
        // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                       cylinder(h = screwTabHeight, r = setScrewRadius);
    }
}

module forearmLower(bearingID, bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength, boundingBox) {
    armWidth = bearingOD / 2;

    rotate([180, 0, 0]) union() {
        boundingBoxHalf = boundingBox / 2;
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID - (2 * bearingStep));
        }
        translate([0, 0, bearingStep * 2])
            bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
        // hub
        translate([0, 0, hubHeight]) rotate([180, 0, 0])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), 0])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, 2 *stepHeight], center = false);
        // forearm extension
             difference() {
            translate([-forearmLength, -armWidth / 2, 0])
                cube([forearmLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-forearmLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD / 2);
            translate([-forearmLength + (bearingOD / 2) /* + (boundingBox / 2)*/, -(armWidth / 2) + boundingBoxHalf, 0])
                #cube([forearmLength - (bearingOD/2) - (boundingBox + boundingBoxHalf), armWidth - boundingBox, bearingStep * 2], center = false);
        }

            intersection() {

                translate([-forearmLength + boundingBox * 2, -(armWidth / 2) + boundingBoxHalf, 0])
                    cube([forearmLength - (bearingOD / 2) - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
                for (i = [ bearingOD / 2 - boundingBoxHalf: armWidth : forearmLength]) {
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, 45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                    translate([ -i, 0, bearingStep])
                        rotate([0, 0, -45])
                            cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                }
            }

    }
}

module copy_mirror(vec=[0,1,0]) {
    children();
    mirror(vec)
        children();
}

module radial_array(vec = [0,0,1], n = 4) {
    for ( i = [0 : n - 1] )
    {
        rotate( i * 360 / n, vec)
            children();
    }
}


checkpoint

checkpoint

use <StepMotor_28BYJ-48.scad>;
use <Hub_28BYJ-48.scad>;
include <Bearing_6807-2RS.scad>;

// global rendering parameters
$fn = 24;

// library examples
// translate([100, 100, 10]) { StepMotor28BYJ(); }
// stepperHub(10, 7, 6, 3.1, 1.5, 2.75);
//translate([0, 0, 8]) bearing6807_2RS();
// bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
//shoulderBase(2, 55, 9.1, 3.1);

// interference fit adjustment for 3D printer
iFitAdjust = .6;

// shoulder base parameters
shoulderBaseHeight = 3;
shoulderBaseDiameter = 55;
shaftBossDiameter = 10;
mountScrewDiameter = 3.1;
bearingStep = 2; // size in mm of bearing interface step
// joint parameters
hubHeight = 10;
hubRadius = 7;
shaftHeight = 6;
shaftRadius = 3.1;
setScrewRadius = 1.5;
setScrewHeight = 2.75;
spokeWidth = 3;
spokes = 6;
screwTabs = 4;
screwTabHeight = 4;
armLength = 200;
// misc
baseDeckExtension = 50;
// 8 is distance from shaft center to screw center on x axis
// 35 is screw center to screw center on y axis
shaftCenterToMountHoldCenterXAxis = 8;
mountHoleCenterToMountHoleCenter = 35;
leadScrewDiameter = 8;

/* Pieces in this model
** Shoulder:
*** Base plate
*** Top plate
*** Lower arm
*** Upper arm
** Forearm:
*** ?
** Hand:
*** ?
*/

// shoulder base
color([.7, .7, 1])
    shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// shoulder stepper
rotate([0, 180, 0])
    translate([-8, 0, 10])
        StepMotor28BYJ();
// lower shoulder bearing
translate([0, 0, shoulderBaseHeight + bearingStep])
    %bearing6807_2RS();
// shoulder - arm joint
color([1, .7, .7])
    translate([0, 0, shoulderBaseHeight + bearing6807_2RS_B])
        armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// arm joint pieces
translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + bearingStep])
    %bearing6807_2RS();
// arm stepper
rotate([0, 180, 0])
    translate([armLength - 8, 0, bearingStep * 2])
        StepMotor28BYJ();
// forearm pieces
translate([-armLength, 0, 0])
    forearmLower(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingSteo, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength);
/*
render()
color([.1, .7, .1])
    translate([-armLength, 0, shoulderBaseHeight + bearing6807_2RS_B + (2* bearingStep)])
        armJointSpacer(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
*/

//bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
module bearingInnerStep(bearingID, stepHeight, stepWidth) {
    difference() {
        union() {
            // this fits inside of the bearing
            cylinder(h = stepHeight * 2, d = bearingID);
            // this rests on the bearing inner lip
            cylinder(h = stepHeight, d = bearingID + stepWidth);
        }
        // remove center
        cylinder(h = stepHeight * 2, d = bearingID - (stepWidth * 2));
    }
}

//translate([0, 0, 12]) bearingOuterStep(bearing6807_2RS_D + iFitAdjust, 2, 2);
module bearingOuterStep(bearingOD, stepHeight, stepWidth) {
    //render(convexivity = 3)
    difference() {
        cylinder(h = stepHeight * 2, d = bearingOD + stepWidth);
        cylinder(h = stepHeight * 2, d = bearingOD - stepWidth);
        cylinder(h = stepHeight, d = bearingOD);
    }
}

// armJointSpacer(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
module armJointSpacer(bearingID, bearingOD, bearingStep, shaftBossDiameter, mountScrewDiameter) {
    union() {
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID);
        }
        translate([0, 0, bearingStep * 2])
                bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//shoulderBase(2, 55, 9.1, 3.1);
// WARNING: has some hard-coded non-parametric values in here!
module shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter) {
    mountHoleDepth = shoulderBaseHeight;

    //render(convexivity = 3)
    difference() {
        union () {
            cylinder(h = shoulderBaseHeight, d = shoulderBaseDiameter);
            translate([0, 0, shoulderBaseHeight])
                bearingInnerStep(bearing6807_2RS_d - iFitAdjust, bearingStep, bearingStep);
            // 40 is the length of deck extension from the baseplate in x
            translate([0, -shoulderBaseDiameter / 2, 0])
                cube([baseDeckExtension, shoulderBaseDiameter, shoulderBaseHeight], center = false);
        }
        // motor shaft hole
        cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
        // mounting holes

        translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        // lead screw hole
        translate([baseDeckExtension - (leadScrewDiameter * 1.5), 0, 0])
            cylinder(h = shoulderBaseHeight, d = leadScrewDiameter + (leadScrewDiameter / 2));
    }
    // NOTE: need to add LM8UU mounts
}

module armLower(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength) {
    boundingBox = 12;
    boundingBoxHalf = boundingBox / 2;
    //
    armWidth = bearingOD + bearingStep;
    //render(convexivity = 3)
    union() {
        armInnerJoint(bearingOD, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
        translate([-armLength, 0, 0])
            armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight);
        difference() {
            translate([-armLength, -armWidth / 2, 0])
                cube([armLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
        }
        difference() {
            intersection() {

            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
            for (i = [ bearingOD / 2 : armWidth / 2 : armLength]) {
                translate([ -i, 0, bearingStep])
                    rotate([0, 0, 45])
                        cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                translate([ -i, 0, bearingStep])
                    rotate([0, 0, -45])
                        cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
            }
        }
    }
   }
}

module armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight) {
    mountHoleDepth = bearingStep * 2;

    union() {
/*
        //render(convexivity = 3)
    difference() {
        cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
        cylinder(h = bearingStep * 2, d = bearingOD - 2 * bearingStep);
    }
         // screw holes for joining to joint
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
*/
        difference() {
            union() {
                translate([0, 0, -(bearingStep * 2)])
                    cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
                translate([0, 0, bearingStep * 2])
                    rotate([0, 180, 0])
                        bearingOuterStep(bearingOD, bearingStep, bearingStep);
            }
            // motor shaft hole
            translate([0, 0, -(bearingStep * 2)])
                cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
            // mounting holes
            translate([0, 0, -(bearingStep * 2)]) {
                translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
                translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
                cylinder(h = mountHoleDepth, d = mountScrewDiameter);
            }
        }

    }
}

//armInnerJoint(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
module armInnerJoint(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight) {
    //translate([0, 0, hubHeight - (2 * stepHeight)])
    union() {
        bearingOuterStep(bearingOD, stepHeight, stepWidth);
        // hub
        translate([0, 0, -(hubHeight - (2 * stepHeight))])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), stepHeight])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, stepHeight], center = false);
        // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

module forearmLower(bearingID, bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, forearmLength) {
}

module copy_mirror(vec=[0,1,0]) {
    children();
    mirror(vec)
        children();
}

module radial_array(vec = [0,0,1], n = 4) {
    for ( i = [0 : n - 1] )
    {
        rotate( i * 360 / n, vec)
            children();
    }
}

use <StepMotor_28BYJ-48.scad>;
use <Hub_28BYJ-48.scad>;
include <Bearing_6807-2RS.scad>;

// global rendering parameters
$fn = 24;

// library examples
// translate([100, 100, 10]) { StepMotor28BYJ(); }
// stepperHub(10, 7, 6, 3.1, 1.5, 2.75);
//translate([0, 0, 8]) bearing6807_2RS();
// bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
//shoulderBase(2, 55, 9.1, 3.1);

// interference fit adjustment for 3D printer
iFitAdjust = .6;

// shoulder base parameters
shoulderBaseHeight = 3;
shoulderBaseDiameter = 55;
shaftBossDiameter = 10;
mountScrewDiameter = 3.1;
bearingStep = 2; // size in mm of bearing interface step
// joint parameters
hubHeight = 10;
hubRadius = 7;
shaftHeight = 6;
shaftRadius = 3.1;
setScrewRadius = 1.5;
setScrewHeight = 2.75;
spokeWidth = 3;
spokes = 6;
screwTabs = 4;
screwTabHeight = 4;
armLength = 200;

/* Pieces in this model
** Shoulder:
*** Base plate
*** Top plate
*** Lower arm
*** Upper arm
** Forearm:
*** ?
** Hand:
*** ?
*/

// shoulder base
color([.7, .7, 1])
    shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter);
// shoulder stepper
rotate([0, 180, 0])
    translate([-8, 0, 10])
        StepMotor28BYJ();
// lower shoulder bearing
translate([0, 0, shoulderBaseHeight + bearingStep])
    %bearing6807_2RS();
// shoulder - arm joint
color([1, .7, .7])
    translate([0, 0, shoulderBaseHeight + 7])
        armLower(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength);
// arm joint pieces
render()
color([.1, .7, .1])
    translate([-armLength, 0, shoulderBaseHeight + 7 + (2* bearingStep)])
        armJointSpacer(bearing6807_2RS_d - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);

//bearingInnerStep(bearing6807_2RS_d - iFitAdjust, 2, 2);
module bearingInnerStep(bearingID, stepHeight, stepWidth) {
    difference() {
        union() {
            // this fits inside of the bearing
            cylinder(h = stepHeight * 2, d = bearingID);
            // this rests on the bearing inner lip
            cylinder(h = stepHeight, d = bearingID + stepWidth);
        }
        // remove center
        cylinder(h = stepHeight * 2, d = bearingID - (stepWidth * 2));
    }
}

//translate([0, 0, 12]) bearingOuterStep(bearing6807_2RS_D + iFitAdjust, 2, 2);
module bearingOuterStep(bearingOD, stepHeight, stepWidth) {
    //render(convexivity = 3)
    difference() {
        cylinder(h = stepHeight * 2, d = bearingOD + stepWidth);
        cylinder(h = stepHeight * 2, d = bearingOD - stepWidth);
        cylinder(h = stepHeight, d = bearingOD);
    }
}

// armJointSpacer(bearing6807_2RS_D - iFitAdjust, bearing6807_2RS_D + iFitAdjust, bearingStep, shaftBossDiameter, mountScrewDiameter);
module armJointSpacer(bearingID, bearingOD, bearingStep, shaftBossDiameter, mountScrewDiameter) {
    union() {
        difference() {
            cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
            cylinder(h = bearingStep * 2, d = bearingID);
        }
        translate([0, 0, bearingStep * 2])
                bearingInnerStep(bearingID, bearingStep, bearingStep);
        // screw holes for joining to arm
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//shoulderBase(2, 55, 9.1, 3.1);
// WARNING: has some hard-coded non-parametric values in here!
module shoulderBase(shoulderBaseHeight, shoulderBaseDiameter, shaftBossDiameter, mountScrewDiameter) {
    mountHoleDepth = shoulderBaseHeight;
    // hardcoded values should be moved out
    baseDeckExtension = 50;
    // 8 is distance from shaft center to screw center on x axis
    // 35 is screw center to screw center on y axis
    shaftCenterToMountHoldCenterXAxis = 8;
    mountHoleCenterToMountHoleCenter = 35;
    leadScrewDiameter = 8;
    // end
    //render(convexivity = 3)
    difference() {
        union () {
            cylinder(h = shoulderBaseHeight, d = shoulderBaseDiameter);
            translate([0, 0, shoulderBaseHeight])
                bearingInnerStep(bearing6807_2RS_d - iFitAdjust, bearingStep, bearingStep);
            // 40 is the length of deck extension from the baseplate in x
            translate([0, -shoulderBaseDiameter / 2, 0])
                cube([baseDeckExtension, shoulderBaseDiameter, shoulderBaseHeight], center = false);
        }
        // motor shaft hole
        cylinder(h = shoulderBaseHeight + (bearingStep * 2), d = shaftBossDiameter);
        // mounting holes

        translate([shaftCenterToMountHoldCenterXAxis, mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        translate([shaftCenterToMountHoldCenterXAxis, -mountHoleCenterToMountHoleCenter/2, 0])
            cylinder(h = mountHoleDepth, d = mountScrewDiameter);
        // lead screw hole
        translate([baseDeckExtension - (leadScrewDiameter * 1.5), 0, 0])
            cylinder(h = shoulderBaseHeight, d = leadScrewDiameter + (leadScrewDiameter / 2));
    }
    // NOTE: need to add LM8UU mounts
}

module armLower(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight, armLength) {
    boundingBox = 12;
    boundingBoxHalf = boundingBox / 2;
    //
    armWidth = bearingOD + bearingStep;
    //render(convexivity = 3)
    union() {
        armInnerJoint(bearingOD, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
        translate([-armLength, 0, 0])
            armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight);
        difference() {
            translate([-armLength, -armWidth / 2, 0])
                cube([armLength, armWidth, bearingStep * 2], center=false);
            cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength, 0, 0])
                cylinder(h = bearingStep * 2, d = bearingOD);
            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
        }
        difference() {
            intersection() {

            translate([-armLength + (bearingOD / 2) + (boundingBox / 2), -(armWidth / 2) + boundingBoxHalf, 0])
                cube([armLength - bearingOD - boundingBox, armWidth - boundingBox, bearingStep * 2], center = false);
            for (i = [ bearingOD / 2 : armWidth / 2 : armLength]) {
                translate([ -i, 0, bearingStep])
                    rotate([0, 0, 45])
                        cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
                translate([ -i, 0, bearingStep])
                    rotate([0, 0, -45])
                        cube([spokeWidth, armWidth + boundingBoxHalf, bearingStep * 2], center = true);
            }
        }
    }
   }
}

module armOuterJointBase(bearingOD, bearingStep, setScrewRadius, screwTabs, screwTabHeight) {
    union() {
           //render(convexivity = 3)
    difference() {
        cylinder(h = bearingStep * 2, d = bearingOD + bearingStep);
        cylinder(h = bearingStep * 2, d = bearingOD - 2 * bearingStep);
    }
         // screw holes for joining to joint
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * bearingStep) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

//armInnerJoint(bearing6807_2RS_D + iFitAdjust, bearingStep, bearingStep, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight);
module armInnerJoint(bearingOD, stepHeight, stepWidth, hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight, spokeWidth, spokes, screwTabs, screwTabHeight) {
    //translate([0, 0, hubHeight - (2 * stepHeight)])
    union() {
        bearingOuterStep(bearingOD, stepHeight, stepWidth);
        // hub
        translate([0, 0, -(hubHeight - (2 * stepHeight))])
            stepperHub(hubHeight, hubRadius, shaftHeight, shaftRadius, setScrewRadius, setScrewHeight);
        // spokes
        radial_array(vec=[0, 0, 1], n = spokes)
                translate([hubRadius - (stepWidth / 2), -(spokeWidth / 2), stepHeight])
                    cube([(bearingOD / 2) - hubRadius, spokeWidth, stepHeight], center = false);
        // screw holes for joining to upper
        radial_array(vec = [0, 0, 1], n = screwTabs)
                translate([bearingOD / 2 + (setScrewRadius * 2), 0, (2 * stepHeight) - screwTabHeight])
                    difference() {
                        union () {
                            cylinder(h = screwTabHeight, r = setScrewRadius * 2);
                            translate([-2 * setScrewRadius, - 2 * setScrewRadius, 0])
                                cube([setScrewRadius * 2, 4 * setScrewRadius, screwTabHeight], center = false);
                        }
                        cylinder(h = screwTabHeight, r = setScrewRadius);
                    }
    }
}

module copy_mirror(vec=[0,1,0]) {
    children();
    mirror(vec)
        children();
}

module radial_array(vec = [0,0,1], n = 4) {
    for ( i = [0 : n - 1] )
    {
        rotate( i * 360 / n, vec)
            children();
    }
}