From 36ecdb9da787a0052b8de2d7c3225a472b4feae2 Mon Sep 17 00:00:00 2001
From: Vitaliy Filippov <vitalif@yourcmc.ru>
Date: Wed, 18 Nov 2015 15:44:13 +0000
Subject: [PATCH] tune axles and gear size

---
 torsen.scad | 32 +++++++++++++++++++++-----------
 1 file changed, 21 insertions(+), 11 deletions(-)

diff --git a/torsen.scad b/torsen.scad
index 60d9da1..3c34022 100644
--- a/torsen.scad
+++ b/torsen.scad
@@ -3,6 +3,7 @@ $fn = 100;
 torsen_diff_36t();
 
 module torsen_diff_36t() {
+    rotate([90, 0, 0])
     union() {
         difference() {
             /*union() {
@@ -15,7 +16,7 @@ module torsen_diff_36t() {
             translate([0, 5, 0]) rotate([90, 0, 0]) cylinder(r=30, h=2, center=true, $fn=100);
             translate([0, -5, 0]) rotate([90, 0, 0]) cylinder(r=30, h=2, center=true, $fn=100);
             rotate([90, 0, 0]) cylinder(r=2.6, h=10, center=true);
-            translate([0, 4, 0]) rotate([90, 0, 0]) cylinder(r=4.2, h=8, center=true);
+            translate([0, 4, 0]) rotate([90, 0, 0]) cylinder(r=4.0, h=8, center=true);
         }
         translate([0, 0, 8]) difference() {
             union() {
@@ -25,7 +26,7 @@ module torsen_diff_36t() {
                 translate([-3.6, 8-3.6, 0]) cube([0.8, 3.6*2, 3.6*2], center=true);
                 translate([3.6, 8, 0]) rotate([90, 0, 90]) cylinder(r=3.6, h=0.8, center=true);
                 translate([3.6, 8-3.6, 0]) cube([0.8, 3.6*2, 3.6*2], center=true);
-                translate([0, 8, 0]) rotate([90, 0, 90]) axle(h=16, axlemesh=1.75);
+                translate([0, 8, 0]) rotate([90, 0, 90]) axleround(h=16, axlemesh=1.75);
             }
         }
         translate([0, 0, -8]) difference() {
@@ -36,12 +37,22 @@ module torsen_diff_36t() {
                 translate([-3.6, 8-3.6, 0]) cube([0.8, 3.6*2, 3.6*2], center=true);
                 translate([3.6, 8, 0]) rotate([90, 0, 90]) cylinder(r=3.6, h=0.8, center=true);
                 translate([3.6, 8-3.6, 0]) cube([0.8, 3.6*2, 3.6*2], center=true);
-                translate([0, 8, 0]) rotate([90, 0, 90]) axle(h=16, axlemesh=1.75);
+                translate([0, 8, 0]) rotate([90, 0, 90]) axleround(h=16, axlemesh=1.75);
             }
         }
     }
 }
 
+module axleround(h = 24, axleradius = 2.4, axlemesh = 1.85) {
+    translate([0, 0, -h/2]) difference() {
+        cylinder($fn=16, r=axleradius, h=h);
+        translate([axlemesh/2, axlemesh/2, -1]) cube([axleradius, axleradius, h+2]);
+        translate([axlemesh/2, -axlemesh/2-axleradius, -1]) cube([axleradius, axleradius, h+2]);
+        translate([-axlemesh/2-axleradius, axlemesh/2, -1]) cube([axleradius, axleradius, h+2]);
+        translate([-axlemesh/2-axleradius, -axlemesh/2-axleradius, -1]) cube([axleradius, axleradius, h+2]);
+    }
+}
+
 module axle(h = 24, axleradius = 2.4, axlemesh = 1.85) {
     union() {
         cube([axleradius*2, axlemesh, h], center=true);
@@ -49,8 +60,7 @@ module axle(h = 24, axleradius = 2.4, axlemesh = 1.85) {
     }
 }
 
-module single_bevel(nteeth = 28)
-{
+module single_bevel(nteeth = 28) {
     union() {
         intersection() {
             translate([0, 0, 1.5])
@@ -69,17 +79,17 @@ module single_bevel(nteeth = 28)
 module double_bevel_36t() {
   intersection() {
     union() {
-      translate([0, 0, 1.5])
+      translate([0, 0, 1.1])
         linear_extrude(slices=5, height=2.5, scale=(36/2+1-2.5*tan(45))/(36/2+1))
         gear_concat_flat(mm_per_tooth=3.4, number_of_teeth=36, backlash=2, clearance=0.8, trim_factor=0.7);
-      translate([0, 0, -1.5])
+      translate([0, 0, -1.1])
         rotate([180, 0, 0])
         linear_extrude(slices=5, height=2.5, scale=(36/2+1-2.5*tan(45))/(36/2+1))
         gear_concat_flat(mm_per_tooth=3.4, number_of_teeth=36, backlash=2, clearance=0.8, trim_factor=0.7);
-      translate([0, 0, -4])
-        cylinder($fn=36*2, h=8, r=2.98*(36/2-1)/3.1415926);
-      translate([0, 0, -1.5])
-        cylinder($fn=36*2, h=3, r=2.98*(36/2+1)/3.1415926+0.5);
+      translate([0, 0, -3.6])
+        cylinder($fn=36*2, h=7.2, r=2.98*(36/2-1)/3.1415926);
+      translate([0, 0, -1.1])
+        cylinder($fn=36*2, h=2.2, r=2.98*(36/2+1)/3.1415926+0.5);
     }
     translate([0, 0, -8]) linear_extrude(slices=5, height=16)
       gear_concat_flat(mm_per_tooth=2.98, number_of_teeth=36, pressure_angle=15, backlash=-0.5, clearance=-0.3);