poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 coarse = false;
   4
   5 main_dia = 71.2 + 0.50 - 2.26;
   6 top_thick_middle = 4;
   7 top_thick_by_oring = 3.0;
   8 top_middle_dr = 11;
   9
  10 main_cnr = 6.0;
  11
  12 min_wall = 3;
  13
  14 rivet_posn = 6.0 + 0.30;
  15 rivet_thick = 1.67;
  16 rivet_width = 4.15 + 1.0;
  17 rivet_tall = 5.51 + 1.49;
  18
  19 over_rivet_wall = 1.0;
  20 side_rivet_gap = 1.5;
  21 inside_rivet_gap = 1.5;
  22
  23 bayo_interf = 0.30;
  24 bayo_behind = 3.5;
  25 bayo_interf_width = 2.0;
  26 bayo_interf_slope = 0.5;
  27
  28 oring_thick = 5.0;
  29 oring_bore = 62.0;
  30
  31 oring_upper_embed_angle = 80;
  32 oring_compress = 0.1; // proportion
  33 oring_compress_more = 0.2;
  34
  35 oring_rm_beside = 8;
  36 oring_rm_scale = 2.0;
  37 oring_rm_angle = 20;
  38
  39 side_taper = 1.0;
  40
  41 bayo_gap = 6.0;
  42
  43 bayo_entry = bayo_behind/3;
  44
  45 bayo_slice_size = coarse ? 5 : 1;
  46
  47 brace_hole_width = 1.0;
  48 brace_above_below = 1.2;
  49 brace_end_shorter = 0.3;
  50
  51 jig_thick = 1.4;
  52 jig_hole_dia = 3.0;
  53 jig_rim = 5;
  54 jig_mark = 5;
  55
  56 strap_hoop_thick = 6;
  57 strap_hoop_inside = 10;
  58 strap_hoop_strlen = 10;
  59 strap_hoop_elevation = 45;
  60
  61 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  62 sm_main_thick = 2.0;
  63 sm_main_width = 20;
  64
  65 sm_bolt_dia = 3.5 + 0.1;
  66 sm_bolt_shaft = 21.9;
  67 sm_bolt_head_dia = 6.94 + 1.0;
  68 sm_bolt_head_thick = 2.14;
  69 sm_bolt_nut_width = 5.89 + 0.25;
  70 sm_bolt_nut_thick = 3.68;
  71 sm_bolt_tighten_allow = 2.0;
  72
  73 sm_bolt_y_clear = 0.75;
  74 sm_bolt_y_over = 0.5;
  75
  76 sm_closure_cnr = 3.0;
  77
  78 catch_stem_h = 3;
  79 catch_stem_len = 50;
  80 catch_stem_th = 3;
  81
  82 catch_knob_dia = 6;
  83 catch_knob_above_gap = 8;
  84 catch_pin_height = 7;
  85
  86 catch_stem_below_gap = 1.0;
  87 catch_stem_beside_gap = 2.0;
  88 catch_pin_gap = 0.5;
  89
  90 // calculated
  91
  92 TAU = PI*2;
  93
  94 bayo_entry_x = bayo_entry;
  95 bayo_entry_z = bayo_entry;
  96 bayo_inramp_x = bayo_entry;
  97 bayo_inramp_z = bayo_entry;
  98
  99 oring_mid_dia = oring_bore + oring_thick;
 100 oring_outer_dia = oring_mid_dia + oring_thick;
 101
 102 oring_oblate = (1 - oring_compress);
 103
 104 oring_y_rad = oring_thick/2 * oring_oblate;
 105 oring_x_rad = oring_thick/2 / oring_oblate;
 106
 107 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 108
 109 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 110 side_thick = rivet_tall + over_rivet_wall;
 111
 112 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 113
 114 middle_bot_z = top_z - top_thick_middle;
 115
 116 bayo_entry = bayo_behind / 3.0;
 117 bayo_top_z = bayo_behind + bayo_gap;
 118
 119 rivet_entry_width = rivet_width + side_rivet_gap;
 120
 121 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 122
 123 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 124 handling_angle = 45;
 125
 126 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 127 sm_outer_rad = sm_inner_rad + sm_main_thick;
 128
 129 smc_pos = [ 0, sm_inner_rad, 0 ];
 130
 131 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 132 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 133
 134 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 135 smc_max_y = smc_bolt_y + sm_bolt_y_over
 136   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 137 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 138   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 139
 140 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
 141 catch_strap_width = sm_main_width;
 142 catch_stem_end_h = catch_stem_h;
 143 catch_pin_width = rivet_entry_width - catch_pin_gap;
 144
 145 cppy6 = -catch_strap_width/2;
 146 cppB = [ catch_pin_width/2,
 147          cppy6
 148          + catch_stem_below_gap
 149          + catch_pin_height
 150          + catch_knob_dia/2 ];
 151 cpp0 = [ 0,
 152          cppB[1]
 153          + catch_knob_dia
 154          + catch_knob_above_gap ];
 155 cpp1 = cpp0 + [0,1] * catch_pin_height;
 156 cpp2 = cpp1 + [1,0] * catch_pin_width;
 157 cpp4 = cpp0 + [0,-1] * catch_stem_end_h;
 158 cpp3 = [ cpp2[0], cpp4[1] ];
 159 cpp5 = [ cpp0[0] - catch_stem_len,
 160          -catch_stem_h ];
 161 cpp7 = cppB + [1,-1] * catch_knob_dia/2
 162             + [ catch_stem_beside_gap, -catch_stem_below_gap ]
 163             + [ 0, -catch_pin_height ]
 164             + [-1,1] * catch_cr;
 165 cpp11 = cpp7 + [1,0] * catch_cr;
 166 cpp10 = [ cpp11[0], 0 - catch_cr ];
 167 cpp8 = cpp10 + [1,0] * catch_cr;
 168 cpp9 = cpp8 + [0,1] * catch_cr;
 169 cppC = cpp8 + [1,1] * catch_cr;
 170 cppA = [ cpp5[0] - catch_cr, 0 ];
 171 cppD = cppC + [0,-1] * catch_strap_width;
 172 cppE = [ cppA[0], cppD[1] ];
 173
 174 $fs= coarse ? 2.5 : 0.5;
 175 $fa= coarse ? 5 : 1;
 176
 177 include <poster-tube-lid-parametric.scad>
 178
 179 // bayonet definition
 180
 181 bayo_a = [ bayo_entry_x, 0 ];
 182 bayo_p = [ 0, bayo_entry_z ];
 183 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 184 bayo_m = [ bayo_inramp_x, bayo_behind ];
 185 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 186 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 187 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 188 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 189 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 190 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 191
 192 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 193 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 194 bayo_c = bayo_d + [0,-5];
 195 bayo_b = bayo_a + [0,-5];
 196
 197 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 198
 199 bayo_polygon = [ bayo_a,
 200                  bayo_b,
 201                  bayo_c,
 202                  bayo_d,
 203                  bayo_e,
 204                  bayo_f,
 205                  bayo_g,
 206                  bayo_h,
 207                  bayo_i,
 208                  bayo_j,
 209                  bayo_k,
 210                  bayo_l,
 211                  bayo_m,
 212                  bayo_n,
 213                  bayo_p ];
 214
 215 echo(bayo_polygon);
 216
 217 module MainProfile(){
 218   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 219   difference(){
 220     union(){
 221       translate(main_cnr_pos){
 222         intersection(){
 223           difference(){
 224             circle(r = main_cnr);
 225             circle(r = main_cnr * 0.5);
 226           }
 227           square([10,10]);
 228         }
 229       }
 230       polygon([[ -top_middle_dr,        middle_bot_z      ],
 231                [ -top_middle_dr,        top_z             ],
 232                [ main_cnr_pos[0],       top_z             ],
 233                [ side_thick,            main_cnr_pos[1]   ],
 234                [ side_thick,            -side_height      ],
 235                [ side_taper,            -side_height      ],
 236                [ 0,                     -rivet_posn       ],
 237                [ 0,                     by_oring_z        ],
 238                [ -oring_x_rad,          by_oring_z        ],
 239                ],
 240               convexity=10);
 241     }
 242     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 243       hull(){
 244       translate([ 0, oring_y_rad ])
 245         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 246         circle(oring_thick/2);
 247       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 248         circle(oring_thick/2);
 249     }
 250   }
 251 }
 252
 253 module StrapHoopProfile(){
 254   circle(r = strap_hoop_thick/2);
 255 }
 256
 257 module StrapHoop(){ ////toplevel
 258   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 259   extralen = strap_hoop_thick * 5;
 260
 261   intersection(){
 262     rotate([strap_hoop_elevation, 0,0]){
 263       for (x= [ -1, +1 ] * bigrad) {
 264         translate([x, -extralen, 0])
 265           rotate([-90,0,0])
 266           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 267                          convexity=10)
 268           StrapHoopProfile();
 269       }
 270       translate([0, strap_hoop_strlen, 0]){
 271         intersection(){
 272           rotate_extrude(convexity=10)
 273             translate([bigrad, 0,0])
 274             StrapHoopProfile();
 275           translate([0,50,0])
 276             cube([100,100,100], center=true);
 277         }
 278       }
 279     }
 280     translate([0, 50, 0])
 281       cube(100, center=true);
 282   }
 283 }
 284
 285 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 286   // nom_rad > real_rad
 287   rotate([0,0, atan2(offset, nom_rad) ]){
 288     intersection(){
 289       translate([-offset, -10, 0])
 290         rotate([90,0,0])
 291         linear_extrude(height= nom_rad*2)
 292         children(0);
 293       translate([0,0, -25])
 294         cylinder(h=50, r= real_rad);
 295       translate([0,0, -25])
 296         linear_extrude(height= 50)
 297         polygon([ [ 0,0 ],
 298                   [ -slice_size, -real_rad*2 ],
 299                   [ +slice_size, -real_rad*2 ] ]);
 300     }
 301   }
 302 }
 303
 304 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 305   offs = [ for (i=[ x_min :
 306                     slice_size :
 307                     x_max + slice_size ]) i ];
 308   echo (offs);
 309   for (off=offs)
 310     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 311     children(0);
 312 }
 313
 314 module BayonetCutout(){
 315   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 316                 main_dia/2 + side_thick,
 317                 main_dia/2 + rivet_tall)
 318     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 319     polygon(bayo_polygon, convexity=10);
 320 }
 321
 322 module ProfilesDemo(){ ////toplevel
 323   translate([-10,0]) MainProfile();
 324   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 325 }
 326
 327 module LimitForHandling(){ ////toplevel
 328   hull() for (r=[0,180])
 329     rotate([0,0,r]) {
 330       for (rs=[-1,+1]) {
 331         for (xd=[0,1]) {
 332           rotate([0,0, rs * handling_angle/2]) {
 333             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 334                        main_dia/2 + side_thick - main_cnr,
 335                        top_z - main_cnr]) {
 336               mirror([0,0,1])
 337                 cylinder(r= main_cnr, h=50);
 338               sphere(main_cnr);
 339             }
 340           }
 341         }
 342       }
 343     }
 344   hull() rotate_extrude(){
 345     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 346       circle(r = main_cnr);
 347       mirror([0,1]) square([ main_cnr, 50 ]);
 348     }
 349   }
 350   //cylinder(r= handling_dia/2, h=20);
 351 }
 352
 353 module Cover(){ ////toplevel
 354   render() difference(){
 355     intersection(){
 356       union(){
 357         rotate_extrude(convexity=10)
 358           translate([main_dia/2, 0])
 359           MainProfile();
 360         translate([0,0, middle_bot_z])
 361           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 362       }
 363       LimitForHandling();
 364     }
 365     for (r=[0,180]){
 366       rotate([0,0, r])
 367         translate([0,0, -side_height])
 368         BayonetCutout();
 369       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 370         translate([0,
 371                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 372                    oring_y_rad * 1.5])
 373         rotate([-oring_rm_angle, 0, 0])
 374         mirror([0,0,1])
 375         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 376     }
 377     for (r=[0 : 60 : 179]) {
 378       rotate([0,0, r]) {
 379         height = top_thick_middle - brace_above_below*2;
 380         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 381         cube(center=true, [ oring_bore - brace_end_shorter,
 382                             brace_hole_width, height ]);
 383       }
 384     }
 385   }
 386   for (r=[0,180])
 387     rotate([0,0,r])
 388       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 389                  -implheadcup_large_dia * .0,
 390                  middle_bot_z + 0.1])
 391       ImplHeadCup();
 392 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 393 //    translate([handling_dia/2, 0, -side_height])
 394 //    rotate([0,180,0]) rotate([0,0,90])
 395 //    StrapHoop();
 396 }
 397
 398 module SavingHole(){
 399   translate([0,0, -10])
 400     cylinder(r= main_dia/2 - jig_rim, h=20);
 401 }
 402
 403 module Jig(){ ////toplevel
 404   difference(){
 405     union(){
 406       translate([0,0, -side_height]){
 407         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 408       }
 409       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 410         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 411     }
 412     translate([0,0, -side_height-1])
 413       cylinder(r= main_dia/2, h= side_height + 1);
 414     SavingHole();
 415     translate([0,0, -rivet_posn])
 416       rotate([90, 0,0])
 417       translate([0,0, -100])
 418       cylinder(r= jig_hole_dia/2, h = 200);
 419   }
 420 }
 421
 422 module CoverTest2(){ ////toplevel
 423   difference(){
 424     Cover();
 425     SavingHole();
 426   }
 427 }
 428
 429 module CoverTest1(){ ////toplevel
 430   difference(){
 431     CoverTest2();
 432     difference(){
 433       for (r= [ 40, 147 ]){
 434         rotate([0,0, r]){
 435           translate([0,0, -10]) {
 436             cube([ main_dia*3, main_dia * .53, 18], center=true);
 437           }
 438         }
 439       }
 440 //      translate([ 50, 0, 0 ])
 441 //      cube([ 100,
 442 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 443 //             100 ],
 444 //           center=true);
 445     }
 446   }
 447 }
 448
 449 module ImplHeadCupTest(){ ////toplevel
 450   for (r=[0,180])
 451     rotate([0,0,r])
 452       translate([-17,0,0])
 453       ImplHeadCup();
 454 }
 455
 456 module StrapMountBolt(l_delta){ ///toplevel
 457   // positioned relative to smc_pos
 458   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 459              smc_bolt_y,
 460              sm_main_width/2]){
 461     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 462       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 463     }
 464     translate([ -sm_bolt_shaft/2, 0,0 ])
 465       rotate([0,-90,0])
 466       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 467                h=smc_bolt_nut_eff_thick + l_delta);
 468     translate([ sm_bolt_shaft/2, 0,0 ])
 469       rotate([0,90,0])
 470       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 471   }
 472 }
 473
 474 module StrapMountProtrusion(half_x, max_y, cnr){
 475   translate(smc_pos){
 476     linear_extrude(height=sm_main_width, convexity=10){
 477       hull(){
 478         for (m = [0,1]) mirror([m,0,0]) {
 479           translate([-(half_x - cnr), max_y - cnr])
 480             circle(r=cnr);
 481           translate([-half_x, -sm_inner_rad])
 482             square([1,1]);
 483         }
 484       }
 485     }
 486   }
 487 }
 488
 489 module StrapMount(){ ////toplevel
 490   difference(){
 491     union(){
 492       cylinder(r=sm_outer_rad, h=sm_main_width);
 493       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 494                            smc_max_y,
 495                            sm_closure_cnr);
 496       rotate([0,0,180]){
 497         StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
 498                              strap_hoop_thick,
 499                              sm_closure_cnr);
 500         translate(smc_pos +
 501                   [0,0, sm_main_width] +
 502                   strap_hoop_thick * [ 0, 0.5, -1.0 ])
 503           StrapHoop();
 504       }
 505     }
 506     translate([0,0,-1])
 507       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 508     translate(smc_pos)
 509       StrapMountBolt(10);
 510     translate(smc_pos)
 511       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 512   }
 513 }
 514
 515 module CatchCoreProfile(){ ////toplevel
 516   difference(){
 517     polygon([ cpp4,
 518               cppB,
 519               cpp3,
 520               cpp2,
 521               cpp1,
 522               cpp0,
 523               cppA,
 524               cppE,
 525               cppD,
 526               cppC,
 527               cpp9,
 528               cpp10,
 529               cpp11,
 530               cpp7,
 531               cpp5,
 532               ], convexity=10);
 533   }
 534 }
 535
 536 //ProfilesDemo();
 537 //BayonetCutout();
 538 //MainProfile();
 539 //Cover();
 540 //Jig();
 541 //CoverTest();