flyscreen-handle: adjustments for strength

[reprap-play.git] / flyscreen-handle.scad

diff --git a/flyscreen-handle.scad b/flyscreen-handle.scad
index 5383efc8fa49d177b1ce6e69ae4386057c8a80f5..35fd7ef1a9334e5f85f50a1d6b2c9ec4ef40f818 100644 (file)
--- a/flyscreen-handle.scad
+++ b/flyscreen-handle.scad
@@ -14,27 +14,35 @@ retain_hgap_adjust = 1.5;
 retain_stalk_len = 8.0;
 retain_stalk_h = 1.5;
 retain_bend_gap = 2.0;
-retain_empir_angle = -25;
-retain_pushmore_adj = 0.45;
+retain_empir_angle = -10;
+retain_pushmore_adj = 0.0;
 
 hgap_empir_adjust = -0.5 -2.50;
 
 topprotr_rad = 0.35;
 
 bot_overlap = 5;
-bot_w = 3;
+top_w = 3;
+bot_w = 5;
 
-handle_w = 10;
+handle_w = 8;
 handle_rh = 3;
 handle_rcut = 3;
 
 cutout_gap = 1.5;
 
 total_len = 40;
+retain_len = 8;
 basics_len = 8;
 
 overret_hch = 5;
 
+peg_width_slop = 0.5;
+peg_inner_thick = 1.0;
+
+peg_wedge_less = 1.0;
+peg_wedge_more = 1.0;
+
 // calculated
 
 ins_irad = openingcnr_dia/2 + gap;
@@ -57,8 +65,17 @@ retain_cutout_h = retain_rad * 2 + retain_bend_gap;
 
 overret_gaplen = retain_cutout_h / cos(retain_empir_angle);
 
-retaining_len = total_len - overret_gaplen - basics_len * 2;
-echo(retaining_len);
+peg_width = retain_stalk_len -
+  (handle_x0 - retain_mxy[0]) / cos(retain_empir_angle)
+  - peg_width_slop;
+
+peg_height = retain_cutout_h - (retain_rad + retain_stalk_h)
+  + retain_pushmore_adj;
+
+retain1_len = retain_len + retain_stalk_len;
+retain1_base = total_len - retain1_len;
+
+peg_len = retain_len;
 
 module InsertSection(){
   hull(){
@@ -69,7 +86,7 @@ module InsertSection(){
               topprotr_y - topprotr_rad])
       circle(r=topprotr_rad, $fn=10);
   }
-  translate([0, -ins_orad]) square([ins_irad+1, ins_th]);
+  translate([0, -ins_orad]) square([ins_irad, ins_th]);
   intersection(){
     translate([0, -ins_irad])
       mirror([1,1])
@@ -93,7 +110,7 @@ module HandleSection(){
       }
     }
     hull(){
-      for (x= [handle_x0 + bot_w + handle_rcut/2,
+      for (x= [handle_x0 + top_w + handle_rcut/2,
               handle_x1 - handle_rh/2 - handle_rcut/2]) {
        translate([x, handle_y1])
          circle(r = handle_rcut/2, $fn=20);
@@ -121,6 +138,25 @@ module RetainSection(){
   }
 }
 
+module PegSection(delta){
+  hull(){
+    translate([0, -delta/2])
+      square([0.1,
+             peg_height + delta]);
+    translate([peg_width - 0.1,
+              peg_height/2 - peg_inner_thick/2])
+      square([0.1, peg_inner_thick]);
+  }
+}
+
+module PegSectionForDemo(delta){
+  translate(retain_mxy)
+    rotate(retain_empir_angle)
+    translate([retain_stalk_len - peg_width - peg_width_slop/2,
+              retain_stalk_h - retain_pushmore_adj])
+    PegSection(delta);
+}
+
 module RetainCutout(gapping=false){
   translate(retain_mxy) {
     rotate(retain_empir_angle) {
@@ -158,31 +194,43 @@ module BasicSection(){
   HandleSection();
 }
 
-module Handle(){
-  bs0 = retaining_len + overret_gaplen + basics_len;
-  bs1 = bs0 + overret_hch;
-  linear_extrude(height=total_len, convexity=100) GappingSection();
+module PegSectionSlice(lambda) {
+  delta = peg_wedge_more * (1-lambda) + -peg_wedge_less * lambda;
+  z = peg_len * lambda;
+  translate([0,0, z])
+    linear_extrude(height=0.1)
+    PegSection(delta);
+}  
 
-  translate([0,0, basics_len]) {
-    intersection(){
-      linear_extrude(height=retaining_len, convexity=100)
-       WithRetainSection();
-      translate([retain_mxy[0], retain_mxy[1], 0])
-       rotate([0,0, retain_empir_angle])
-       translate([retain_stalk_len, -30, 0])
-       multmatrix([[1,0,-1,0],
-                   [0,1,0,0],
-                   [0,0,1,0],
-                   [0,0,0,1]])
-       cube([50, 60, 50]);
+module Peg(){
+  iters = 20;
+  for (i = [0 : iters-1]) {
+    lambda = i/iters;
+    hull(){
+      PegSectionSlice(lambda);
+      PegSectionSlice(lambda + 1/iters);
     }
   }
+}
 
-  for (z= [0, bs1]) {
-    translate([0,0, z])
-      linear_extrude(height= basics_len)
-      BasicSection();
-  }
+module PegPrintL(){
+  rotate([0,-90,0]) Peg();
+}
+
+module PegPrintR(){
+  mirror([1,0,0]) PegPrintL();
+}
+
+module Handle(){
+  bs1 = retain_len + overret_gaplen + 4;
+
+  translate([0,0,0])
+    linear_extrude(height= retain_len)
+    WithRetainSection();
+
+  translate([0,0, bs1])
+    linear_extrude(height= basics_len)
+    BasicSection();
 
   translate([0,0, bs1+0.1]) mirror([0,0,1]) {
     intersection_for (sl=[0,1]) {
@@ -194,11 +242,29 @@ module Handle(){
        BasicSection();
     }
   }
+  
+  linear_extrude(height=total_len, convexity=100) GappingSection();
+
+  translate([0,0, retain1_base]) {
+    intersection(){
+      linear_extrude(height=retain1_len, convexity=100)
+       WithRetainSection();
+      translate([retain_mxy[0], retain_mxy[1], 0])
+       rotate([0,0, retain_empir_angle])
+       translate([retain_stalk_len, -30, 0])
+       multmatrix([[1,0,-1,0],
+                   [0,1,0,0],
+                   [0,0,1,0],
+                   [0,0,0,1]])
+       cube([50, 60, 50]);
+    }
+  }
 }
 
 module Demo(){
   color("red") translate([0,0,-3]) BasicSection();
   color("blue") translate([0,0,3]) WithRetainSection();
+  color("orange") translate([0,0,7]) PegSectionForDemo(0);
 }
 
 module Test(){
@@ -209,6 +275,13 @@ module Test(){
   }
 }
 
+module PegTestKit(){
+  PegPrintL();
+  translate([2,0,0]) PegPrintR();
+  translate([0,-2,0])
+    linear_extrude(height=retain_len, convexity=100) WithRetainSection();
+}
+
 //Demo();
 //HandleSection();
 //InsertSection();
@@ -216,5 +289,8 @@ module Test(){
 //BasicSection();
 //GappingSection();
 //Test();
+//Peg();
+//PegPrintR();
+PegTestKit();
 //Demo();
-Handle();
+//Handle();