chiark / gitweb /
earring-stand: 3d clips wip adjustments
[reprap-play.git] / belt-slot-cut-jig.scad
1 // -*- C -*-
2
3 // todo
4 //  various registration marks
5 //   protrustions at ends at strap width and middle
6 //   grooves on top face at 1/4,1/2,3/4 length and 1/2 width
7
8 strap_thick = 3;
9 strap_width = 26.75 + 0.7;
10
11 jig_interval = 25;
12
13 edgewall_width = 3;
14 crewpunch_slop = 0.3;
15 main_slop = 0.25;
16
17 holder_min_wall = 2;
18 holder_attach_near_wall = 5;
19
20 holder_attach_xsz = 5;
21 holder_ctie_width = 4.0 + 0.5;
22 holder_ctie_thick = 3.0 + 0.5;
23 holder_attach_walls = 3;
24 holder_attach_roof = 2.5;
25
26 holder_corner_round = 2.0;
27
28 punch_travel = 8;
29
30 // from careful measurement
31
32 crewpunch_shape =
33   [[  6, [0.6, 6.0], [1.6, 12.3] ],
34    [  8, [1.1, 6.2], [1.9, 12.5] ],
35    [ 10, [1.6, 6.5], [2.1, 12.8] ],
36    [ 12, [1.8, 6.6], [2.3, 12.7] ],
37    [ 14, [2.1, 6.8], [2.6, 13.0] ],
38    [ 16, [2.4, 6.9], [2.7, 13.2] ],
39    [ 18, [2.5, 7.0], [2.9, 13.3] ],
40    [ 22, [3.1, 7.1], [3.2, 13.4] ],
41    [ 26, [3.3, 7.2], [3.5, 13.6] ], 
42    ];
43
44 crewpunch_shaft_max_y = 7.5;
45
46 crewpunch_systematic_size_error = +0.36;
47
48 crewpunch_smallest_shape = crewpunch_shape[0];
49 crewpunch_biggest_shape = crewpunch_shape[len(crewpunch_shape)-1];
50
51 crewpunch_skew_angle = 3.5; //degrees
52 crewpunch_skew_yoff = +1.1; //mm
53
54 // computed
55
56 punch_dx = 0.5 * (-crewpunch_biggest_shape[2][0]
57                   +crewpunch_biggest_shape[2][1]);
58 punch_dy = 0.5 * (+crewpunch_biggest_shape[1][1]
59                   -crewpunch_biggest_shape[1][0]) + crewpunch_skew_yoff;
60
61 attach_ysz = holder_attach_walls*2 + holder_ctie_width;
62
63 holder_block_zsz = crewpunch_biggest_shape[0] - crewpunch_smallest_shape[0];
64 holder_xsz = crewpunch_biggest_shape[2][0] + crewpunch_biggest_shape[2][1] +
65   holder_min_wall*2;
66
67 holder_skewangle_yextra = holder_xsz/2 * sin(abs(crewpunch_skew_angle));
68
69 holder_max_y = punch_dy + crewpunch_biggest_shape[1][0] + holder_min_wall
70   + crewpunch_systematic_size_error + holder_skewangle_yextra;
71
72 holder_attach_max_y = punch_dy
73   - max(crewpunch_biggest_shape[1][1], crewpunch_shaft_max_y)
74   - crewpunch_systematic_size_error - holder_skewangle_yextra;
75
76 holder_block_min_y = punch_dy
77   - crewpunch_biggest_shape[1][1] - holder_attach_near_wall +
78   - crewpunch_systematic_size_error - holder_skewangle_yextra;
79
80 holder_all_min_y = holder_attach_max_y - attach_ysz;
81
82 jig_max_y = max(holder_max_y + main_slop, strap_width/2) + edgewall_width;
83 jig_min_y = min(holder_all_min_y - main_slop, -strap_width/2) - edgewall_width;
84
85 jig_main_zsz = holder_block_zsz + punch_travel;
86
87 // common stuff
88
89 include <belt-cut-jig-common.scad>
90
91 // objects
92
93 module CrewPunch(){
94   ourslop = crewpunch_slop - crewpunch_systematic_size_error;
95   hull(){
96     for(layer=crewpunch_shape){
97       translate([0,0, layer[0]]){
98         for(xind=[0,1]) //translate([xind?0:1,0,0])
99           for(yind=[0,1]) //translate([0,yind?0.5:0,0])
100             mirror([xind?1:0,0,0]) mirror([0,yind?0:1,0]){
101               translate([-0.1,-0.1,-0.1])
102                 cube([0.1 + layer[2][xind] + ourslop,
103                       0.1 + layer[1][1-yind] + ourslop,
104                       0.2]);
105             }
106       }
107     }
108   }
109 }
110
111 module MaybeRoundedCube(sizes, roundedness){
112   if (roundedness > 0) {
113     translate([roundedness, roundedness, 0]){
114       minkowski(){
115         cube([sizes[0] - roundedness*2,
116               sizes[1] - roundedness*2,
117               sizes[2]]);
118         cylinder(h=0.05, r=roundedness, $fn=20);
119       }
120     }
121   } else {
122     cube(sizes);
123   }
124 }
125
126 module PunchHolder(cutouts=true){
127   roundedness = cutouts ? holder_corner_round : 0;
128     difference(){
129       translate([-holder_xsz/2, holder_block_min_y, 0])
130         MaybeRoundedCube([holder_xsz,
131                           holder_max_y - holder_block_min_y,
132                           holder_block_zsz],
133                          roundedness);
134       if (cutouts)
135         rotate([0,0,-crewpunch_skew_angle])
136         translate([punch_dx,
137                    punch_dy,
138                    -crewpunch_smallest_shape[0]])
139           CrewPunch();
140     }
141     difference(){
142       translate([-holder_attach_xsz/2, holder_all_min_y, 0])
143         MaybeRoundedCube([holder_attach_xsz,
144                           attach_ysz,
145                           holder_block_zsz + punch_travel
146                           + holder_ctie_thick + holder_attach_roof + 1],
147                          roundedness);
148       if (cutouts)
149         translate([-30,
150                    holder_all_min_y + holder_attach_walls,
151                    holder_block_zsz + punch_travel])
152           cube([60, holder_ctie_width, holder_ctie_thick]);
153     }
154 }
155
156 module OneJigCutout(){
157   minkowski(){
158     cube([main_slop*2, main_slop*2, 50], center=true);
159     PunchHolder(false);
160   }
161 }
162
163 module JigT(){ ////toplevel
164   JigPrint();
165 }
166
167 module PunchHolderT(){ ////toplevel
168   PunchHolder(true);
169 }
170
171 module Demo(){ ////toplevel
172   %PunchHolder();
173   Jig();
174 }
175
176 module Kit(){ ////toplevel
177   JigT();
178   rotate([0,0,-45]){
179     translate([(jig_iters-1)*jig_interval/2,
180                jig_min_y - holder_max_y - 5,
181                0])
182       PunchHolder();
183   }
184 }
185
186 //CrewPunch();
187 //PunchHolder();
188 //PunchHolder(false);
189 //OneJig();
190 //Jig();
191 Demo();
192 //JigT();
193 //RegistrationProtrusion();
194 //PunchHolderT();
195 //Kit();