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();