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 + 0.1;
  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 = 0.44;
  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 // calculated
  79
  80 TAU = PI*2;
  81
  82 bayo_entry_x = bayo_entry;
  83 bayo_entry_z = bayo_entry;
  84 bayo_inramp_x = bayo_entry;
  85 bayo_inramp_z = bayo_entry;
  86
  87 oring_mid_dia = oring_bore + oring_thick;
  88 oring_outer_dia = oring_mid_dia + oring_thick;
  89
  90 oring_oblate = (1 - oring_compress);
  91
  92 oring_y_rad = oring_thick/2 * oring_oblate;
  93 oring_x_rad = oring_thick/2 / oring_oblate;
  94
  95 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  96
  97 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  98 side_thick = rivet_tall + over_rivet_wall;
  99
 100 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 101
 102 middle_bot_z = top_z - top_thick_middle;
 103
 104 bayo_entry = bayo_behind / 3.0;
 105 bayo_top_z = bayo_behind + bayo_gap;
 106
 107 rivet_entry_width = rivet_width + side_rivet_gap;
 108
 109 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 110
 111 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 112 handling_angle = 45;
 113
 114 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 115 sm_outer_rad = sm_inner_rad + sm_main_thick;
 116
 117 smc_pos = [ 0, sm_inner_rad, 0 ];
 118
 119 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 120 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 121
 122 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 123 smc_max_y = smc_bolt_y + sm_bolt_y_over
 124   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 125 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 126   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 127
 128 $fs= coarse ? 2.5 : 0.5;
 129 $fa= coarse ? 5 : 1;
 130
 131 // bayonet definition
 132
 133 bayo_a = [ bayo_entry_x, 0 ];
 134 bayo_p = [ 0, bayo_entry_z ];
 135 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 136 bayo_m = [ bayo_inramp_x, bayo_behind ];
 137 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 138 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 139 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 140 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 141 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 142 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 143
 144 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 145 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 146 bayo_c = bayo_d + [0,-5];
 147 bayo_b = bayo_a + [0,-5];
 148
 149 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 150
 151 bayo_polygon = [ bayo_a,
 152                  bayo_b,
 153                  bayo_c,
 154                  bayo_d,
 155                  bayo_e,
 156                  bayo_f,
 157                  bayo_g,
 158                  bayo_h,
 159                  bayo_i,
 160                  bayo_j,
 161                  bayo_k,
 162                  bayo_l,
 163                  bayo_m,
 164                  bayo_n,
 165                  bayo_p ];
 166
 167 echo(bayo_polygon);
 168
 169 module MainProfile(){
 170   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 171   difference(){
 172     union(){
 173       translate(main_cnr_pos){
 174         intersection(){
 175           difference(){
 176             circle(r = main_cnr);
 177             circle(r = main_cnr * 0.5);
 178           }
 179           square([10,10]);
 180         }
 181       }
 182       polygon([[ -top_middle_dr,        middle_bot_z      ],
 183                [ -top_middle_dr,        top_z             ],
 184                [ main_cnr_pos[0],       top_z             ],
 185                [ side_thick,            main_cnr_pos[1]   ],
 186                [ side_thick,            -side_height      ],
 187                [ side_taper,            -side_height      ],
 188                [ 0,                     -rivet_posn       ],
 189                [ 0,                     by_oring_z        ],
 190                [ -oring_x_rad,          by_oring_z        ],
 191                ],
 192               convexity=10);
 193     }
 194     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 195       hull(){
 196       translate([ 0, oring_y_rad ])
 197         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 198         circle(oring_thick/2);
 199       #translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 200         circle(oring_thick/2);
 201     }
 202   }
 203 }
 204
 205 module StrapHoopProfile(){
 206   circle(r = strap_hoop_thick/2);
 207 }
 208
 209 module StrapHoop(){ ////toplevel
 210   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 211   extralen = strap_hoop_thick * 5;
 212
 213   intersection(){
 214     rotate([strap_hoop_elevation, 0,0]){
 215       for (x= [ -1, +1 ] * bigrad) {
 216         translate([x, -extralen, 0])
 217           rotate([-90,0,0])
 218           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 219                          convexity=10)
 220           StrapHoopProfile();
 221       }
 222       translate([0, strap_hoop_strlen, 0]){
 223         intersection(){
 224           rotate_extrude(convexity=10)
 225             translate([bigrad, 0,0])
 226             StrapHoopProfile();
 227           translate([0,50,0])
 228             cube([100,100,100], center=true);
 229         }
 230       }
 231     }
 232     translate([0, 50, 0])
 233       cube(100, center=true);
 234   }
 235 }
 236
 237 module HandlingProfile(){
 238 //  translate([
 239 }
 240
 241 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 242   // nom_rad > real_rad
 243   rotate([0,0, atan2(offset, nom_rad) ]){
 244     intersection(){
 245       translate([-offset, -10, 0])
 246         rotate([90,0,0])
 247         linear_extrude(height= nom_rad*2)
 248         children(0);
 249       translate([0,0, -25])
 250         cylinder(h=50, r= real_rad);
 251       translate([0,0, -25])
 252         linear_extrude(height= 50)
 253         polygon([ [ 0,0 ],
 254                   [ -slice_size, -real_rad*2 ],
 255                   [ +slice_size, -real_rad*2 ] ]);
 256     }
 257   }
 258 }
 259
 260 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 261   offs = [ for (i=[ x_min :
 262                     slice_size :
 263                     x_max + slice_size ]) i ];
 264   echo (offs);
 265   for (off=offs)
 266     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 267     children(0);
 268 }
 269
 270 module BayonetCutout(){
 271   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 272                 main_dia/2 + side_thick,
 273                 main_dia/2 + rivet_tall)
 274     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 275     polygon(bayo_polygon, convexity=10);
 276 }
 277
 278 module ProfilesDemo(){ ////toplevel
 279   translate([-10,0]) MainProfile();
 280   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 281 }
 282
 283 module LimitForHandling(){ ////toplevel
 284   hull() for (r=[0,180])
 285     rotate([0,0,r]) {
 286       for (rs=[-1,+1]) {
 287         for (xd=[0,1]) {
 288           rotate([0,0, rs * handling_angle/2]) {
 289             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 290                        main_dia/2 + side_thick - main_cnr,
 291                        top_z - main_cnr]) {
 292               mirror([0,0,1])
 293                 cylinder(r= main_cnr, h=50);
 294               sphere(main_cnr);
 295             }
 296           }
 297         }
 298       }
 299     }
 300   hull() rotate_extrude(){
 301     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 302       circle(r = main_cnr);
 303       mirror([0,1]) square([ main_cnr, 50 ]);
 304     }
 305   }
 306   //cylinder(r= handling_dia/2, h=20);
 307 }
 308
 309 module Cover(){ ////toplevel
 310   render() difference(){
 311     intersection(){
 312       union(){
 313         rotate_extrude(convexity=10)
 314           translate([main_dia/2, 0])
 315           MainProfile();
 316         translate([0,0, middle_bot_z])
 317           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 318       }
 319       LimitForHandling();
 320     }
 321     for (r=[0,180]){
 322       rotate([0,0, r])
 323         translate([0,0, -side_height])
 324         BayonetCutout();
 325       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 326         translate([0,
 327                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 328                    oring_y_rad * 1.5])
 329         rotate([-oring_rm_angle, 0, 0])
 330         mirror([0,0,1])
 331         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 332     }
 333     for (r=[0 : 60 : 179]) {
 334       rotate([0,0, r]) {
 335         height = top_thick_middle - brace_above_below*2;
 336         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 337         cube(center=true, [ oring_bore - brace_end_shorter,
 338                             brace_hole_width, height ]);
 339       }
 340     }
 341   }
 342 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 343 //    translate([handling_dia/2, 0, -side_height])
 344 //    rotate([0,180,0]) rotate([0,0,90])
 345 //    StrapHoop();
 346 }
 347
 348 module SavingHole(){
 349   translate([0,0, -10])
 350     cylinder(r= main_dia/2 - jig_rim, h=20);
 351 }
 352
 353 module Jig(){ ////toplevel
 354   difference(){
 355     union(){
 356       translate([0,0, -side_height]){
 357         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 358       }
 359       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 360         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 361     }
 362     translate([0,0, -side_height-1])
 363       cylinder(r= main_dia/2, h= side_height + 1);
 364     SavingHole();
 365     translate([0,0, -rivet_posn])
 366       rotate([90, 0,0])
 367       translate([0,0, -100])
 368       cylinder(r= jig_hole_dia/2, h = 200);
 369   }
 370 }
 371
 372 module CoverTest2(){ ////toplevel
 373   difference(){
 374     Cover();
 375     SavingHole();
 376   }
 377 }
 378
 379 module CoverTest1(){ ////toplevel
 380   difference(){
 381     CoverTest2();
 382     difference(){
 383       for (r= [ 40, 147 ]){
 384         rotate([0,0, r]){
 385           translate([0,0, -10]) {
 386             cube([ main_dia*3, main_dia * .53, 18], center=true);
 387           }
 388         }
 389       }
 390 //      translate([ 50, 0, 0 ])
 391 //      cube([ 100,
 392 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 393 //             100 ],
 394 //           center=true);
 395     }
 396   }
 397 }
 398
 399 module StrapMountBolt(l_delta){ ///toplevel
 400   // positioned relative to smc_pos
 401   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 402              smc_bolt_y,
 403              sm_main_width/2]){
 404     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 405       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 406     }
 407     translate([ -sm_bolt_shaft/2, 0,0 ])
 408       rotate([0,-90,0])
 409       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 410                h=smc_bolt_nut_eff_thick + l_delta);
 411     translate([ sm_bolt_shaft/2, 0,0 ])
 412       rotate([0,90,0])
 413       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 414   }
 415 }
 416
 417 module StrapMountProtrusion(half_x, max_y, cnr){
 418   translate(smc_pos){
 419     linear_extrude(height=sm_main_width, convexity=10){
 420       hull(){
 421         for (m = [0,1]) mirror([m,0,0]) {
 422           translate([-(half_x - cnr), max_y - cnr])
 423             circle(r=cnr);
 424           translate([-half_x, -sm_inner_rad])
 425             square([1,1]);
 426         }
 427       }
 428     }
 429   }
 430 }
 431
 432 module StrapMount(){ ////toplevel
 433   difference(){
 434     union(){
 435       cylinder(r=sm_outer_rad, h=sm_main_width);
 436       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 437                            smc_max_y,
 438                            sm_closure_cnr);
 439       rotate([0,0,180]){
 440         StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
 441                              strap_hoop_thick,
 442                              sm_closure_cnr);
 443         translate(smc_pos +
 444                   [0,0, sm_main_width] +
 445                   strap_hoop_thick * [ 0, 0.5, -1.0 ])
 446           StrapHoop();
 447       }
 448     }
 449     translate([0,0,-1])
 450       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 451     translate(smc_pos)
 452       StrapMountBolt(10);
 453     translate(smc_pos)
 454       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 455   }
 456 }
 457
 458 //ProfilesDemo();
 459 //BayonetCutout();
 460 //MainProfile();
 461 //Cover();
 462 //Jig();
 463 //CoverTest();