chiark / gitweb /
poster-tube-lid: Add actual knob
[reprap-play.git] / 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_knob_height = 6;
85 catch_pin_height = 7;
86
87 catch_stem_below_gap = 1.0;
88 catch_stem_beside_gap = 2.0;
89 catch_pin_gap = 0.5;
90 catch_hook_slope = 0.15;
91
92 // calculated
93
94 TAU = PI*2;
95
96 bayo_entry_x = bayo_entry;
97 bayo_entry_z = bayo_entry;
98 bayo_inramp_x = bayo_entry;
99 bayo_inramp_z = bayo_entry;
100
101 oring_mid_dia = oring_bore + oring_thick;
102 oring_outer_dia = oring_mid_dia + oring_thick;
103
104 oring_oblate = (1 - oring_compress);
105
106 oring_y_rad = oring_thick/2 * oring_oblate;
107 oring_x_rad = oring_thick/2 / oring_oblate;
108
109 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
110
111 side_height = rivet_posn + bayo_behind + rivet_thick/2;
112 side_thick = rivet_tall + over_rivet_wall;
113
114 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
115
116 middle_bot_z = top_z - top_thick_middle;
117
118 bayo_entry = bayo_behind / 3.0;
119 bayo_top_z = bayo_behind + bayo_gap;
120
121 bayo_nom_rad = main_dia/2 + side_thick;
122 bayo_real_rad = main_dia/2 + rivet_tall;
123
124 rivet_entry_width = rivet_width + side_rivet_gap;
125
126 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
127
128 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
129 handling_angle = 45;
130
131 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
132 sm_outer_rad = sm_inner_rad + sm_main_thick;
133
134 smc_pos = [ 0, sm_inner_rad, 0 ];
135
136 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
137 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
138
139 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
140 smc_max_y = smc_bolt_y + sm_bolt_y_over
141   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
142 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
143   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
144
145 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
146 catch_strap_width = sm_main_width;
147 catch_strap_thick = sm_main_thick;
148 catch_stem_end_h = catch_stem_h;
149 catch_pin_width = (rivet_entry_width * sm_inner_rad / bayo_nom_rad)
150                    - catch_pin_gap;
151
152 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
153
154 cppy6 = -catch_strap_width/2;
155 cppxC = 0.34 * sm_inner_rad * TAU;
156 cppB = [ catch_pin_width/2,
157          cppy6
158          + catch_stem_below_gap
159          + catch_pin_height
160          + catch_knob_dia/2 ];
161 cpp0 = [ 0,
162          cppB[1]
163          + catch_knob_dia
164          + catch_knob_above_gap ];
165 cpp12 = cpp0 + [1,0] * (catch_pin_height * catch_hook_slope);
166 cpp1 = cpp0 + [0,1] * catch_pin_height;
167 cpp2 = cpp1 + [1,0] * catch_pin_width;
168 cpp4 = cpp0 + [0,-1] * catch_stem_end_h;
169 cpp3 = [ cpp2[0], cpp4[1] ];
170 cpp5 = [ cpp0[0] - catch_stem_len,
171          -catch_stem_h ];
172 cpp6 = [ cpp5[0], catch_cr ];
173 cpp7 = cppB + [1,-1] * catch_knob_dia/2
174             + [ catch_stem_beside_gap, -catch_stem_below_gap ]
175             + [ 0, -catch_pin_height ]
176             + [-1,1] * catch_cr;
177 cpp11 = cpp7 + [1,0] * catch_cr;
178 cpp10 = [ cpp11[0], 0 - catch_cr ];
179 cpp8 = cpp10 + [1,0] * catch_cr;
180 cpp9 = cpp8 + [0,1] * catch_cr;
181 cppC = [ cppxC, cpp9[1] ];
182 cppA = [ -cppxC, 0 ];
183 cppD = cppC + [0,-1] * catch_strap_width;
184 cppE = [ cppA[0], cppD[1] ];
185
186 $fs= coarse ? 2.5 : 0.5;
187 $fa= coarse ? 5 : 1;
188
189 include <poster-tube-lid-parametric.scad>
190
191 // bayonet definition
192
193 bayo_a = [ bayo_entry_x, 0 ];
194 bayo_p = [ 0, bayo_entry_z ];
195 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
196 bayo_m = [ bayo_inramp_x, bayo_behind ];
197 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
198 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
199 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
200 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
201 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
202 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
203
204 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
205 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
206 bayo_c = bayo_d + [0,-5];
207 bayo_b = bayo_a + [0,-5];
208
209 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
210
211 bayo_polygon = [ bayo_a,
212                  bayo_b,
213                  bayo_c,
214                  bayo_d,
215                  bayo_e,
216                  bayo_f,
217                  bayo_g,
218                  bayo_h,
219                  bayo_i,
220                  bayo_j,
221                  bayo_k,
222                  bayo_l,
223                  bayo_m,
224                  bayo_n,
225                  bayo_p ];
226
227 echo(bayo_polygon);
228
229 module MainProfile(){
230   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
231   difference(){
232     union(){
233       translate(main_cnr_pos){
234         intersection(){
235           difference(){
236             circle(r = main_cnr);
237             circle(r = main_cnr * 0.5);
238           }
239           square([10,10]);
240         }
241       }
242       polygon([[ -top_middle_dr,        middle_bot_z      ],
243                [ -top_middle_dr,        top_z             ],
244                [ main_cnr_pos[0],       top_z             ],
245                [ side_thick,            main_cnr_pos[1]   ],
246                [ side_thick,            -side_height      ],
247                [ side_taper,            -side_height      ],
248                [ 0,                     -rivet_posn       ],
249                [ 0,                     by_oring_z        ],
250                [ -oring_x_rad,          by_oring_z        ],
251                ],
252               convexity=10);
253     }
254     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
255       hull(){
256       translate([ 0, oring_y_rad ])
257         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
258         circle(oring_thick/2);
259       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
260         circle(oring_thick/2);
261     }
262   }
263 }
264
265 module StrapHoopProfile(){
266   circle(r = strap_hoop_thick/2);
267 }
268
269 module StrapHoop(){ ////toplevel
270   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
271   extralen = strap_hoop_thick * 5;
272
273   intersection(){
274     rotate([strap_hoop_elevation, 0,0]){
275       for (x= [ -1, +1 ] * bigrad) {
276         translate([x, -extralen, 0])
277           rotate([-90,0,0])
278           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
279                          convexity=10)
280           StrapHoopProfile();
281       }
282       translate([0, strap_hoop_strlen, 0]){
283         intersection(){
284           rotate_extrude(convexity=10)
285             translate([bigrad, 0,0])
286             StrapHoopProfile();
287           translate([0,50,0])
288             cube([100,100,100], center=true);
289         }
290       }
291     }
292     translate([0, 50, 0])
293       cube(100, center=true);
294   }
295 }
296
297 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
298   // nom_rad > real_rad
299   rotate([0,0, atan2(offset, nom_rad) ]){
300     intersection(){
301       translate([-offset, -10, 0])
302         rotate([90,0,0])
303         linear_extrude(height= nom_rad*2)
304         children(0);
305       translate([0,0, -25])
306         cylinder(h=50, r= real_rad);
307       translate([0,0, -25])
308         linear_extrude(height= 50)
309         polygon([ [ 0,0 ],
310                   [ -slice_size, -real_rad*2 ],
311                   [ +slice_size, -real_rad*2 ] ]);
312     }
313   }
314 }
315
316 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
317   offs = [ for (i=[ x_min :
318                     slice_size :
319                     x_max + slice_size ]) i ];
320   echo (offs);
321   for (off=offs)
322     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
323     children(0);
324 }
325
326 module BayonetCutout(){
327   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
328                 bayo_nom_rad, 
329                 bayo_real_rad)
330     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
331     polygon(bayo_polygon, convexity=10);
332 }
333
334 module ProfilesDemo(){ ////toplevel
335   translate([-10,0]) MainProfile();
336   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
337 }
338
339 module LimitForHandling(){ ////toplevel
340   hull() for (r=[0,180])
341     rotate([0,0,r]) {
342       for (rs=[-1,+1]) {
343         for (xd=[0,1]) {
344           rotate([0,0, rs * handling_angle/2]) {
345             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
346                        main_dia/2 + side_thick - main_cnr,
347                        top_z - main_cnr]) {
348               mirror([0,0,1])
349                 cylinder(r= main_cnr, h=50);
350               sphere(main_cnr);
351             }
352           }
353         }
354       } 
355     }
356   hull() rotate_extrude(){
357     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
358       circle(r = main_cnr);
359       mirror([0,1]) square([ main_cnr, 50 ]);
360     }
361   }
362   //cylinder(r= handling_dia/2, h=20);
363 }
364
365 module Cover(){ ////toplevel
366   render() difference(){
367     intersection(){
368       union(){
369         rotate_extrude(convexity=10)
370           translate([main_dia/2, 0])
371           MainProfile();
372         translate([0,0, middle_bot_z])
373           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
374       }
375       LimitForHandling();
376     }
377     for (r=[0,180]){
378       rotate([0,0, r])
379         translate([0,0, -side_height])
380         BayonetCutout();
381       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
382         translate([0,
383                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
384                    oring_y_rad * 1.5])
385         rotate([-oring_rm_angle, 0, 0])
386         mirror([0,0,1])
387         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
388     }
389     for (r=[0 : 60 : 179]) {
390       rotate([0,0, r]) {
391         height = top_thick_middle - brace_above_below*2;
392         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
393         cube(center=true, [ oring_bore - brace_end_shorter,
394                             brace_hole_width, height ]);
395       }
396     }
397   }
398   for (r=[0,180])
399     rotate([0,0,r])
400       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
401                  -implheadcup_large_dia * .0,
402                  middle_bot_z + 0.1])
403       ImplHeadCup();
404 //  translate(strap_hoop_thick * [-0.5, 0, +1])
405 //    translate([handling_dia/2, 0, -side_height])
406 //    rotate([0,180,0]) rotate([0,0,90])
407 //    StrapHoop();
408 }
409
410 module SavingHole(){
411   translate([0,0, -10])
412     cylinder(r= main_dia/2 - jig_rim, h=20);
413 }
414
415 module Jig(){ ////toplevel
416   difference(){
417     union(){
418       translate([0,0, -side_height]){
419         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
420       }
421       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
422         cube([jig_mark_rad*2, jig_mark, jig_mark]);
423     }
424     translate([0,0, -side_height-1])
425       cylinder(r= main_dia/2, h= side_height + 1);
426     SavingHole();
427     translate([0,0, -rivet_posn])
428       rotate([90, 0,0])
429       translate([0,0, -100])
430       cylinder(r= jig_hole_dia/2, h = 200);
431   }
432 }
433
434 module CoverTest2(){ ////toplevel
435   difference(){
436     Cover();
437     SavingHole();
438   }
439 }
440
441 module CoverTest1(){ ////toplevel
442   difference(){
443     CoverTest2();
444     difference(){
445       for (r= [ 40, 147 ]){
446         rotate([0,0, r]){
447           translate([0,0, -10]) {
448             cube([ main_dia*3, main_dia * .53, 18], center=true);
449           }
450         }
451       }
452 //      translate([ 50, 0, 0 ])
453 //      cube([ 100,
454 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
455 //             100 ],
456 //           center=true);
457     }
458   }
459 }
460
461 module ImplHeadCupTest(){ ////toplevel
462   for (r=[0,180])
463     rotate([0,0,r])
464       translate([-17,0,0])
465       ImplHeadCup();
466 }
467
468 module SomeStrap(){
469   // children(0) is to add, (1) subtract
470   difference(){
471     union(){
472       cylinder(r=sm_outer_rad, h=sm_main_width);
473       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
474                            smc_max_y,
475                            sm_closure_cnr);
476       children(0);
477     }
478     translate([0,0,-1])
479       cylinder(r=sm_inner_rad, h=sm_main_width+2);
480     translate(smc_pos)
481       StrapMountBolt(10);
482     translate(smc_pos)
483       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
484     children(1);
485   }
486 }
487
488 module StrapMountBolt(l_delta){ ///toplevel
489   // positioned relative to smc_pos
490   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
491              smc_bolt_y,
492              sm_main_width/2]){
493     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
494       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
495     }
496     translate([ -sm_bolt_shaft/2, 0,0 ])
497       rotate([0,-90,0])
498       cylinder($fn=6, r=smc_bolt_nut_dia/2,
499                h=smc_bolt_nut_eff_thick + l_delta);
500     translate([ sm_bolt_shaft/2, 0,0 ])
501       rotate([0,90,0])
502       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
503   }
504 }
505
506 module StrapMountProtrusion(half_x, max_y, cnr){
507   translate(smc_pos){
508     linear_extrude(height=sm_main_width, convexity=10){
509       hull(){
510         for (m = [0,1]) mirror([m,0,0]) {
511           translate([-(half_x - cnr), max_y - cnr])
512             circle(r=cnr);
513           translate([-half_x, -sm_inner_rad])
514             square([1,1]);
515         }
516       }
517     }
518   }
519 }
520
521 module StrapMount(){ ////toplevel
522   SomeStrap(){
523     rotate([0,0,180]){
524       StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
525                            strap_hoop_thick,
526                            sm_closure_cnr);
527       translate(smc_pos +
528                 [0,0, sm_main_width] +
529                 strap_hoop_thick * [ 0, 0.5, -1.0 ])
530         StrapHoop();
531     }
532     union(){ };
533   }
534 }
535
536 module CatchCoreProfile(){ ////toplevel
537   hull(){
538     translate(cppB) circle(r= catch_knob_dia/2);
539     polygon([cpp4,
540              cppB,
541              cpp3]);
542   }
543   translate(cpp8)
544     circle(catch_cr);
545   polygon([
546            cpp4,
547            cppB,
548            cpp3,
549            cpp2,
550            cpp1,
551            cpp12,
552            ]);
553   difference(){
554     polygon([ cpp4,
555               cpp3,
556               cpp12,
557               cppA,
558               cppE,
559               cppD,
560               cppC,
561               cpp9,
562               cpp10,
563               cpp11,
564               cpp7,
565               cpp5,
566               ], convexity=10);
567     hull(){
568       translate(cpp7) circle(r= catch_cr);
569       polygon([ cpp7,
570                 cpp5,
571                 cpp11 ]);
572     }
573     hull(){
574       translate(cpp6) circle(catch_cr);
575       polygon([ cppA,
576                 cpp0,
577                 cpp1 ]);
578     }
579   }
580 }
581
582 module CatchCore(){ /////toplevel
583   linear_extrude(height=catch_strap_thick, convexity=10)
584     CatchCoreProfile();
585
586   translate(concat(cppB,[0])) hull(){
587     translate([0,0, catch_knob_height - catch_knob_dia/2])
588       sphere(r = catch_knob_dia/2);
589     cylinder(r = catch_knob_dia/2, h = 0.1);
590   }
591 }
592
593 module CatchPreDistort(){ /////toplevel
594   scale(100 / sm_inner_rad)
595     rotate([90,0,0])
596     CatchCore();
597 }
598
599 module CatchAssembly(){ /////toplevel
600   rotate([0,0, -0.5 * (cpp1[0] + cpp2[0]) / sm_inner_rad * 360/TAU])
601     translate([0,0, catch_strap_width])
602     scale(sm_inner_rad / 100)
603     import(str("poster-tube-lid,CatchPostDistort-fa",
604                (coarse ? 20 : 3),
605                ".stl"),
606            convexity=20);
607
608   SomeStrap(){
609     union(){ }
610     union(){
611       translate([-200, -200, -200])
612         cube([400, 200, 400]);
613     }
614   }
615 }
616
617 module CatchDemo(){ /////toplevel
618   color("blue") translate([0,0,
619              -catch_strap_width
620              -cpp0[1]
621              ])
622     CatchAssembly();
623   translate([0,0,+side_height
624              ])
625     Cover();
626 }
627
628 module CatchDemoS(){ /////toplevel
629   color("blue") translate([0,0,
630              -catch_strap_width
631              -cpp0[1]
632              ])
633     CatchAssembly();
634   intersection(){
635     translate([0,0,+side_height
636                ])
637       Cover();
638     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
639   }
640   color("black")
641     translate([0,-33,0])
642     cube([6.15, 2,2], center=true);
643 }
644
645 module CatchPinProfileDemo(){ /////toplevel
646   echo("G ",
647        cpp2[0] - cpp1[0],
648        bayo_n[0] - bayo_e[0]);
649   color("blue") translate([-cpp2[0],
650                            -cpp2[1],
651                            +1,
652              ])
653     CatchCoreProfile();
654   polygon(bayo_polygon, convexity=10);
655 }
656
657 //ProfilesDemo();
658 //BayonetCutout();
659 //MainProfile();
660 //Cover();
661 //Jig();
662 //CoverTest();