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