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 rivet_posn = 6.0;
  13 rivet_thick = 1.67;
  14 rivet_width = 4.15 + 1.0;
  15 rivet_tall = 5.51 + 1.49;
  16
  17 over_rivet_wall = 1.0;
  18 side_rivet_gap = 1.5;
  19
  20 bayo_interf = 1.25;
  21 bayo_behind = 3.5;
  22 bayo_interf_width = 2.0;
  23 bayo_interf_slope = 0.75;
  24
  25 oring_thick = 5.0;
  26 oring_bore = 62.0;
  27
  28 oring_upper_embed_angle = 80;
  29 oring_compress = 0.05; // proportion
  30
  31 oring_rm_beside = 10;
  32 oring_rm_scale = 2.0;
  33 oring_rm_angle = 20;
  34
  35 side_taper = 1.0;
  36
  37 bayo_above_gap = 1.0;
  38
  39 bayo_entry = bayo_behind/3;
  40
  41 bayo_slice_size = coarse ? 5 : 1;
  42
  43 brace_hole_width = 1.0;
  44 brace_above_below = 1.2;
  45 brace_end_shorter = 0.3;
  46
  47 jig_thick = 1.4;
  48 jig_hole_dia = 3.0;
  49 jig_rim = 5;
  50 jig_mark = 5;
  51
  52 // calculated
  53
  54 bayo_entry_x = bayo_entry;
  55 bayo_entry_z = bayo_entry;
  56 bayo_inramp_x = bayo_entry;
  57 bayo_inramp_z = bayo_entry;
  58
  59 oring_mid_dia = oring_bore + oring_thick;
  60 oring_outer_dia = oring_mid_dia + oring_thick;
  61
  62 oring_oblate = (1 - oring_compress);
  63
  64 oring_y_rad = oring_thick/2 * oring_oblate;
  65 oring_x_rad = oring_thick/2 / oring_oblate;
  66
  67 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  68
  69 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  70 side_thick = rivet_tall + over_rivet_wall;
  71
  72 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
  73
  74 middle_bot_z = top_z - top_thick_middle;
  75
  76 bayo_entry = bayo_behind / 3.0;
  77 bayo_top_z = bayo_behind + rivet_thick + bayo_above_gap;
  78 bayo_entry_ramp = bayo_entry + bayo_interf;
  79
  80 rivet_entry_width = rivet_width + side_rivet_gap;
  81
  82 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
  83
  84 $fs= coarse ? 2.5 : 0.5;
  85 $fa= coarse ? 5 : 1;
  86
  87 // bayonet definition
  88
  89 bayo_a = [ bayo_entry_x, 0 ];
  90 bayo_p = [ 0, bayo_entry_z ];
  91 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
  92 bayo_m = [ bayo_inramp_x, bayo_behind ];
  93 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
  94 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
  95 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
  96 bayo_i = bayo_j + [ rivet_width, 0 ];
  97 bayo_h = [ bayo_i[0], bayo_behind + rivet_thick
  98                       + bayo_above_gap + bayo_interf ];
  99 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 100
 101 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 102 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 103 bayo_c = bayo_d + [0,-5];
 104 bayo_b = bayo_a + [0,-5];
 105
 106 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 107
 108 bayo_polygon = [ bayo_a,
 109                  bayo_b,
 110                  bayo_c,
 111                  bayo_d,
 112                  bayo_e,
 113                  bayo_f,
 114                  bayo_g,
 115                  bayo_h,
 116                  bayo_i,
 117                  bayo_j,
 118                  bayo_k,
 119                  bayo_l,
 120                  bayo_m,
 121                  bayo_n,
 122                  bayo_p ];
 123
 124 echo(bayo_polygon);
 125
 126 module MainProfile(){
 127   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 128   difference(){
 129     union(){
 130       translate(main_cnr_pos){
 131         intersection(){
 132           difference(){
 133             circle(r = main_cnr);
 134             circle(r = main_cnr * 0.5);
 135           }
 136           square([10,10]);
 137         }
 138       }
 139       polygon([[ -top_middle_dr,        middle_bot_z      ],
 140                [ -top_middle_dr,        top_z             ],
 141                [ main_cnr_pos[0],       top_z             ],
 142                [ side_thick,            main_cnr_pos[1]   ],
 143                [ side_thick,            -side_height      ],
 144                [ side_taper,            -side_height      ],
 145                [ 0,                     -rivet_posn       ],
 146                [ 0,                     by_oring_z        ],
 147                [ -oring_x_rad,          by_oring_z        ],
 148                ],
 149               convexity=10);
 150     }
 151     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 152       hull(){
 153       translate([ 0, oring_y_rad ])
 154         scale([ 1/oring_oblate, oring_oblate ])
 155         circle(oring_thick/2);
 156       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 157         circle(oring_thick/2);
 158     }
 159   }
 160 }
 161
 162 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 163   // nom_rad > real_rad
 164   rotate([0,0, atan2(offset, nom_rad) ]){
 165     intersection(){
 166       translate([-offset, -10, 0])
 167         rotate([90,0,0])
 168         linear_extrude(height= nom_rad*2)
 169         children(0);
 170       translate([0,0, -25])
 171         cylinder(h=50, r= real_rad);
 172       translate([0,0, -25])
 173         linear_extrude(height= 50)
 174         polygon([ [ 0,0 ],
 175                   [ -slice_size, -real_rad*2 ],
 176                   [ +slice_size, -real_rad*2 ] ]);
 177     }
 178   }
 179 }
 180
 181 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 182   offs = [ for (i=[ x_min :
 183                     slice_size :
 184                     x_max + slice_size ]) i ];
 185   echo (offs);
 186   for (off=offs)
 187     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 188     children(0);
 189 }
 190
 191 module BayonetCutout(){
 192   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 193                 main_dia/2 + side_thick,
 194                 main_dia/2 + rivet_tall)
 195     polygon(bayo_polygon, convexity=10);
 196 }
 197
 198 module ProfilesDemo(){ ////toplevel
 199   translate([-10,0]) MainProfile();
 200   translate([+10,0]) polygon(bayo_polygon, convexity=10);
 201 }
 202
 203 module Cover(){ ////toplevel
 204   render() difference(){
 205     union(){
 206       rotate_extrude(convexity=10)
 207         translate([main_dia/2, 0])
 208         MainProfile();
 209       translate([0,0, middle_bot_z])
 210         cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 211     }
 212     for (r=[0,180]){
 213       rotate([0,0, r])
 214         translate([0,0, -side_height])
 215         BayonetCutout();
 216       rotate([0,0, r + asin((-bayo_d[0] + oring_rm_beside) / (main_dia/2))])
 217         translate([0,
 218                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 219                    oring_y_rad * 1.5])
 220         rotate([-oring_rm_angle, 0, 0])
 221         mirror([0,0,1])
 222         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 223     }
 224     for (r=[0 : 60 : 179]) {
 225       rotate([0,0, r]) {
 226         height = top_thick_middle - brace_above_below*2;
 227         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 228         cube(center=true, [ oring_bore - brace_end_shorter,
 229                             brace_hole_width, height ]);
 230       }
 231     }
 232   }
 233 }
 234
 235 module SavingHole(){
 236   translate([0,0, -10])
 237     cylinder(r= main_dia/2 - jig_rim, h=20);
 238 }
 239
 240 module Jig(){ ////toplevel
 241   difference(){
 242     union(){
 243       translate([0,0, -side_height]){
 244         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 245       }
 246       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 247         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 248     }
 249     translate([0,0, -side_height-1])
 250       cylinder(r= main_dia/2, h= side_height + 1);
 251     SavingHole();
 252     translate([0,0, -rivet_posn])
 253       rotate([90, 0,0])
 254       translate([0,0, -100])
 255       cylinder(r= jig_hole_dia/2, h = 200);
 256   }
 257 }
 258
 259 module CoverTest2(){ ////toplevel
 260   difference(){
 261     Cover();
 262     SavingHole();
 263   }
 264 }
 265
 266 module CoverTest1(){ ////toplevel
 267   difference(){
 268     CoverTest2();
 269     for (r= [ 40, 147 ]){
 270       rotate([0,0, r]){
 271         translate([0,0, -10]) {
 272           cube([ main_dia*3, main_dia * .55, 18], center=true);
 273         }
 274       }
 275     }
 276   }
 277 }
 278
 279 //ProfilesDemo();
 280 //BayonetCutout();
 281 //MainProfile();
 282 //Cover();
 283 //Jig();
 284 //CoverTest();