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 + 0.6;
  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 = 0.85;
  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
  34 oring_rm_beside = 8;
  35 oring_rm_scale = 2.0;
  36 oring_rm_angle = 20;
  37
  38 side_taper = 1.0;
  39
  40 bayo_gap = 6.0;
  41
  42 bayo_entry = bayo_behind/3;
  43
  44 bayo_slice_size = coarse ? 5 : 1;
  45
  46 brace_hole_width = 1.0;
  47 brace_above_below = 1.2;
  48 brace_end_shorter = 0.3;
  49
  50 jig_thick = 1.4;
  51 jig_hole_dia = 3.0;
  52 jig_rim = 5;
  53 jig_mark = 5;
  54
  55 strap_hoop_thick = 6;
  56 strap_hoop_inside = 10;
  57 strap_hoop_strlen = 10;
  58
  59 // calculated
  60
  61 bayo_entry_x = bayo_entry;
  62 bayo_entry_z = bayo_entry;
  63 bayo_inramp_x = bayo_entry;
  64 bayo_inramp_z = bayo_entry;
  65
  66 oring_mid_dia = oring_bore + oring_thick;
  67 oring_outer_dia = oring_mid_dia + oring_thick;
  68
  69 oring_oblate = (1 - oring_compress);
  70
  71 oring_y_rad = oring_thick/2 * oring_oblate;
  72 oring_x_rad = oring_thick/2 / oring_oblate;
  73
  74 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  75
  76 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  77 side_thick = rivet_tall + over_rivet_wall;
  78
  79 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
  80
  81 middle_bot_z = top_z - top_thick_middle;
  82
  83 bayo_entry = bayo_behind / 3.0;
  84 bayo_top_z = bayo_behind + bayo_gap;
  85
  86 rivet_entry_width = rivet_width + side_rivet_gap;
  87
  88 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
  89
  90 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
  91 handling_angle = 45;
  92
  93 $fs= coarse ? 2.5 : 0.5;
  94 $fa= coarse ? 5 : 1;
  95
  96 // bayonet definition
  97
  98 bayo_a = [ bayo_entry_x, 0 ];
  99 bayo_p = [ 0, bayo_entry_z ];
 100 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 101 bayo_m = [ bayo_inramp_x, bayo_behind ];
 102 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 103 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 104 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 105 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 106 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 107 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 108
 109 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 110 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 111 bayo_c = bayo_d + [0,-5];
 112 bayo_b = bayo_a + [0,-5];
 113
 114 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 115
 116 bayo_polygon = [ bayo_a,
 117                  bayo_b,
 118                  bayo_c,
 119                  bayo_d,
 120                  bayo_e,
 121                  bayo_f,
 122                  bayo_g,
 123                  bayo_h,
 124                  bayo_i,
 125                  bayo_j,
 126                  bayo_k,
 127                  bayo_l,
 128                  bayo_m,
 129                  bayo_n,
 130                  bayo_p ];
 131
 132 echo(bayo_polygon);
 133
 134 module MainProfile(){
 135   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 136   difference(){
 137     union(){
 138       translate(main_cnr_pos){
 139         intersection(){
 140           difference(){
 141             circle(r = main_cnr);
 142             circle(r = main_cnr * 0.5);
 143           }
 144           square([10,10]);
 145         }
 146       }
 147       polygon([[ -top_middle_dr,        middle_bot_z      ],
 148                [ -top_middle_dr,        top_z             ],
 149                [ main_cnr_pos[0],       top_z             ],
 150                [ side_thick,            main_cnr_pos[1]   ],
 151                [ side_thick,            -side_height      ],
 152                [ side_taper,            -side_height      ],
 153                [ 0,                     -rivet_posn       ],
 154                [ 0,                     by_oring_z        ],
 155                [ -oring_x_rad,          by_oring_z        ],
 156                ],
 157               convexity=10);
 158     }
 159     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 160       hull(){
 161       translate([ 0, oring_y_rad ])
 162         scale([ 1/oring_oblate, oring_oblate ])
 163         circle(oring_thick/2);
 164       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 165         circle(oring_thick/2);
 166     }
 167   }
 168 }
 169
 170 module StrapHoopProfile(){
 171   circle(r = strap_hoop_thick/2);
 172 }
 173
 174 module StrapHoop(){ ////toplevel
 175   bigrad = strap_hoop_inside + strap_hoop_thick/2;
 176   extralen = strap_hoop_thick;
 177
 178   for (x= [ -1, +1 ] * bigrad) {
 179     translate([x, -extralen, 0])
 180       rotate([-90,0,0])
 181       linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 182                      convexity=10)
 183       StrapHoopProfile();
 184   }
 185   translate([0, strap_hoop_strlen, 0]){
 186     intersection(){
 187       rotate_extrude(convexity=10)
 188         translate([bigrad, 0,0])
 189         StrapHoopProfile();
 190       translate([0,50,0])
 191         cube([100,100,100], center=true);
 192     }
 193   }
 194 }
 195
 196 module HandlingProfile(){
 197 //  translate([
 198 }
 199
 200 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 201   // nom_rad > real_rad
 202   rotate([0,0, atan2(offset, nom_rad) ]){
 203     intersection(){
 204       translate([-offset, -10, 0])
 205         rotate([90,0,0])
 206         linear_extrude(height= nom_rad*2)
 207         children(0);
 208       translate([0,0, -25])
 209         cylinder(h=50, r= real_rad);
 210       translate([0,0, -25])
 211         linear_extrude(height= 50)
 212         polygon([ [ 0,0 ],
 213                   [ -slice_size, -real_rad*2 ],
 214                   [ +slice_size, -real_rad*2 ] ]);
 215     }
 216   }
 217 }
 218
 219 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 220   offs = [ for (i=[ x_min :
 221                     slice_size :
 222                     x_max + slice_size ]) i ];
 223   echo (offs);
 224   for (off=offs)
 225     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 226     children(0);
 227 }
 228
 229 module BayonetCutout(){
 230   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 231                 main_dia/2 + side_thick,
 232                 main_dia/2 + rivet_tall)
 233     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 234     polygon(bayo_polygon, convexity=10);
 235 }
 236
 237 module ProfilesDemo(){ ////toplevel
 238   translate([-10,0]) MainProfile();
 239   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 240 }
 241
 242 module LimitForHandling(){ ////toplevel
 243   hull() for (r=[0,180])
 244     rotate([0,0,r]) {
 245       for (rs=[-1,+1]) {
 246         for (xd=[0,1]) {
 247           rotate([0,0, rs * handling_angle/2]) {
 248             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 249                        main_dia/2 + side_thick - main_cnr,
 250                        top_z - main_cnr]) {
 251               mirror([0,0,1])
 252                 cylinder(r= main_cnr, h=50);
 253               sphere(main_cnr);
 254             }
 255           }
 256         }
 257       }
 258     }
 259   hull() rotate_extrude(){
 260     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 261       circle(r = main_cnr);
 262       mirror([0,1]) square([ main_cnr, 50 ]);
 263     }
 264   }
 265   //cylinder(r= handling_dia/2, h=20);
 266 }
 267
 268 module Cover(){ ////toplevel
 269   render() difference(){
 270     intersection(){
 271       union(){
 272         rotate_extrude(convexity=10)
 273           translate([main_dia/2, 0])
 274           MainProfile();
 275         translate([0,0, middle_bot_z])
 276           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 277       }
 278       LimitForHandling();
 279     }
 280     for (r=[0,180]){
 281       rotate([0,0, r])
 282         translate([0,0, -side_height])
 283         BayonetCutout();
 284       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 285         translate([0,
 286                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 287                    oring_y_rad * 1.5])
 288         rotate([-oring_rm_angle, 0, 0])
 289         mirror([0,0,1])
 290         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 291     }
 292     for (r=[0 : 60 : 179]) {
 293       rotate([0,0, r]) {
 294         height = top_thick_middle - brace_above_below*2;
 295         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 296         cube(center=true, [ oring_bore - brace_end_shorter,
 297                             brace_hole_width, height ]);
 298       }
 299     }
 300   }
 301   translate([handling_dia/2, 0, -side_height])
 302     rotate([0,0,-90])
 303     rotate([-45, 0,0])
 304     StrapHoop();
 305 }
 306
 307 module SavingHole(){
 308   translate([0,0, -10])
 309     cylinder(r= main_dia/2 - jig_rim, h=20);
 310 }
 311
 312 module Jig(){ ////toplevel
 313   difference(){
 314     union(){
 315       translate([0,0, -side_height]){
 316         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 317       }
 318       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 319         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 320     }
 321     translate([0,0, -side_height-1])
 322       cylinder(r= main_dia/2, h= side_height + 1);
 323     SavingHole();
 324     translate([0,0, -rivet_posn])
 325       rotate([90, 0,0])
 326       translate([0,0, -100])
 327       cylinder(r= jig_hole_dia/2, h = 200);
 328   }
 329 }
 330
 331 module CoverTest2(){ ////toplevel
 332   difference(){
 333     Cover();
 334     SavingHole();
 335   }
 336 }
 337
 338 module CoverTest1(){ ////toplevel
 339   difference(){
 340     CoverTest2();
 341     for (r= [ 40, 147 ]){
 342       rotate([0,0, r]){
 343         translate([0,0, -10]) {
 344           cube([ main_dia*3, main_dia * .55, 18], center=true);
 345         }
 346       }
 347     }
 348   }
 349 }
 350
 351 //ProfilesDemo();
 352 //BayonetCutout();
 353 //MainProfile();
 354 //Cover();
 355 //Jig();
 356 //CoverTest();