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