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