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 + 0.1;
  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 = 0.55;
  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 strap_hoop_elevation = 45;
  59
  60 // calculated
  61
  62 bayo_entry_x = bayo_entry;
  63 bayo_entry_z = bayo_entry;
  64 bayo_inramp_x = bayo_entry;
  65 bayo_inramp_z = bayo_entry;
  66
  67 oring_mid_dia = oring_bore + oring_thick;
  68 oring_outer_dia = oring_mid_dia + oring_thick;
  69
  70 oring_oblate = (1 - oring_compress);
  71
  72 oring_y_rad = oring_thick/2 * oring_oblate;
  73 oring_x_rad = oring_thick/2 / oring_oblate;
  74
  75 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  76
  77 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  78 side_thick = rivet_tall + over_rivet_wall;
  79
  80 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
  81
  82 middle_bot_z = top_z - top_thick_middle;
  83
  84 bayo_entry = bayo_behind / 3.0;
  85 bayo_top_z = bayo_behind + bayo_gap;
  86
  87 rivet_entry_width = rivet_width + side_rivet_gap;
  88
  89 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
  90
  91 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
  92 handling_angle = 45;
  93
  94 $fs= coarse ? 2.5 : 0.5;
  95 $fa= coarse ? 5 : 1;
  96
  97 // bayonet definition
  98
  99 bayo_a = [ bayo_entry_x, 0 ];
 100 bayo_p = [ 0, bayo_entry_z ];
 101 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 102 bayo_m = [ bayo_inramp_x, bayo_behind ];
 103 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 104 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 105 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 106 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 107 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 108 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 109
 110 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 111 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 112 bayo_c = bayo_d + [0,-5];
 113 bayo_b = bayo_a + [0,-5];
 114
 115 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 116
 117 bayo_polygon = [ bayo_a,
 118                  bayo_b,
 119                  bayo_c,
 120                  bayo_d,
 121                  bayo_e,
 122                  bayo_f,
 123                  bayo_g,
 124                  bayo_h,
 125                  bayo_i,
 126                  bayo_j,
 127                  bayo_k,
 128                  bayo_l,
 129                  bayo_m,
 130                  bayo_n,
 131                  bayo_p ];
 132
 133 echo(bayo_polygon);
 134
 135 module MainProfile(){
 136   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 137   difference(){
 138     union(){
 139       translate(main_cnr_pos){
 140         intersection(){
 141           difference(){
 142             circle(r = main_cnr);
 143             circle(r = main_cnr * 0.5);
 144           }
 145           square([10,10]);
 146         }
 147       }
 148       polygon([[ -top_middle_dr,        middle_bot_z      ],
 149                [ -top_middle_dr,        top_z             ],
 150                [ main_cnr_pos[0],       top_z             ],
 151                [ side_thick,            main_cnr_pos[1]   ],
 152                [ side_thick,            -side_height      ],
 153                [ side_taper,            -side_height      ],
 154                [ 0,                     -rivet_posn       ],
 155                [ 0,                     by_oring_z        ],
 156                [ -oring_x_rad,          by_oring_z        ],
 157                ],
 158               convexity=10);
 159     }
 160     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 161       hull(){
 162       translate([ 0, oring_y_rad ])
 163         scale([ 1/oring_oblate, oring_oblate ])
 164         circle(oring_thick/2);
 165       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 166         circle(oring_thick/2);
 167     }
 168   }
 169 }
 170
 171 module StrapHoopProfile(){
 172   circle(r = strap_hoop_thick/2);
 173 }
 174
 175 module StrapHoop(){ ////toplevel
 176   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 177   extralen = strap_hoop_thick * 5;
 178
 179   intersection(){
 180     rotate([strap_hoop_elevation, 0,0]){
 181       for (x= [ -1, +1 ] * bigrad) {
 182         translate([x, -extralen, 0])
 183           rotate([-90,0,0])
 184           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 185                          convexity=10)
 186           StrapHoopProfile();
 187       }
 188       translate([0, strap_hoop_strlen, 0]){
 189         intersection(){
 190           rotate_extrude(convexity=10)
 191             translate([bigrad, 0,0])
 192             StrapHoopProfile();
 193           translate([0,50,0])
 194             cube([100,100,100], center=true);
 195         }
 196       }
 197     }
 198     translate([0, 50, 0])
 199       cube(100, center=true);
 200   }
 201 }
 202
 203 module HandlingProfile(){
 204 //  translate([
 205 }
 206
 207 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 208   // nom_rad > real_rad
 209   rotate([0,0, atan2(offset, nom_rad) ]){
 210     intersection(){
 211       translate([-offset, -10, 0])
 212         rotate([90,0,0])
 213         linear_extrude(height= nom_rad*2)
 214         children(0);
 215       translate([0,0, -25])
 216         cylinder(h=50, r= real_rad);
 217       translate([0,0, -25])
 218         linear_extrude(height= 50)
 219         polygon([ [ 0,0 ],
 220                   [ -slice_size, -real_rad*2 ],
 221                   [ +slice_size, -real_rad*2 ] ]);
 222     }
 223   }
 224 }
 225
 226 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 227   offs = [ for (i=[ x_min :
 228                     slice_size :
 229                     x_max + slice_size ]) i ];
 230   echo (offs);
 231   for (off=offs)
 232     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 233     children(0);
 234 }
 235
 236 module BayonetCutout(){
 237   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 238                 main_dia/2 + side_thick,
 239                 main_dia/2 + rivet_tall)
 240     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 241     polygon(bayo_polygon, convexity=10);
 242 }
 243
 244 module ProfilesDemo(){ ////toplevel
 245   translate([-10,0]) MainProfile();
 246   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 247 }
 248
 249 module LimitForHandling(){ ////toplevel
 250   hull() for (r=[0,180])
 251     rotate([0,0,r]) {
 252       for (rs=[-1,+1]) {
 253         for (xd=[0,1]) {
 254           rotate([0,0, rs * handling_angle/2]) {
 255             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 256                        main_dia/2 + side_thick - main_cnr,
 257                        top_z - main_cnr]) {
 258               mirror([0,0,1])
 259                 cylinder(r= main_cnr, h=50);
 260               sphere(main_cnr);
 261             }
 262           }
 263         }
 264       }
 265     }
 266   hull() rotate_extrude(){
 267     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 268       circle(r = main_cnr);
 269       mirror([0,1]) square([ main_cnr, 50 ]);
 270     }
 271   }
 272   //cylinder(r= handling_dia/2, h=20);
 273 }
 274
 275 module Cover(){ ////toplevel
 276   render() difference(){
 277     intersection(){
 278       union(){
 279         rotate_extrude(convexity=10)
 280           translate([main_dia/2, 0])
 281           MainProfile();
 282         translate([0,0, middle_bot_z])
 283           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 284       }
 285       LimitForHandling();
 286     }
 287     for (r=[0,180]){
 288       rotate([0,0, r])
 289         translate([0,0, -side_height])
 290         BayonetCutout();
 291       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 292         translate([0,
 293                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 294                    oring_y_rad * 1.5])
 295         rotate([-oring_rm_angle, 0, 0])
 296         mirror([0,0,1])
 297         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 298     }
 299     for (r=[0 : 60 : 179]) {
 300       rotate([0,0, r]) {
 301         height = top_thick_middle - brace_above_below*2;
 302         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 303         cube(center=true, [ oring_bore - brace_end_shorter,
 304                             brace_hole_width, height ]);
 305       }
 306     }
 307   }
 308 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 309 //    translate([handling_dia/2, 0, -side_height])
 310 //    rotate([0,180,0]) rotate([0,0,90])
 311 //    StrapHoop();
 312 }
 313
 314 module SavingHole(){
 315   translate([0,0, -10])
 316     cylinder(r= main_dia/2 - jig_rim, h=20);
 317 }
 318
 319 module Jig(){ ////toplevel
 320   difference(){
 321     union(){
 322       translate([0,0, -side_height]){
 323         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 324       }
 325       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 326         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 327     }
 328     translate([0,0, -side_height-1])
 329       cylinder(r= main_dia/2, h= side_height + 1);
 330     SavingHole();
 331     translate([0,0, -rivet_posn])
 332       rotate([90, 0,0])
 333       translate([0,0, -100])
 334       cylinder(r= jig_hole_dia/2, h = 200);
 335   }
 336 }
 337
 338 module CoverTest2(){ ////toplevel
 339   difference(){
 340     Cover();
 341     SavingHole();
 342   }
 343 }
 344
 345 module CoverTest1(){ ////toplevel
 346   difference(){
 347     CoverTest2();
 348     difference(){
 349       for (r= [ 40, 147 ]){
 350         rotate([0,0, r]){
 351           translate([0,0, -10]) {
 352             cube([ main_dia*3, main_dia * .53, 18], center=true);
 353           }
 354         }
 355       }
 356 //      translate([ 50, 0, 0 ])
 357 //      cube([ 100,
 358 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 359 //             100 ],
 360 //           center=true);
 361     }
 362   }
 363 }
 364
 365 //ProfilesDemo();
 366 //BayonetCutout();
 367 //MainProfile();
 368 //Cover();
 369 //Jig();
 370 //CoverTest();