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 catch_hook_slope = 0.15;
  90
  91 // calculated
  92
  93 TAU = PI*2;
  94
  95 bayo_entry_x = bayo_entry;
  96 bayo_entry_z = bayo_entry;
  97 bayo_inramp_x = bayo_entry;
  98 bayo_inramp_z = bayo_entry;
  99
 100 oring_mid_dia = oring_bore + oring_thick;
 101 oring_outer_dia = oring_mid_dia + oring_thick;
 102
 103 oring_oblate = (1 - oring_compress);
 104
 105 oring_y_rad = oring_thick/2 * oring_oblate;
 106 oring_x_rad = oring_thick/2 / oring_oblate;
 107
 108 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 109
 110 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 111 side_thick = rivet_tall + over_rivet_wall;
 112
 113 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 114
 115 middle_bot_z = top_z - top_thick_middle;
 116
 117 bayo_entry = bayo_behind / 3.0;
 118 bayo_top_z = bayo_behind + bayo_gap;
 119
 120 bayo_nom_rad = main_dia/2 + side_thick;
 121 bayo_real_rad = main_dia/2 + rivet_tall;
 122
 123 rivet_entry_width = rivet_width + side_rivet_gap;
 124
 125 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 126
 127 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 128 handling_angle = 45;
 129
 130 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 131 sm_outer_rad = sm_inner_rad + sm_main_thick;
 132
 133 smc_pos = [ 0, sm_inner_rad, 0 ];
 134
 135 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 136 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 137
 138 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 139 smc_max_y = smc_bolt_y + sm_bolt_y_over
 140   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 141 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 142   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 143
 144 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
 145 catch_strap_width = sm_main_width;
 146 catch_strap_thick = sm_main_thick;
 147 catch_stem_end_h = catch_stem_h;
 148 catch_pin_width = (rivet_entry_width * sm_inner_rad / bayo_nom_rad)
 149                    - catch_pin_gap;
 150
 151 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 152
 153 cppy6 = -catch_strap_width/2;
 154 cppxC = 0.34 * sm_inner_rad * TAU;
 155 cppB = [ catch_pin_width/2,
 156          cppy6
 157          + catch_stem_below_gap
 158          + catch_pin_height
 159          + catch_knob_dia/2 ];
 160 cpp0 = [ 0,
 161          cppB[1]
 162          + catch_knob_dia
 163          + catch_knob_above_gap ];
 164 cpp12 = cpp0 + [1,0] * (catch_pin_height * catch_hook_slope);
 165 cpp1 = cpp0 + [0,1] * catch_pin_height;
 166 cpp2 = cpp1 + [1,0] * catch_pin_width;
 167 cpp4 = cpp0 + [0,-1] * catch_stem_end_h;
 168 cpp3 = [ cpp2[0], cpp4[1] ];
 169 cpp5 = [ cpp0[0] - catch_stem_len,
 170          -catch_stem_h ];
 171 cpp6 = [ cpp5[0], catch_cr ];
 172 cpp7 = cppB + [1,-1] * catch_knob_dia/2
 173             + [ catch_stem_beside_gap, -catch_stem_below_gap ]
 174             + [ 0, -catch_pin_height ]
 175             + [-1,1] * catch_cr;
 176 cpp11 = cpp7 + [1,0] * catch_cr;
 177 cpp10 = [ cpp11[0], 0 - catch_cr ];
 178 cpp8 = cpp10 + [1,0] * catch_cr;
 179 cpp9 = cpp8 + [0,1] * catch_cr;
 180 cppC = [ cppxC, cpp9[1] ];
 181 cppA = [ -cppxC, 0 ];
 182 cppD = cppC + [0,-1] * catch_strap_width;
 183 cppE = [ cppA[0], cppD[1] ];
 184
 185 $fs= coarse ? 2.5 : 0.5;
 186 $fa= coarse ? 5 : 1;
 187
 188 include <poster-tube-lid-parametric.scad>
 189
 190 // bayonet definition
 191
 192 bayo_a = [ bayo_entry_x, 0 ];
 193 bayo_p = [ 0, bayo_entry_z ];
 194 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 195 bayo_m = [ bayo_inramp_x, bayo_behind ];
 196 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 197 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 198 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 199 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 200 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 201 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 202
 203 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 204 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 205 bayo_c = bayo_d + [0,-5];
 206 bayo_b = bayo_a + [0,-5];
 207
 208 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 209
 210 bayo_polygon = [ bayo_a,
 211                  bayo_b,
 212                  bayo_c,
 213                  bayo_d,
 214                  bayo_e,
 215                  bayo_f,
 216                  bayo_g,
 217                  bayo_h,
 218                  bayo_i,
 219                  bayo_j,
 220                  bayo_k,
 221                  bayo_l,
 222                  bayo_m,
 223                  bayo_n,
 224                  bayo_p ];
 225
 226 echo(bayo_polygon);
 227
 228 module MainProfile(){
 229   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 230   difference(){
 231     union(){
 232       translate(main_cnr_pos){
 233         intersection(){
 234           difference(){
 235             circle(r = main_cnr);
 236             circle(r = main_cnr * 0.5);
 237           }
 238           square([10,10]);
 239         }
 240       }
 241       polygon([[ -top_middle_dr,        middle_bot_z      ],
 242                [ -top_middle_dr,        top_z             ],
 243                [ main_cnr_pos[0],       top_z             ],
 244                [ side_thick,            main_cnr_pos[1]   ],
 245                [ side_thick,            -side_height      ],
 246                [ side_taper,            -side_height      ],
 247                [ 0,                     -rivet_posn       ],
 248                [ 0,                     by_oring_z        ],
 249                [ -oring_x_rad,          by_oring_z        ],
 250                ],
 251               convexity=10);
 252     }
 253     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 254       hull(){
 255       translate([ 0, oring_y_rad ])
 256         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 257         circle(oring_thick/2);
 258       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 259         circle(oring_thick/2);
 260     }
 261   }
 262 }
 263
 264 module StrapHoopProfile(){
 265   circle(r = strap_hoop_thick/2);
 266 }
 267
 268 module StrapHoop(){ ////toplevel
 269   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 270   extralen = strap_hoop_thick * 5;
 271
 272   intersection(){
 273     rotate([strap_hoop_elevation, 0,0]){
 274       for (x= [ -1, +1 ] * bigrad) {
 275         translate([x, -extralen, 0])
 276           rotate([-90,0,0])
 277           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 278                          convexity=10)
 279           StrapHoopProfile();
 280       }
 281       translate([0, strap_hoop_strlen, 0]){
 282         intersection(){
 283           rotate_extrude(convexity=10)
 284             translate([bigrad, 0,0])
 285             StrapHoopProfile();
 286           translate([0,50,0])
 287             cube([100,100,100], center=true);
 288         }
 289       }
 290     }
 291     translate([0, 50, 0])
 292       cube(100, center=true);
 293   }
 294 }
 295
 296 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 297   // nom_rad > real_rad
 298   rotate([0,0, atan2(offset, nom_rad) ]){
 299     intersection(){
 300       translate([-offset, -10, 0])
 301         rotate([90,0,0])
 302         linear_extrude(height= nom_rad*2)
 303         children(0);
 304       translate([0,0, -25])
 305         cylinder(h=50, r= real_rad);
 306       translate([0,0, -25])
 307         linear_extrude(height= 50)
 308         polygon([ [ 0,0 ],
 309                   [ -slice_size, -real_rad*2 ],
 310                   [ +slice_size, -real_rad*2 ] ]);
 311     }
 312   }
 313 }
 314
 315 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 316   offs = [ for (i=[ x_min :
 317                     slice_size :
 318                     x_max + slice_size ]) i ];
 319   echo (offs);
 320   for (off=offs)
 321     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 322     children(0);
 323 }
 324
 325 module BayonetCutout(){
 326   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 327                 bayo_nom_rad,
 328                 bayo_real_rad)
 329     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 330     polygon(bayo_polygon, convexity=10);
 331 }
 332
 333 module ProfilesDemo(){ ////toplevel
 334   translate([-10,0]) MainProfile();
 335   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 336 }
 337
 338 module LimitForHandling(){ ////toplevel
 339   hull() for (r=[0,180])
 340     rotate([0,0,r]) {
 341       for (rs=[-1,+1]) {
 342         for (xd=[0,1]) {
 343           rotate([0,0, rs * handling_angle/2]) {
 344             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 345                        main_dia/2 + side_thick - main_cnr,
 346                        top_z - main_cnr]) {
 347               mirror([0,0,1])
 348                 cylinder(r= main_cnr, h=50);
 349               sphere(main_cnr);
 350             }
 351           }
 352         }
 353       }
 354     }
 355   hull() rotate_extrude(){
 356     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 357       circle(r = main_cnr);
 358       mirror([0,1]) square([ main_cnr, 50 ]);
 359     }
 360   }
 361   //cylinder(r= handling_dia/2, h=20);
 362 }
 363
 364 module Cover(){ ////toplevel
 365   render() difference(){
 366     intersection(){
 367       union(){
 368         rotate_extrude(convexity=10)
 369           translate([main_dia/2, 0])
 370           MainProfile();
 371         translate([0,0, middle_bot_z])
 372           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 373       }
 374       LimitForHandling();
 375     }
 376     for (r=[0,180]){
 377       rotate([0,0, r])
 378         translate([0,0, -side_height])
 379         BayonetCutout();
 380       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 381         translate([0,
 382                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 383                    oring_y_rad * 1.5])
 384         rotate([-oring_rm_angle, 0, 0])
 385         mirror([0,0,1])
 386         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 387     }
 388     for (r=[0 : 60 : 179]) {
 389       rotate([0,0, r]) {
 390         height = top_thick_middle - brace_above_below*2;
 391         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 392         cube(center=true, [ oring_bore - brace_end_shorter,
 393                             brace_hole_width, height ]);
 394       }
 395     }
 396   }
 397   for (r=[0,180])
 398     rotate([0,0,r])
 399       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 400                  -implheadcup_large_dia * .0,
 401                  middle_bot_z + 0.1])
 402       ImplHeadCup();
 403 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 404 //    translate([handling_dia/2, 0, -side_height])
 405 //    rotate([0,180,0]) rotate([0,0,90])
 406 //    StrapHoop();
 407 }
 408
 409 module SavingHole(){
 410   translate([0,0, -10])
 411     cylinder(r= main_dia/2 - jig_rim, h=20);
 412 }
 413
 414 module Jig(){ ////toplevel
 415   difference(){
 416     union(){
 417       translate([0,0, -side_height]){
 418         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 419       }
 420       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 421         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 422     }
 423     translate([0,0, -side_height-1])
 424       cylinder(r= main_dia/2, h= side_height + 1);
 425     SavingHole();
 426     translate([0,0, -rivet_posn])
 427       rotate([90, 0,0])
 428       translate([0,0, -100])
 429       cylinder(r= jig_hole_dia/2, h = 200);
 430   }
 431 }
 432
 433 module CoverTest2(){ ////toplevel
 434   difference(){
 435     Cover();
 436     SavingHole();
 437   }
 438 }
 439
 440 module CoverTest1(){ ////toplevel
 441   difference(){
 442     CoverTest2();
 443     difference(){
 444       for (r= [ 40, 147 ]){
 445         rotate([0,0, r]){
 446           translate([0,0, -10]) {
 447             cube([ main_dia*3, main_dia * .53, 18], center=true);
 448           }
 449         }
 450       }
 451 //      translate([ 50, 0, 0 ])
 452 //      cube([ 100,
 453 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 454 //             100 ],
 455 //           center=true);
 456     }
 457   }
 458 }
 459
 460 module ImplHeadCupTest(){ ////toplevel
 461   for (r=[0,180])
 462     rotate([0,0,r])
 463       translate([-17,0,0])
 464       ImplHeadCup();
 465 }
 466
 467 module SomeStrap(){
 468   // children(0) is to add, (1) subtract
 469   difference(){
 470     union(){
 471       cylinder(r=sm_outer_rad, h=sm_main_width);
 472       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 473                            smc_max_y,
 474                            sm_closure_cnr);
 475       children(0);
 476     }
 477     translate([0,0,-1])
 478       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 479     translate(smc_pos)
 480       StrapMountBolt(10);
 481     translate(smc_pos)
 482       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 483     children(1);
 484   }
 485 }
 486
 487 module StrapMountBolt(l_delta){ ///toplevel
 488   // positioned relative to smc_pos
 489   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 490              smc_bolt_y,
 491              sm_main_width/2]){
 492     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 493       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 494     }
 495     translate([ -sm_bolt_shaft/2, 0,0 ])
 496       rotate([0,-90,0])
 497       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 498                h=smc_bolt_nut_eff_thick + l_delta);
 499     translate([ sm_bolt_shaft/2, 0,0 ])
 500       rotate([0,90,0])
 501       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 502   }
 503 }
 504
 505 module StrapMountProtrusion(half_x, max_y, cnr){
 506   translate(smc_pos){
 507     linear_extrude(height=sm_main_width, convexity=10){
 508       hull(){
 509         for (m = [0,1]) mirror([m,0,0]) {
 510           translate([-(half_x - cnr), max_y - cnr])
 511             circle(r=cnr);
 512           translate([-half_x, -sm_inner_rad])
 513             square([1,1]);
 514         }
 515       }
 516     }
 517   }
 518 }
 519
 520 module StrapMount(){ ////toplevel
 521   SomeStrap(){
 522     rotate([0,0,180]){
 523       StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
 524                            strap_hoop_thick,
 525                            sm_closure_cnr);
 526       translate(smc_pos +
 527                 [0,0, sm_main_width] +
 528                 strap_hoop_thick * [ 0, 0.5, -1.0 ])
 529         StrapHoop();
 530     }
 531     union(){ };
 532   }
 533 }
 534
 535 module CatchCoreProfile(){ ////toplevel
 536   hull(){
 537     translate(cppB) circle(r= catch_knob_dia/2);
 538     polygon([cpp4,
 539              cppB,
 540              cpp3]);
 541   }
 542   translate(cpp8)
 543     circle(catch_cr);
 544   polygon([
 545            cpp4,
 546            cppB,
 547            cpp3,
 548            cpp2,
 549            cpp1,
 550            cpp12,
 551            ]);
 552   difference(){
 553     polygon([ cpp4,
 554               cpp3,
 555               cpp12,
 556               cppA,
 557               cppE,
 558               cppD,
 559               cppC,
 560               cpp9,
 561               cpp10,
 562               cpp11,
 563               cpp7,
 564               cpp5,
 565               ], convexity=10);
 566     hull(){
 567       translate(cpp7) circle(r= catch_cr);
 568       polygon([ cpp7,
 569                 cpp5,
 570                 cpp11 ]);
 571     }
 572     hull(){
 573       translate(cpp6) circle(catch_cr);
 574       polygon([ cppA,
 575                 cpp0,
 576                 cpp1 ]);
 577     }
 578   }
 579 }
 580
 581 module CatchPreDistort(){ /////toplevel
 582   scale(100 / sm_inner_rad)
 583     rotate([90,0,0])
 584     linear_extrude(height=catch_strap_thick, convexity=10)
 585     CatchCoreProfile();
 586 }
 587
 588 module CatchAssembly(){ /////toplevel
 589   rotate([0,0, -0.5 * (cpp1[0] + cpp2[0]) / sm_inner_rad * 360/TAU])
 590     translate([0,0, catch_strap_width])
 591     scale(sm_inner_rad / 100)
 592     import(str("poster-tube-lid,CatchPostDistort-fa",
 593                (coarse ? 20 : 3),
 594                ".stl"),
 595            convexity=20);
 596
 597   SomeStrap(){
 598     union(){ }
 599     union(){
 600       translate([-200, -200, -200])
 601         cube([400, 200, 400]);
 602     }
 603   }
 604 }
 605
 606 module CatchDemo(){ /////toplevel
 607   color("blue") translate([0,0,
 608              -catch_strap_width
 609              -cpp0[1]
 610              ])
 611     CatchAssembly();
 612   translate([0,0,+side_height
 613              ])
 614     Cover();
 615 }
 616
 617 module CatchDemoS(){ /////toplevel
 618   color("blue") translate([0,0,
 619              -catch_strap_width
 620              -cpp0[1]
 621              ])
 622     CatchAssembly();
 623   intersection(){
 624     translate([0,0,+side_height
 625                ])
 626       Cover();
 627     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 628   }
 629   color("black")
 630     translate([0,-33,0])
 631     cube([6.15, 2,2], center=true);
 632 }
 633
 634 module CatchPinProfileDemo(){ /////toplevel
 635   echo("G ",
 636        cpp2[0] - cpp1[0],
 637        bayo_n[0] - bayo_e[0]);
 638   color("blue") translate([-cpp2[0],
 639                            -cpp2[1],
 640                            +1,
 641              ])
 642     CatchCoreProfile();
 643   polygon(bayo_polygon, convexity=10);
 644 }
 645
 646 //ProfilesDemo();
 647 //BayonetCutout();
 648 //MainProfile();
 649 //Cover();
 650 //Jig();
 651 //CoverTest();