poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 main_dia = 71.2 + 0.50 - 2.26;
   4 top_thick_middle = 4;
   5 top_thick_by_oring = 2.5;
   6 top_middle_dr = 11;
   7
   8 main_cnr = 4.0;
   9
  10 rivet_posn = 6.0;
  11 rivet_thick = 1.67;
  12 rivet_width = 4.15 + 1.0;
  13 rivet_tall = 5.51 + 0.49;
  14
  15 over_rivet_wall = 0.5;
  16 side_rivet_gap = 1.5;
  17
  18 bayo_interf = 1.25;
  19 bayo_behind = 3.5;
  20 bayo_interf_width = 2.0;
  21 bayo_interf_slope = 0.75;
  22
  23 oring_thick = 5.0;
  24 oring_bore = 62.0;
  25
  26 oring_upper_embed_angle = 80;
  27 oring_compress = 0.1; // proportion
  28
  29 side_taper = 1.0;
  30
  31 bayo_above_gap = 1.0;
  32
  33 bayo_entry = bayo_behind/3;
  34
  35 bayo_slice_size = 1;
  36
  37 brace_hole_width = 1.0;
  38 brace_above_below = 1.2;
  39 brace_end_shorter = 0.3;
  40
  41 jig_thick = 1.4;
  42 jig_hole_dia = 3.0;
  43 jig_rim = 5;
  44 jig_mark = 5;
  45
  46 // calculated
  47
  48 bayo_entry_x = bayo_entry;
  49 bayo_entry_z = bayo_entry;
  50 bayo_inramp_x = bayo_entry;
  51 bayo_inramp_z = bayo_entry;
  52
  53 oring_mid_dia = oring_bore + oring_thick;
  54 oring_outer_dia = oring_mid_dia + oring_thick;
  55
  56 oring_oblate = (1 - oring_compress);
  57
  58 oring_y_rad = oring_thick/2 * oring_oblate;
  59 oring_x_rad = oring_thick/2 / oring_oblate;
  60
  61 seal_thick = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  62
  63 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  64 side_thick = rivet_tall + over_rivet_wall;
  65
  66 top_z = top_thick_by_oring + oring_y_rad + seal_thick;
  67
  68 middle_bot_z = top_z - top_thick_middle;
  69
  70 bayo_entry = bayo_behind / 3.0;
  71 bayo_top_z = bayo_behind + rivet_thick + bayo_above_gap;
  72 bayo_entry_ramp = bayo_entry + bayo_interf;
  73
  74 rivet_entry_width = rivet_width + side_rivet_gap;
  75
  76 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
  77
  78 $fs=0.5;
  79 $fa=1;
  80
  81 // bayonet definition
  82
  83 bayo_a = [ bayo_entry_x, 0 ];
  84 bayo_p = [ 0, bayo_entry_z ];
  85 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
  86 bayo_m = [ bayo_inramp_x, bayo_behind ];
  87 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
  88 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
  89 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
  90 bayo_i = bayo_j + [ rivet_width, 0 ];
  91 bayo_h = [ bayo_i[0], bayo_behind + rivet_thick
  92                       + bayo_above_gap + bayo_interf ];
  93 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
  94
  95 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
  96 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
  97 bayo_c = bayo_d + [0,-5];
  98 bayo_b = bayo_a + [0,-5];
  99
 100 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 101
 102 bayo_polygon = [ bayo_a,
 103                  bayo_b,
 104                  bayo_c,
 105                  bayo_d,
 106                  bayo_e,
 107                  bayo_f,
 108                  bayo_g,
 109                  bayo_h,
 110                  bayo_i,
 111                  bayo_j,
 112                  bayo_k,
 113                  bayo_l,
 114                  bayo_m,
 115                  bayo_n,
 116                  bayo_p ];
 117
 118 echo(bayo_polygon);
 119
 120 module MainProfile(){
 121   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 122   difference(){
 123     union(){
 124       translate(main_cnr_pos){
 125         intersection(){
 126           difference(){
 127             circle(r = main_cnr);
 128             circle(r = main_cnr * 0.5);
 129           }
 130           square([10,10]);
 131         }
 132       }
 133       polygon([[ -top_middle_dr,        middle_bot_z      ],
 134                [ -top_middle_dr,        top_z             ],
 135                [ main_cnr_pos[0],       top_z             ],
 136                [ side_thick,            main_cnr_pos[1]   ],
 137                [ side_thick,            -side_height      ],
 138                [ side_taper,            -side_height      ],
 139                [ 0,                     -rivet_posn       ],
 140                [ 0,                     seal_thick        ],
 141                [ -oring_x_rad,          seal_thick        ],
 142                ],
 143               convexity=10);
 144     }
 145     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 146       hull(){
 147       translate([ 0, oring_y_rad ])
 148         scale([ 1/oring_oblate, oring_oblate ])
 149         circle(oring_thick/2);
 150       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 151         circle(oring_thick/2);
 152     }
 153   }
 154 }
 155
 156 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 157   // nom_rad > real_rad
 158   rotate([0,0, atan2(offset, nom_rad) ]){
 159     intersection(){
 160       translate([-offset, -10, 0])
 161         rotate([90,0,0])
 162         linear_extrude(height= nom_rad*2)
 163         children(0);
 164       translate([0,0, -25])
 165         cylinder(h=50, r= real_rad);
 166       translate([0,0, -25])
 167         linear_extrude(height= 50)
 168         polygon([ [ 0,0 ],
 169                   [ -slice_size, -real_rad*2 ],
 170                   [ +slice_size, -real_rad*2 ] ]);
 171     }
 172   }
 173 }
 174
 175 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 176   offs = [ for (i=[ x_min :
 177                     slice_size :
 178                     x_max + slice_size ]) i ];
 179   echo (offs);
 180   for (off=offs)
 181     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 182     children(0);
 183 }
 184
 185 module BayonetCutout(){
 186   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 187                 main_dia/2 + side_thick,
 188                 main_dia/2 + rivet_tall)
 189     polygon(bayo_polygon, convexity=10);
 190 }
 191
 192 module ProfilesDemo(){ ////toplevel
 193   translate([-10,0]) MainProfile();
 194   translate([+10,0]) polygon(bayo_polygon, convexity=10);
 195 }
 196
 197 module Cover(){ ////toplevel
 198   render() difference(){
 199     union(){
 200       rotate_extrude(convexity=10)
 201         translate([main_dia/2, 0])
 202         MainProfile();
 203       translate([0,0, middle_bot_z])
 204         cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 205     }
 206     for (r=[0,180])
 207       rotate([0,0, r])
 208         translate([0,0, -side_height])
 209         BayonetCutout();
 210     for (r=[0 : 60 : 179]) {
 211       rotate([0,0, r]) {
 212         height = top_thick_middle - brace_above_below*2;
 213         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 214         cube(center=true, [ oring_bore - brace_end_shorter,
 215                             brace_hole_width, height ]);
 216       }
 217     }
 218   }
 219 }
 220
 221 module SavingHole(){
 222   translate([0,0, -10])
 223     cylinder(r= main_dia/2 - jig_rim, h=20);
 224 }
 225
 226 module Jig(){ ////toplevel
 227   difference(){
 228     union(){
 229       translate([0,0, -side_height]){
 230         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 231       }
 232       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 233         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 234     }
 235     translate([0,0, -side_height-1])
 236       cylinder(r= main_dia/2, h= side_height + 1);
 237     SavingHole();
 238     translate([0,0, -rivet_posn])
 239       rotate([90, 0,0])
 240       translate([0,0, -100])
 241       cylinder(r= jig_hole_dia/2, h = 200);
 242   }
 243 }
 244
 245 module CoverTest2(){ ////toplevel
 246   difference(){
 247     Cover();
 248     SavingHole();
 249   }
 250 }
 251
 252 module CoverTest1(){ ////toplevel
 253   difference(){
 254     CoverTest2();
 255     translate([0,0, -10])
 256       cube([ main_dia*3, main_dia * .85, 20], center=true);
 257   }
 258 }
 259
 260 //ProfilesDemo();
 261 //BayonetCutout();
 262 //MainProfile();
 263 //Cover();
 264 //Jig();
 265 //CoverTest();