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 + 0.5;
  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
  22 bayo_interf = 1.25;
  23 bayo_behind = 3.5;
  24 bayo_interf_width = 2.0;
  25 bayo_interf_slope = 0.75;
  26
  27 oring_thick = 5.0;
  28 oring_bore = 62.0;
  29
  30 oring_upper_embed_angle = 80;
  31 oring_compress = 0.1; // proportion
  32
  33 oring_rm_beside = 8;
  34 oring_rm_scale = 2.0;
  35 oring_rm_angle = 20;
  36
  37 side_taper = 1.0;
  38
  39 bayo_above_gap = 1.0;
  40
  41 bayo_entry = bayo_behind/3;
  42
  43 bayo_slice_size = coarse ? 5 : 1;
  44
  45 brace_hole_width = 1.0;
  46 brace_above_below = 1.2;
  47 brace_end_shorter = 0.3;
  48
  49 jig_thick = 1.4;
  50 jig_hole_dia = 3.0;
  51 jig_rim = 5;
  52 jig_mark = 5;
  53
  54 // calculated
  55
  56 bayo_entry_x = bayo_entry;
  57 bayo_entry_z = bayo_entry;
  58 bayo_inramp_x = bayo_entry;
  59 bayo_inramp_z = bayo_entry;
  60
  61 oring_mid_dia = oring_bore + oring_thick;
  62 oring_outer_dia = oring_mid_dia + oring_thick;
  63
  64 oring_oblate = (1 - oring_compress);
  65
  66 oring_y_rad = oring_thick/2 * oring_oblate;
  67 oring_x_rad = oring_thick/2 / oring_oblate;
  68
  69 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  70
  71 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  72 side_thick = rivet_tall + over_rivet_wall;
  73
  74 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
  75
  76 middle_bot_z = top_z - top_thick_middle;
  77
  78 bayo_entry = bayo_behind / 3.0;
  79 bayo_top_z = bayo_behind + rivet_thick + bayo_above_gap;
  80 bayo_entry_ramp = bayo_entry + bayo_interf;
  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, 0 ];
 102 bayo_h = [ bayo_i[0], bayo_behind + rivet_thick
 103                       + bayo_above_gap + bayo_interf ];
 104 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 105
 106 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 107 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 108 bayo_c = bayo_d + [0,-5];
 109 bayo_b = bayo_a + [0,-5];
 110
 111 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 112
 113 bayo_polygon = [ bayo_a,
 114                  bayo_b,
 115                  bayo_c,
 116                  bayo_d,
 117                  bayo_e,
 118                  bayo_f,
 119                  bayo_g,
 120                  bayo_h,
 121                  bayo_i,
 122                  bayo_j,
 123                  bayo_k,
 124                  bayo_l,
 125                  bayo_m,
 126                  bayo_n,
 127                  bayo_p ];
 128
 129 echo(bayo_polygon);
 130
 131 module MainProfile(){
 132   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 133   difference(){
 134     union(){
 135       translate(main_cnr_pos){
 136         intersection(){
 137           difference(){
 138             circle(r = main_cnr);
 139             circle(r = main_cnr * 0.5);
 140           }
 141           square([10,10]);
 142         }
 143       }
 144       polygon([[ -top_middle_dr,        middle_bot_z      ],
 145                [ -top_middle_dr,        top_z             ],
 146                [ main_cnr_pos[0],       top_z             ],
 147                [ side_thick,            main_cnr_pos[1]   ],
 148                [ side_thick,            -side_height      ],
 149                [ side_taper,            -side_height      ],
 150                [ 0,                     -rivet_posn       ],
 151                [ 0,                     by_oring_z        ],
 152                [ -oring_x_rad,          by_oring_z        ],
 153                ],
 154               convexity=10);
 155     }
 156     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 157       hull(){
 158       translate([ 0, oring_y_rad ])
 159         scale([ 1/oring_oblate, oring_oblate ])
 160         circle(oring_thick/2);
 161       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 162         circle(oring_thick/2);
 163     }
 164   }
 165 }
 166
 167 module HandlingProfile(){
 168 //  translate([
 169 }
 170
 171 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 172   // nom_rad > real_rad
 173   rotate([0,0, atan2(offset, nom_rad) ]){
 174     intersection(){
 175       translate([-offset, -10, 0])
 176         rotate([90,0,0])
 177         linear_extrude(height= nom_rad*2)
 178         children(0);
 179       translate([0,0, -25])
 180         cylinder(h=50, r= real_rad);
 181       translate([0,0, -25])
 182         linear_extrude(height= 50)
 183         polygon([ [ 0,0 ],
 184                   [ -slice_size, -real_rad*2 ],
 185                   [ +slice_size, -real_rad*2 ] ]);
 186     }
 187   }
 188 }
 189
 190 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 191   offs = [ for (i=[ x_min :
 192                     slice_size :
 193                     x_max + slice_size ]) i ];
 194   echo (offs);
 195   for (off=offs)
 196     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 197     children(0);
 198 }
 199
 200 module BayonetCutout(){
 201   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 202                 main_dia/2 + side_thick,
 203                 main_dia/2 + rivet_tall)
 204     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 205     polygon(bayo_polygon, convexity=10);
 206 }
 207
 208 module ProfilesDemo(){ ////toplevel
 209   translate([-10,0]) MainProfile();
 210   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 211 }
 212
 213 module LimitForHandling(){ ////toplevel
 214   hull() for (r=[0,180])
 215     rotate([0,0,r]) {
 216       for (rs=[-1,+1]) {
 217         for (xd=[0,1]) {
 218           rotate([0,0, rs * handling_angle/2]) {
 219             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 220                        main_dia/2 + side_thick - main_cnr,
 221                        top_z - main_cnr]) {
 222               mirror([0,0,1])
 223                 cylinder(r= main_cnr, h=50);
 224               sphere(main_cnr);
 225             }
 226           }
 227         }
 228       }
 229     }
 230   hull() rotate_extrude(){
 231     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 232       circle(r = main_cnr);
 233       mirror([0,1]) square([ main_cnr, 50 ]);
 234     }
 235   }
 236   //cylinder(r= handling_dia/2, h=20);
 237 }
 238
 239 module Cover(){ ////toplevel
 240   render() difference(){
 241     intersection(){
 242       union(){
 243         rotate_extrude(convexity=10)
 244           translate([main_dia/2, 0])
 245           MainProfile();
 246         translate([0,0, middle_bot_z])
 247           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 248       }
 249       LimitForHandling();
 250     }
 251     for (r=[0,180]){
 252       rotate([0,0, r])
 253         translate([0,0, -side_height])
 254         BayonetCutout();
 255       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 256         translate([0,
 257                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 258                    oring_y_rad * 1.5])
 259         rotate([-oring_rm_angle, 0, 0])
 260         mirror([0,0,1])
 261         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 262     }
 263     for (r=[0 : 60 : 179]) {
 264       rotate([0,0, r]) {
 265         height = top_thick_middle - brace_above_below*2;
 266         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 267         cube(center=true, [ oring_bore - brace_end_shorter,
 268                             brace_hole_width, height ]);
 269       }
 270     }
 271   }
 272 }
 273
 274 module SavingHole(){
 275   translate([0,0, -10])
 276     cylinder(r= main_dia/2 - jig_rim, h=20);
 277 }
 278
 279 module Jig(){ ////toplevel
 280   difference(){
 281     union(){
 282       translate([0,0, -side_height]){
 283         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 284       }
 285       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 286         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 287     }
 288     translate([0,0, -side_height-1])
 289       cylinder(r= main_dia/2, h= side_height + 1);
 290     SavingHole();
 291     translate([0,0, -rivet_posn])
 292       rotate([90, 0,0])
 293       translate([0,0, -100])
 294       cylinder(r= jig_hole_dia/2, h = 200);
 295   }
 296 }
 297
 298 module CoverTest2(){ ////toplevel
 299   difference(){
 300     Cover();
 301     SavingHole();
 302   }
 303 }
 304
 305 module CoverTest1(){ ////toplevel
 306   difference(){
 307     CoverTest2();
 308     for (r= [ 40, 147 ]){
 309       rotate([0,0, r]){
 310         translate([0,0, -10]) {
 311           cube([ main_dia*3, main_dia * .55, 18], center=true);
 312         }
 313       }
 314     }
 315   }
 316 }
 317
 318 //ProfilesDemo();
 319 //BayonetCutout();
 320 //MainProfile();
 321 //Cover();
 322 //Jig();
 323 //CoverTest();