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 = 0.44;
  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 sm_inner_circum = 239;
  61 sm_main_thick = 2.5;
  62 sm_main_width = 25;
  63
  64 sm_bolt_dia = 3.5;
  65 sm_bolt_shaft = 21.9;
  66 sm_bolt_head_dia = 6.94 + 1.0;
  67 sm_bolt_head_thick = 2.14;
  68 sm_bolt_nut_width = 5.89 + 0.25;
  69 sm_bolt_nut_thick = 3.68;
  70
  71 sm_bolt_y_clear = 0.5;
  72 sm_bolt_y_over = 0.5;
  73
  74 sm_closure_cnr = 3.0;
  75
  76 // calculated
  77
  78 TAU = PI*2;
  79
  80 bayo_entry_x = bayo_entry;
  81 bayo_entry_z = bayo_entry;
  82 bayo_inramp_x = bayo_entry;
  83 bayo_inramp_z = bayo_entry;
  84
  85 oring_mid_dia = oring_bore + oring_thick;
  86 oring_outer_dia = oring_mid_dia + oring_thick;
  87
  88 oring_oblate = (1 - oring_compress);
  89
  90 oring_y_rad = oring_thick/2 * oring_oblate;
  91 oring_x_rad = oring_thick/2 / oring_oblate;
  92
  93 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  94
  95 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  96 side_thick = rivet_tall + over_rivet_wall;
  97
  98 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
  99
 100 middle_bot_z = top_z - top_thick_middle;
 101
 102 bayo_entry = bayo_behind / 3.0;
 103 bayo_top_z = bayo_behind + bayo_gap;
 104
 105 rivet_entry_width = rivet_width + side_rivet_gap;
 106
 107 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 108
 109 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 110 handling_angle = 45;
 111
 112 sm_inner_rad = sm_inner_circum / TAU;
 113 sm_outer_rad = sm_inner_rad + sm_main_thick;
 114
 115 smc_pos = [ 0, sm_inner_rad, 0 ];
 116
 117 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 118
 119 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 120 smc_max_y = smc_bolt_y + sm_bolt_y_over
 121   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 122 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 123   - max(sm_bolt_head_thick, sm_bolt_nut_thick);
 124
 125 $fs= coarse ? 2.5 : 0.5;
 126 $fa= coarse ? 5 : 1;
 127
 128 // bayonet definition
 129
 130 bayo_a = [ bayo_entry_x, 0 ];
 131 bayo_p = [ 0, bayo_entry_z ];
 132 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 133 bayo_m = [ bayo_inramp_x, bayo_behind ];
 134 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 135 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 136 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 137 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 138 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 139 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 140
 141 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 142 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 143 bayo_c = bayo_d + [0,-5];
 144 bayo_b = bayo_a + [0,-5];
 145
 146 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 147
 148 bayo_polygon = [ bayo_a,
 149                  bayo_b,
 150                  bayo_c,
 151                  bayo_d,
 152                  bayo_e,
 153                  bayo_f,
 154                  bayo_g,
 155                  bayo_h,
 156                  bayo_i,
 157                  bayo_j,
 158                  bayo_k,
 159                  bayo_l,
 160                  bayo_m,
 161                  bayo_n,
 162                  bayo_p ];
 163
 164 echo(bayo_polygon);
 165
 166 module MainProfile(){
 167   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 168   difference(){
 169     union(){
 170       translate(main_cnr_pos){
 171         intersection(){
 172           difference(){
 173             circle(r = main_cnr);
 174             circle(r = main_cnr * 0.5);
 175           }
 176           square([10,10]);
 177         }
 178       }
 179       polygon([[ -top_middle_dr,        middle_bot_z      ],
 180                [ -top_middle_dr,        top_z             ],
 181                [ main_cnr_pos[0],       top_z             ],
 182                [ side_thick,            main_cnr_pos[1]   ],
 183                [ side_thick,            -side_height      ],
 184                [ side_taper,            -side_height      ],
 185                [ 0,                     -rivet_posn       ],
 186                [ 0,                     by_oring_z        ],
 187                [ -oring_x_rad,          by_oring_z        ],
 188                ],
 189               convexity=10);
 190     }
 191     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 192       hull(){
 193       translate([ 0, oring_y_rad ])
 194         scale([ 1/oring_oblate, oring_oblate ])
 195         circle(oring_thick/2);
 196       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 197         circle(oring_thick/2);
 198     }
 199   }
 200 }
 201
 202 module StrapHoopProfile(){
 203   circle(r = strap_hoop_thick/2);
 204 }
 205
 206 module StrapHoop(){ ////toplevel
 207   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 208   extralen = strap_hoop_thick * 5;
 209
 210   intersection(){
 211     rotate([strap_hoop_elevation, 0,0]){
 212       for (x= [ -1, +1 ] * bigrad) {
 213         translate([x, -extralen, 0])
 214           rotate([-90,0,0])
 215           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 216                          convexity=10)
 217           StrapHoopProfile();
 218       }
 219       translate([0, strap_hoop_strlen, 0]){
 220         intersection(){
 221           rotate_extrude(convexity=10)
 222             translate([bigrad, 0,0])
 223             StrapHoopProfile();
 224           translate([0,50,0])
 225             cube([100,100,100], center=true);
 226         }
 227       }
 228     }
 229     translate([0, 50, 0])
 230       cube(100, center=true);
 231   }
 232 }
 233
 234 module HandlingProfile(){
 235 //  translate([
 236 }
 237
 238 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 239   // nom_rad > real_rad
 240   rotate([0,0, atan2(offset, nom_rad) ]){
 241     intersection(){
 242       translate([-offset, -10, 0])
 243         rotate([90,0,0])
 244         linear_extrude(height= nom_rad*2)
 245         children(0);
 246       translate([0,0, -25])
 247         cylinder(h=50, r= real_rad);
 248       translate([0,0, -25])
 249         linear_extrude(height= 50)
 250         polygon([ [ 0,0 ],
 251                   [ -slice_size, -real_rad*2 ],
 252                   [ +slice_size, -real_rad*2 ] ]);
 253     }
 254   }
 255 }
 256
 257 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 258   offs = [ for (i=[ x_min :
 259                     slice_size :
 260                     x_max + slice_size ]) i ];
 261   echo (offs);
 262   for (off=offs)
 263     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 264     children(0);
 265 }
 266
 267 module BayonetCutout(){
 268   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 269                 main_dia/2 + side_thick,
 270                 main_dia/2 + rivet_tall)
 271     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 272     polygon(bayo_polygon, convexity=10);
 273 }
 274
 275 module ProfilesDemo(){ ////toplevel
 276   translate([-10,0]) MainProfile();
 277   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 278 }
 279
 280 module LimitForHandling(){ ////toplevel
 281   hull() for (r=[0,180])
 282     rotate([0,0,r]) {
 283       for (rs=[-1,+1]) {
 284         for (xd=[0,1]) {
 285           rotate([0,0, rs * handling_angle/2]) {
 286             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 287                        main_dia/2 + side_thick - main_cnr,
 288                        top_z - main_cnr]) {
 289               mirror([0,0,1])
 290                 cylinder(r= main_cnr, h=50);
 291               sphere(main_cnr);
 292             }
 293           }
 294         }
 295       }
 296     }
 297   hull() rotate_extrude(){
 298     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 299       circle(r = main_cnr);
 300       mirror([0,1]) square([ main_cnr, 50 ]);
 301     }
 302   }
 303   //cylinder(r= handling_dia/2, h=20);
 304 }
 305
 306 module Cover(){ ////toplevel
 307   render() difference(){
 308     intersection(){
 309       union(){
 310         rotate_extrude(convexity=10)
 311           translate([main_dia/2, 0])
 312           MainProfile();
 313         translate([0,0, middle_bot_z])
 314           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 315       }
 316       LimitForHandling();
 317     }
 318     for (r=[0,180]){
 319       rotate([0,0, r])
 320         translate([0,0, -side_height])
 321         BayonetCutout();
 322       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 323         translate([0,
 324                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 325                    oring_y_rad * 1.5])
 326         rotate([-oring_rm_angle, 0, 0])
 327         mirror([0,0,1])
 328         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 329     }
 330     for (r=[0 : 60 : 179]) {
 331       rotate([0,0, r]) {
 332         height = top_thick_middle - brace_above_below*2;
 333         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 334         cube(center=true, [ oring_bore - brace_end_shorter,
 335                             brace_hole_width, height ]);
 336       }
 337     }
 338   }
 339 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 340 //    translate([handling_dia/2, 0, -side_height])
 341 //    rotate([0,180,0]) rotate([0,0,90])
 342 //    StrapHoop();
 343 }
 344
 345 module SavingHole(){
 346   translate([0,0, -10])
 347     cylinder(r= main_dia/2 - jig_rim, h=20);
 348 }
 349
 350 module Jig(){ ////toplevel
 351   difference(){
 352     union(){
 353       translate([0,0, -side_height]){
 354         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 355       }
 356       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 357         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 358     }
 359     translate([0,0, -side_height-1])
 360       cylinder(r= main_dia/2, h= side_height + 1);
 361     SavingHole();
 362     translate([0,0, -rivet_posn])
 363       rotate([90, 0,0])
 364       translate([0,0, -100])
 365       cylinder(r= jig_hole_dia/2, h = 200);
 366   }
 367 }
 368
 369 module CoverTest2(){ ////toplevel
 370   difference(){
 371     Cover();
 372     SavingHole();
 373   }
 374 }
 375
 376 module CoverTest1(){ ////toplevel
 377   difference(){
 378     CoverTest2();
 379     difference(){
 380       for (r= [ 40, 147 ]){
 381         rotate([0,0, r]){
 382           translate([0,0, -10]) {
 383             cube([ main_dia*3, main_dia * .53, 18], center=true);
 384           }
 385         }
 386       }
 387 //      translate([ 50, 0, 0 ])
 388 //      cube([ 100,
 389 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 390 //             100 ],
 391 //           center=true);
 392     }
 393   }
 394 }
 395
 396 module StrapMountBolt(){ ///toplevel
 397   // positioned relative to smc_pos
 398 }
 399
 400 module StrapMount(){ ////toplevel
 401   difference(){
 402     union(){
 403       cylinder(r=sm_outer_rad, h=sm_main_width);
 404       translate(smc_pos){
 405         linear_extrude(height=sm_main_width, convexity=10){
 406           hull(){
 407             for (m = [0,1]) mirror([m,0,0]) {
 408               translate([-smc_cnr_c_x, smc_max_y - sm_closure_cnr])
 409                 circle(r=sm_closure_cnr);
 410               translate([-smc_cnr_c_x, -sm_inner_rad])
 411                 square([1,1]);
 412             }
 413           }
 414         }
 415       }
 416     }
 417     translate([0,0,-1])
 418       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 419   }
 420 }
 421
 422 //ProfilesDemo();
 423 //BayonetCutout();
 424 //MainProfile();
 425 //Cover();
 426 //Jig();
 427 //CoverTest();