poster-tube-lid.scad

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