chiark / gitweb /
poster-tube-lid: catch: rework going well
[reprap-play.git] / poster-tube-lid.scad
1 // -*- C -*-
2
3 include <funcs.scad>
4
5 coarse = false;
6
7 main_dia = 71.2 + 0.50 - 2.26;
8 top_thick_middle = 4;
9 top_thick_by_oring = 3.0;
10 top_middle_dr = 11;
11
12 main_cnr = 6.0;
13
14 min_wall = 3;
15
16 rivet_posn = 6.0 + 0.30;
17 rivet_thick = 1.67;
18 rivet_width = 4.15 + 1.0;
19 rivet_tall = 5.51 + 1.49;
20
21 over_rivet_wall = 1.0;
22 side_rivet_gap = 1.5;
23 inside_rivet_gap = 1.5;
24
25 bayo_interf = 0.30;
26 bayo_behind = 3.5;
27 bayo_interf_width = 2.0;
28 bayo_interf_slope = 0.5;
29
30 oring_thick = 5.0;
31 oring_bore = 62.0;
32
33 oring_upper_embed_angle = 80;
34 oring_compress = 0.1; // proportion
35 oring_compress_more = 0.2;
36
37 oring_rm_beside = 8;
38 oring_rm_scale = 2.0;
39 oring_rm_angle = 20;
40
41 side_taper = 1.0;
42
43 bayo_gap = 6.0;
44
45 bayo_entry = bayo_behind/3;
46
47 bayo_slice_size = coarse ? 5 : 1;
48
49 brace_hole_width = 1.0;
50 brace_above_below = 1.2;
51 brace_end_shorter = 0.3;
52
53 jig_thick = 1.4;
54 jig_hole_dia = 3.0;
55 jig_rim = 5;
56 jig_mark = 5;
57
58 strap_hoop_thick = 6;
59 strap_hoop_inside = 10;
60 strap_hoop_strlen = 10;
61 strap_hoop_elevation = 45;
62
63 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
64 sm_main_thick = 2.0;
65 sm_main_width = 20;
66
67 sm_bolt_dia = 3.5 + 0.1;
68 sm_bolt_shaft = 21.9;
69 sm_bolt_head_dia = 6.94 + 1.0;
70 sm_bolt_head_thick = 2.14;
71 sm_bolt_nut_width = 5.89 + 0.25;
72 sm_bolt_nut_thick = 3.68;
73 sm_bolt_tighten_allow = 2.0;
74
75 sm_bolt_y_clear = 0.75;
76 sm_bolt_y_over = 0.5;
77
78 sm_closure_cnr = 3.0;
79
80 catch_stem_h = 3;
81 catch_stem_len = 50;
82 catch_stem_th = 3;
83
84 catch_pin_slop = 0.25; // each side, and above
85 catch_stalk_above_gap = 1.5;
86 catch_stalk_eff_bend_rad = catch_stem_len * 0.75;
87
88 catch_stalk_base_width = 15;
89
90 catch_knob_dia = 6;
91 catch_knob_above_gap = 8;
92 catch_knob_height = 6;
93
94 catch_stem_below_gap = 1.0;
95 catch_stem_beside_gap = 2.0;
96 catch_pin_gap = 0.5;
97 catch_hook_slope = 0.15;
98
99 // calculated
100
101 TAU = PI*2;
102
103 bayo_entry_x = bayo_entry;
104 bayo_entry_z = bayo_entry;
105 bayo_inramp_x = bayo_entry;
106 bayo_inramp_z = bayo_entry;
107
108 oring_mid_dia = oring_bore + oring_thick;
109 oring_outer_dia = oring_mid_dia + oring_thick;
110
111 oring_oblate = (1 - oring_compress);
112
113 oring_y_rad = oring_thick/2 * oring_oblate;
114 oring_x_rad = oring_thick/2 / oring_oblate;
115
116 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
117
118 side_height = rivet_posn + bayo_behind + rivet_thick/2;
119 side_thick = rivet_tall + over_rivet_wall;
120
121 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
122
123 middle_bot_z = top_z - top_thick_middle;
124
125 bayo_entry = bayo_behind / 3.0;
126 bayo_top_z = bayo_behind + bayo_gap;
127
128 bayo_nom_rad = main_dia/2 + side_thick;
129 bayo_real_rad = main_dia/2 + rivet_tall;
130
131 rivet_entry_width = rivet_width + side_rivet_gap;
132
133 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
134
135 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
136 handling_angle = 45;
137
138 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
139 sm_outer_rad = sm_inner_rad + sm_main_thick;
140
141 smc_pos = [ 0, sm_inner_rad, 0 ];
142
143 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
144 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
145
146 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
147 smc_max_y = smc_bolt_y + sm_bolt_y_over
148   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
149 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
150   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
151
152 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
153 catch_strap_width = sm_main_width;
154 catch_strap_thick = sm_main_thick;
155 catch_stem_end_h = catch_stem_h;
156 catch_pin_width = (rivet_entry_width * sm_inner_rad / bayo_nom_rad)
157                    - catch_pin_gap;
158
159 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
160
161 $fs= coarse ? 2.5 : 0.5;
162 $fa= coarse ? 5 : 1;
163
164 include <poster-tube-lid-parametric.scad>
165
166 // bayonet definition
167
168 bayo_a = [ bayo_entry_x, 0 ];
169 bayo_p = [ 0, bayo_entry_z ];
170 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
171 bayo_m = [ bayo_inramp_x, bayo_behind ];
172 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
173 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
174 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
175 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
176 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
177 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
178
179 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
180 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
181 bayo_c = bayo_d + [0,-5];
182 bayo_b = bayo_a + [0,-5];
183
184 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
185
186 bayo_polygon = [ bayo_a,
187                  bayo_b,
188                  bayo_c,
189                  bayo_d,
190                  bayo_e,
191                  bayo_f,
192                  bayo_g,
193                  bayo_h,
194                  bayo_i,
195                  bayo_j,
196                  bayo_k,
197                  bayo_l,
198                  bayo_m,
199                  bayo_n,
200                  bayo_p ];
201
202 echo(bayo_polygon);
203
204 // CATCH
205
206 //cppy6 = -catch_strap_width * 2/3;
207
208 cppxC = 0.41 * sm_inner_rad * TAU;
209
210 // catch pin
211
212 cppa = bayo_f + [1,-1] * catch_pin_slop;
213 cppb = bayo_g + [1,-1] * catch_pin_slop;
214 cppd = [ bayo_n[0] - catch_pin_slop, -catch_stalk_above_gap ];
215 cppc = [ cppd[0], cppb[1] ];
216 cpph = cppd + [0,-1] * catch_stem_h;
217 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
218 cppf = [ cppa[0], cppe[1] ];
219 cppg = [ cppa[0], cpph[1] ];
220 cppB = 0.5 * (cppf + cppe);
221
222 // catch assembly depression below pin
223
224 cppy6 = cppB[1] - (catch_knob_dia/2
225                    + (cppc[1] - cppd[1])
226                    + catch_stem_below_gap);
227 cpp7 = [ cppB[0], cppy6 + catch_cr ];
228 cpp11 = cpp7 + [1,0] * catch_cr;
229 cppy9 = cppy6 + catch_strap_width * 1/3;
230 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
231 cpp8 = cpp9 + [0,-1] * catch_cr;
232 cpp10 = cpp8 + [-1,0] * catch_cr;
233 cppC = [ cppxC, cpp9[1] ];
234 cppD = cppC + [0,-1] * catch_strap_width;
235
236 // catch assembly stalk and so on
237
238 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
239 cpp4 = [ cppg[0] - catch_stem_len, cpph[1] ] + [1,-1] * catch_cr;
240 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
241 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
242 cpp2r = cpp2 + [1,0] * catch_cr;
243 cpp2d = cpp2 + [0,-1] * catch_cr;
244 cpp3 = [ cpp2[0] + catch_cr * 2, cppd[1] - catch_cr ];
245 cppA = [ -cppxC, cpp9[1] ];
246 cppE = [ cppA[0], cppD[1] ];
247
248
249 module MainProfile(){
250   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
251   difference(){
252     union(){
253       translate(main_cnr_pos){
254         intersection(){
255           difference(){
256             circle(r = main_cnr);
257             circle(r = main_cnr * 0.5);
258           }
259           square([10,10]);
260         }
261       }
262       polygon([[ -top_middle_dr,        middle_bot_z      ],
263                [ -top_middle_dr,        top_z             ],
264                [ main_cnr_pos[0],       top_z             ],
265                [ side_thick,            main_cnr_pos[1]   ],
266                [ side_thick,            -side_height      ],
267                [ side_taper,            -side_height      ],
268                [ 0,                     -rivet_posn       ],
269                [ 0,                     by_oring_z        ],
270                [ -oring_x_rad,          by_oring_z        ],
271                ],
272               convexity=10);
273     }
274     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
275       hull(){
276       translate([ 0, oring_y_rad ])
277         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
278         circle(oring_thick/2);
279       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
280         circle(oring_thick/2);
281     }
282   }
283 }
284
285 module StrapHoopProfile(){
286   circle(r = strap_hoop_thick/2);
287 }
288
289 module StrapHoop(){ ////toplevel
290   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
291   extralen = strap_hoop_thick * 5;
292
293   intersection(){
294     rotate([strap_hoop_elevation, 0,0]){
295       for (x= [ -1, +1 ] * bigrad) {
296         translate([x, -extralen, 0])
297           rotate([-90,0,0])
298           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
299                          convexity=10)
300           StrapHoopProfile();
301       }
302       translate([0, strap_hoop_strlen, 0]){
303         intersection(){
304           rotate_extrude(convexity=10)
305             translate([bigrad, 0,0])
306             StrapHoopProfile();
307           translate([0,50,0])
308             cube([100,100,100], center=true);
309         }
310       }
311     }
312     translate([0, 50, 0])
313       cube(100, center=true);
314   }
315 }
316
317 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
318   // nom_rad > real_rad
319   rotate([0,0, atan2(offset, nom_rad) ]){
320     intersection(){
321       translate([-offset, -10, 0])
322         rotate([90,0,0])
323         linear_extrude(height= nom_rad*2)
324         children(0);
325       translate([0,0, -25])
326         cylinder(h=50, r= real_rad);
327       translate([0,0, -25])
328         linear_extrude(height= 50)
329         polygon([ [ 0,0 ],
330                   [ -slice_size, -real_rad*2 ],
331                   [ +slice_size, -real_rad*2 ] ]);
332     }
333   }
334 }
335
336 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
337   offs = [ for (i=[ x_min :
338                     slice_size :
339                     x_max + slice_size ]) i ];
340   echo (offs);
341   for (off=offs)
342     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
343     children(0);
344 }
345
346 module BayonetCutout(){
347   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
348                 bayo_nom_rad, 
349                 bayo_real_rad)
350     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
351     polygon(bayo_polygon, convexity=10);
352 }
353
354 module ProfilesDemo(){ ////toplevel
355   translate([-10,0]) MainProfile();
356   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
357 }
358
359 module LimitForHandling(){ ////toplevel
360   hull() for (r=[0,180])
361     rotate([0,0,r]) {
362       for (rs=[-1,+1]) {
363         for (xd=[0,1]) {
364           rotate([0,0, rs * handling_angle/2]) {
365             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
366                        main_dia/2 + side_thick - main_cnr,
367                        top_z - main_cnr]) {
368               mirror([0,0,1])
369                 cylinder(r= main_cnr, h=50);
370               sphere(main_cnr);
371             }
372           }
373         }
374       } 
375     }
376   hull() rotate_extrude(){
377     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
378       circle(r = main_cnr);
379       mirror([0,1]) square([ main_cnr, 50 ]);
380     }
381   }
382   //cylinder(r= handling_dia/2, h=20);
383 }
384
385 module Cover(){ ////toplevel
386   render() difference(){
387     intersection(){
388       union(){
389         rotate_extrude(convexity=10)
390           translate([main_dia/2, 0])
391           MainProfile();
392         translate([0,0, middle_bot_z])
393           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
394       }
395       LimitForHandling();
396     }
397     for (r=[0,180]){
398       rotate([0,0, r])
399         translate([0,0, -side_height])
400         BayonetCutout();
401       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
402         translate([0,
403                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
404                    oring_y_rad * 1.5])
405         rotate([-oring_rm_angle, 0, 0])
406         mirror([0,0,1])
407         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
408     }
409     for (r=[0 : 60 : 179]) {
410       rotate([0,0, r]) {
411         height = top_thick_middle - brace_above_below*2;
412         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
413         cube(center=true, [ oring_bore - brace_end_shorter,
414                             brace_hole_width, height ]);
415       }
416     }
417   }
418   for (r=[0,180])
419     rotate([0,0,r])
420       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
421                  -implheadcup_large_dia * .0,
422                  middle_bot_z + 0.1])
423       ImplHeadCup();
424 //  translate(strap_hoop_thick * [-0.5, 0, +1])
425 //    translate([handling_dia/2, 0, -side_height])
426 //    rotate([0,180,0]) rotate([0,0,90])
427 //    StrapHoop();
428 }
429
430 module SavingHole(){
431   translate([0,0, -10])
432     cylinder(r= main_dia/2 - jig_rim, h=20);
433 }
434
435 module Jig(){ ////toplevel
436   difference(){
437     union(){
438       translate([0,0, -side_height]){
439         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
440       }
441       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
442         cube([jig_mark_rad*2, jig_mark, jig_mark]);
443     }
444     translate([0,0, -side_height-1])
445       cylinder(r= main_dia/2, h= side_height + 1);
446     SavingHole();
447     translate([0,0, -rivet_posn])
448       rotate([90, 0,0])
449       translate([0,0, -100])
450       cylinder(r= jig_hole_dia/2, h = 200);
451   }
452 }
453
454 module CoverTest2(){ ////toplevel
455   difference(){
456     Cover();
457     SavingHole();
458   }
459 }
460
461 module CoverTest1(){ ////toplevel
462   difference(){
463     CoverTest2();
464     difference(){
465       for (r= [ 40, 147 ]){
466         rotate([0,0, r]){
467           translate([0,0, -10]) {
468             cube([ main_dia*3, main_dia * .53, 18], center=true);
469           }
470         }
471       }
472 //      translate([ 50, 0, 0 ])
473 //      cube([ 100,
474 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
475 //             100 ],
476 //           center=true);
477     }
478   }
479 }
480
481 module ImplHeadCupTest(){ ////toplevel
482   for (r=[0,180])
483     rotate([0,0,r])
484       translate([-17,0,0])
485       ImplHeadCup();
486 }
487
488 module SomeStrap(){
489   // children(0) is to add, (1) subtract
490   difference(){
491     union(){
492       cylinder(r=sm_outer_rad, h=sm_main_width);
493       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
494                            smc_max_y,
495                            sm_closure_cnr);
496       children(0);
497     }
498     translate([0,0,-1])
499       cylinder(r=sm_inner_rad, h=sm_main_width+2);
500     translate(smc_pos)
501       StrapMountBolt(10);
502     translate(smc_pos)
503       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
504     children(1);
505   }
506 }
507
508 module StrapMountBolt(l_delta){ ///toplevel
509   // positioned relative to smc_pos
510   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
511              smc_bolt_y,
512              sm_main_width/2]){
513     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
514       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
515     }
516     translate([ -sm_bolt_shaft/2, 0,0 ])
517       rotate([0,-90,0])
518       cylinder($fn=6, r=smc_bolt_nut_dia/2,
519                h=smc_bolt_nut_eff_thick + l_delta);
520     translate([ sm_bolt_shaft/2, 0,0 ])
521       rotate([0,90,0])
522       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
523   }
524 }
525
526 module StrapMountProtrusion(half_x, max_y, cnr){
527   translate(smc_pos){
528     linear_extrude(height=sm_main_width, convexity=10){
529       hull(){
530         for (m = [0,1]) mirror([m,0,0]) {
531           translate([-(half_x - cnr), max_y - cnr])
532             circle(r=cnr);
533           translate([-half_x, -sm_inner_rad])
534             square([1,1]);
535         }
536       }
537     }
538   }
539 }
540
541 module StrapMount(){ ////toplevel
542   SomeStrap(){
543     rotate([0,0,180]){
544       StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
545                            strap_hoop_thick,
546                            sm_closure_cnr);
547       translate(smc_pos +
548                 [0,0, sm_main_width] +
549                 strap_hoop_thick * [ 0, 0.5, -1.0 ])
550         StrapHoop();
551     }
552     union(){ };
553   }
554 }
555
556 module CatchAssemblyCoreProfile(){
557   difference(){
558     union(){
559       hull(){
560         translate(cpp3) circle(r= catch_cr);
561         polygon([ cpp3,
562                   cpp2r,
563                   cpp5,
564                   cpph,
565                   cppd
566                   ]);
567       }
568       polygon([cppD,
569                cppC,
570                cpp9,
571                cpp10,
572                cpp11,
573                cpp4,
574                cpp2r,
575                cpp2d,
576                cppA,
577                cppE
578                ]);
579       translate(cpp8) circle(r= catch_cr);
580     }
581     hull(){
582       translate(cpp4) circle(r= catch_cr);
583       translate(cpp5) circle(r= catch_cr);
584       translate(cpp7) circle(r= catch_cr);
585       polygon([cpp4,
586                cppg,
587                cpph,
588                cpp10,
589                cpp11,
590                ]);
591     }
592   }
593 }
594
595 module CatchHeadProfile(){
596   intersection(){
597     translate(cppF){
598       difference(){
599         circle(r = dist2d(cppF, cppd));
600         circle(r = dist2d(cppF, cppa));
601       }
602     }
603     polygon([ cppa,
604               cppg,
605               cpph,
606               cppd,
607               cppc,
608               cppb ]);
609   }
610   polygon([ cppd,
611             cppg,
612             cppf,
613             cppe,
614             cpph ]);
615 }
616
617
618 module CatchCore(){ /////toplevel
619   linear_extrude(height=catch_strap_thick, convexity=10)
620     CatchAssemblyCoreProfile();
621
622   linear_extrude(height=catch_strap_thick, convexity=10)
623     CatchHeadProfile();
624
625   translate(concat(cppB,[0])) hull(){
626     translate([0,0, catch_knob_height - catch_knob_dia/2])
627       sphere(r = catch_knob_dia/2);
628     cylinder(r = catch_knob_dia/2, h = 0.1);
629   }
630 }
631
632 module CatchPreDistort(){ /////toplevel
633   scale(100 / sm_inner_rad)
634     rotate([90,0,0])
635     CatchCore();
636 }
637
638 module CatchAssembly(){ /////toplevel
639   rotate([0,0, -0.5 * (cpp1[0] + cpp2[0]) / sm_inner_rad * 360/TAU])
640     translate([0,0, catch_strap_width])
641     scale(sm_inner_rad / 100)
642     import(str("poster-tube-lid,CatchPostDistort-fa",
643                (coarse ? 20 : 3),
644                ".stl"),
645            convexity=20);
646
647   SomeStrap(){
648     union(){ }
649     union(){
650       translate([-200, -200, -200])
651         cube([400, 200, 400]);
652     }
653   }
654 }
655
656 module CatchDemo(){ /////toplevel
657   color("blue") translate([0,0,
658              -catch_strap_width
659              -cpp0[1]
660              ])
661     CatchAssembly();
662   translate([0,0,+side_height
663              ])
664     Cover();
665 }
666
667 module CatchDemoS(){ /////toplevel
668   color("blue") translate([0,0,
669              -catch_strap_width
670              -cpp0[1]
671              ])
672     CatchAssembly();
673   intersection(){
674     translate([0,0,+side_height
675                ])
676       Cover();
677     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
678   }
679   color("black")
680     translate([0,-33,0])
681     cube([6.15, 2,2], center=true);
682 }
683
684 module CatchPinProfileDemo(){ /////toplevel
685   echo("G ",
686        cpp2[0] - cpp1[0],
687        bayo_n[0] - bayo_e[0]);
688   color("blue") translate([0,0,
689                            +1,
690              ]) {
691     CatchAssemblyCoreProfile();
692     CatchHeadProfile();
693   }
694   polygon(bayo_polygon, convexity=10);
695 }
696
697 //ProfilesDemo();
698 //BayonetCutout();
699 //MainProfile();
700 //Cover();
701 //Jig();
702 //CoverTest();