poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 // Print, for each end:
   4 //
   5 //   CoverPrint
   6 //   StrapMount
   7 //   CatchAssembly
   8
   9 include <funcs.scad>
  10 include <utils.scad>
  11
  12 coarse = false;
  13 enable_head_cups = false;
  14
  15 main_dia = 71.2 + 0.50 - 2.26;
  16 top_thick_middle = 4;
  17 top_thick_by_oring = 3.0;
  18 top_middle_dr = 11;
  19
  20 main_cnr = 6.0;
  21
  22 min_wall = 3;
  23
  24 rivet_posn = 6.0 + 0.30;
  25 rivet_thick = 1.67;
  26 rivet_width = 4.15 + 1.0;
  27 rivet_tall = 5.51 + 1.49;
  28
  29 over_rivet_wall = 1.0;
  30 side_rivet_gap = 1.5;
  31 inside_rivet_gap = 1.5;
  32
  33 bayo_interf = 0.30;
  34 bayo_behind = 8.5;
  35 bayo_interf_width = 2.0;
  36 bayo_interf_slope = 0.5;
  37
  38 oring_thick = 5.0;
  39 oring_bore = 62.0;
  40
  41 oring_upper_embed_angle = 80;
  42 oring_compress = 0.1; // proportion
  43 oring_compress_more = 0.2;
  44
  45 oring_rm_beside = 8;
  46 oring_rm_scale = 2.0;
  47 oring_rm_angle = 20;
  48
  49 side_taper = 1.0;
  50
  51 bayo_gap = 6.0;
  52
  53 bayo_entry = 1.167;
  54 bayo_inramp = 0.9;
  55
  56 bayo_slice_size = coarse ? 5 : 1;
  57
  58 brace_hole_width = 1.0;
  59 brace_above_below = 1.2;
  60 brace_end_shorter = 0.3;
  61
  62 jig_thick = 1.4;
  63 jig_hole_dia = 3.0;
  64 jig_rim = 5;
  65 jig_mark = 5;
  66
  67 strap_loop_thick = 6;
  68 strap_loop_inside = 10;
  69 strap_loop_strlen = 10;
  70 strap_loop_elevation = 45;
  71
  72 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  73 sm_main_thick = 2.0;
  74 sm_main_width = 20;
  75
  76 sm_bolt_dia = 3.5 + 0.1;
  77 sm_bolt_shaft = 21.0;
  78 sm_bolt_head_dia = 6.94 + 1.0;
  79 sm_bolt_head_thick = 2.14;
  80 sm_bolt_nut_width = 5.89 + 0.25;
  81 sm_bolt_nut_thick = 3.68;
  82 sm_bolt_tighten_allow = 2.0;
  83
  84 sm_bolt_y_clear = 0.75;
  85 sm_bolt_y_over = 0.5;
  86
  87 sm_closure_cnr = 3.0;
  88
  89 wm_thick = 5;
  90 wm_screw_dia = 4.5; // XXX
  91 wm_screwdriver_dia = 6.0; // XXX
  92 wm_screw_around = 4.0; // XXX
  93 wm_screw_slot = 3.5;
  94 wm_screw_head = 7.5; // XXX
  95
  96 wmb_screw_dia = 5;
  97 wmb_screw_head_dia = 10; // XXX
  98 wmb_screw_around_x = 4; // XXX
  99 wmb_screw_around_z = 6; // XXX
 100 wmb_screw_depth_min = 10;
 101 web_screw_len = 15 + 1; // XXX
 102 wmb_nut_across = 8; // XXX
 103 wmb_nut_around_min = 2; // XXX
 104 wmb_nut_behind_min = 5;
 105 wmb_nut_th = 4; // XXX
 106 wmb_mount_wall = 4.5;
 107 wmb_mount_gap_xy = 0.5;
 108 wmb_mount_gap_z = 0.5;
 109 wmb_mount_y_width = 10;
 110 wmb_ring_gap = 1.0;
 111
 112 catch_stalk_h = 4.5;
 113 catch_stalk_len = 50;
 114 catch_tip_th = 4;
 115 catch_head_th = 3;
 116
 117 catch_pin_slop = 0.25; // each side, and above
 118 catch_pin_slop_x_extra = 0.0; // only on one side
 119 catch_stalk_above_gap = 1.5;
 120 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 121
 122 catch_strap_width = 12;
 123 catch_stalk_base_width = 15;
 124
 125 catch_knob_dia = 6;
 126 catch_knob_above_gap = 5;
 127 catch_knob_height = 3.0;
 128
 129 catch_stalk_below_gap = 1.0;
 130 catch_stalk_beside_gap = 2.0;
 131
 132 // calculated
 133
 134 TAU = PI*2;
 135
 136 bayo_entry_x = bayo_entry;
 137 bayo_entry_z = bayo_entry;
 138 bayo_inramp_x = bayo_inramp;
 139 bayo_inramp_z = bayo_inramp;
 140
 141 oring_mid_dia = oring_bore + oring_thick;
 142 oring_outer_dia = oring_mid_dia + oring_thick;
 143
 144 oring_oblate = (1 - oring_compress);
 145
 146 oring_y_rad = oring_thick/2 * oring_oblate;
 147 oring_x_rad = oring_thick/2 / oring_oblate;
 148
 149 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 150
 151 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 152 side_thick = rivet_tall + over_rivet_wall;
 153
 154 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 155
 156 middle_bot_z = top_z - top_thick_middle;
 157
 158 bayo_top_z = bayo_behind + bayo_gap;
 159
 160 bayo_nom_rad = main_dia/2 + side_thick;
 161 bayo_real_rad = main_dia/2 + rivet_tall;
 162
 163 rivet_entry_width = rivet_width + side_rivet_gap;
 164
 165 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 166
 167 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 168 handling_angle = 45;
 169
 170 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 171 sm_outer_rad = sm_inner_rad + sm_main_thick;
 172
 173 wm_main_width = sm_main_width;
 174 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 175                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 176 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 177 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 178 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 179 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 180 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 181 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 182 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 183 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 184 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 185
 186 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
 187 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
 188 wmb_x_screw_plus_around_r = max(
 189                                 wmb_screw_around_x + wmb_screw_dia/2,
 190                                 wmb_nut_around_min + wmb_nut_across/2
 191                                 );
 192 wmb_x_screw = -sm_outer_rad + wmb_x_screw_plus_around_r;
 193 wmb_x_outer = -sm_outer_rad + wmb_x_screw_plus_around_r * 2;
 194 function wmb_screw_thing_y_min(dia) = sqrt(
 195                        pow(wmb_mount_cut_rad, 2) -
 196                        pow(wmb_x_screw + dia/2, 2)
 197                        );
 198 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 199 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2);
 200 wmb_y_mount_max = max(
 201                       wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
 202                       wmb_y_screw_end + wmb_screw_depth_min
 203                       );
 204 wmb_z_screw = max(
 205                   wmb_screw_around_z + wmb_screw_dia/2,
 206                   wmb_nut_around_min + wmb_nut_rad
 207                   );
 208 wmb_z_max = wmb_z_screw * 2;
 209 wmbb_y_max = wmb_y_mount_max + wmb_mount_gap_xy + wmb_mount_wall;
 210 wmbb_x_outer = wmb_x_outer + (wmb_mount_gap_xy + wmb_mount_wall);
 211 wmbb_z_min = -20; // XXX
 212
 213 smc_pos = [ 0, sm_inner_rad, 0 ];
 214
 215 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 216 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 217
 218 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 219 smc_max_y = smc_bolt_y + sm_bolt_y_over
 220   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 221 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 222   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 223
 224 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 225 catch_strap_thick = sm_main_thick;
 226
 227 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 228
 229 $fs= coarse ? 2.5 : 0.5;
 230 $fa= coarse ? 5 : 1;
 231
 232 include <poster-tube-lid-parametric.scad>
 233
 234 // bayonet definition
 235
 236 bayo_a = [ bayo_entry_x, 0 ];
 237 bayo_p = [ 0, bayo_entry_z ];
 238 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 239 bayo_m = [ bayo_inramp_x, bayo_behind ];
 240 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 241 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 242 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 243 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 244 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 245 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 246
 247 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 248 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 249 bayo_c = bayo_d + [0,-5];
 250 bayo_b = bayo_a + [0,-5];
 251
 252 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 253
 254 bayo_polygon = [ bayo_a,
 255                  bayo_b,
 256                  bayo_c,
 257                  bayo_d,
 258                  bayo_e,
 259                  bayo_f,
 260                  bayo_g,
 261                  bayo_h,
 262                  bayo_i,
 263                  bayo_j,
 264                  bayo_k,
 265                  bayo_l,
 266                  bayo_m,
 267                  bayo_n,
 268                  bayo_p ];
 269
 270 echo(bayo_polygon);
 271
 272 // CATCH
 273
 274 cppxC = 0.41 * sm_inner_rad * TAU;
 275
 276 // catch pin
 277
 278 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 279 // radius scaling due to nom and actual radius difference in
 280 // bayo entry construction
 281
 282 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 283 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 284 cppd = [ bayo_n[0]
 285          - catch_pin_slop - catch_pin_slop_x_extra,
 286          -catch_stalk_above_gap ];
 287 cppi = [ cppa[0], cppd[1] ];
 288 cppc = [ cppd[0], cppb[1] ];
 289 cpph = cppd + [0,-1] * catch_stalk_h;
 290 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 291 cppf = [ cppa[0], cppe[1] ];
 292 cppg = [ cppa[0], cpph[1] ];
 293 cppB = 0.5 * (cppf + cppe);
 294
 295 echo("RR", sm_inner_rad / bayo_nom_rad);
 296
 297 // catch assembly depression below pin
 298
 299 cppy6 = cppB[1] - (catch_knob_dia/2
 300                    + (cppc[1] - cppd[1])
 301                    + catch_stalk_below_gap);
 302 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 303 cpp11 = cpp7 + [1,0] * catch_cr;
 304 cppy9 = cppy6 + catch_strap_width * 1/3;
 305 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 306 cpp8 = cpp9 + [0,-1] * catch_cr;
 307 cpp10 = cpp8 + [-1,0] * catch_cr;
 308 cppC = [ cppxC, cpp9[1] ];
 309 cppD = cppC + [0,-1] * catch_strap_width;
 310
 311 // catch assembly stalk and so on
 312
 313 catch_cr3 = catch_cr + catch_stalk_h;
 314
 315 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 316 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 317 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 318 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 319 cpp2r = cpp2 + [1,0] * catch_cr;
 320 cpp2d = cpp2 + [0,-1] * catch_cr;
 321 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 322 cppA = [ -cppxC, cpp9[1] ];
 323 cppE = [ cppA[0], cppD[1] ];
 324
 325 catch_assembly_dy = -cppy9 + catch_strap_width;
 326
 327
 328 module MainProfile(){
 329   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 330   difference(){
 331     union(){
 332       translate(main_cnr_pos){
 333         intersection(){
 334           difference(){
 335             circle(r = main_cnr);
 336             circle(r = main_cnr * 0.5);
 337           }
 338           square([10,10]);
 339         }
 340       }
 341       polygon([[ -top_middle_dr,        middle_bot_z      ],
 342                [ -top_middle_dr,        top_z             ],
 343                [ main_cnr_pos[0],       top_z             ],
 344                [ side_thick,            main_cnr_pos[1]   ],
 345                [ side_thick,            -side_height      ],
 346                [ side_taper,            -side_height      ],
 347                [ 0,                     -rivet_posn       ],
 348                [ 0,                     by_oring_z        ],
 349                [ -oring_x_rad,          by_oring_z        ],
 350                ],
 351               convexity=10);
 352     }
 353     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 354       hull(){
 355       translate([ 0, oring_y_rad ])
 356         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 357         circle(oring_thick/2);
 358       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 359         circle(oring_thick/2);
 360     }
 361   }
 362 }
 363
 364 module StrapLoopProfile(){
 365   circle(r = strap_loop_thick/2);
 366 }
 367
 368 module StrapLoop(){ ////toplevel
 369   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 370   extralen = strap_loop_thick * 5;
 371
 372   intersection(){
 373     rotate([strap_loop_elevation, 0,0]){
 374       for (x= [ -1, +1 ] * bigrad) {
 375         translate([x, -extralen, 0])
 376           rotate([-90,0,0])
 377           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 378                          convexity=10)
 379           StrapLoopProfile();
 380       }
 381       translate([0, strap_loop_strlen, 0]){
 382         intersection(){
 383           rotate_extrude(convexity=10)
 384             translate([bigrad, 0,0])
 385             StrapLoopProfile();
 386           translate([0,50,0])
 387             cube([100,100,100], center=true);
 388         }
 389       }
 390     }
 391     translate([0, 50, 0])
 392       cube(100, center=true);
 393   }
 394 }
 395
 396 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 397   // nom_rad > real_rad
 398   rotate([0,0, atan2(offset, nom_rad) ]){
 399     intersection(){
 400       translate([-offset, -10, 0])
 401         rotate([90,0,0])
 402         linear_extrude(height= nom_rad*2, convexity=50)
 403         children(0);
 404       translate([0,0, -25])
 405         cylinder(h=50, r= real_rad);
 406       translate([0,0, -25])
 407         linear_extrude(height= 50, convexity=50)
 408         polygon([ [ 0,0 ],
 409                   [ -slice_size, -real_rad*2 ],
 410                   [ +slice_size, -real_rad*2 ] ]);
 411     }
 412   }
 413 }
 414
 415 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 416   offs = [ for (i=[ x_min :
 417                     slice_size :
 418                     x_max + slice_size ]) i ];
 419   echo (offs);
 420   for (off=offs)
 421     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 422     children(0);
 423 }
 424
 425 module BayonetCutout(){
 426   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 427                 bayo_nom_rad,
 428                 bayo_real_rad)
 429     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 430     polygon(bayo_polygon, convexity=10);
 431 }
 432
 433 module ProfilesDemo(){ ////toplevel
 434   translate([-10,0]) MainProfile();
 435   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 436 }
 437
 438 module LimitForHandling(){ ////toplevel
 439   hull() for (r=[0,180])
 440     rotate([0,0,r]) {
 441       for (rs=[-1,+1]) {
 442         for (xd=[0,1]) {
 443           rotate([0,0, rs * handling_angle/2]) {
 444             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 445                        main_dia/2 + side_thick - main_cnr,
 446                        top_z - main_cnr]) {
 447               mirror([0,0,1])
 448                 cylinder(r= main_cnr, h=50);
 449               sphere(main_cnr);
 450             }
 451           }
 452         }
 453       }
 454     }
 455   hull() rotate_extrude(convexity=10){
 456     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 457       circle(r = main_cnr);
 458       mirror([0,1]) square([ main_cnr, 50 ]);
 459     }
 460   }
 461   //cylinder(r= handling_dia/2, h=20);
 462 }
 463
 464 module Cover(){ ////toplevel
 465   render() difference(){
 466     intersection(){
 467       union(){
 468         rotate_extrude(convexity=10)
 469           translate([main_dia/2, 0])
 470           MainProfile();
 471         translate([0,0, middle_bot_z])
 472           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 473       }
 474       LimitForHandling();
 475     }
 476     for (r=[0,180]){
 477       rotate([0,0, r])
 478         translate([0,0, -side_height])
 479         BayonetCutout();
 480       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 481         translate([0,
 482                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 483                    oring_y_rad * 1.5])
 484         rotate([-oring_rm_angle, 0, 0])
 485         mirror([0,0,1])
 486         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 487     }
 488     for (r=[0 : 60 : 179]) {
 489       rotate([0,0, r]) {
 490         height = top_thick_middle - brace_above_below*2;
 491         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 492         cube(center=true, [ oring_bore - brace_end_shorter,
 493                             brace_hole_width, height ]);
 494       }
 495     }
 496   }
 497   if (enable_head_cups)
 498     for (r=[0,180])
 499       rotate([0,0,r])
 500         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 501                    -implheadcup_large_dia * .0,
 502                    middle_bot_z + 0.1])
 503         ImplHeadCup();
 504
 505 //  translate(strap_loop_thick * [-0.5, 0, +1])
 506 //    translate([handling_dia/2, 0, -side_height])
 507 //    rotate([0,180,0]) rotate([0,0,90])
 508 //    StrapLoop();
 509 }
 510
 511 module SavingHole(){
 512   translate([0,0, -10])
 513     cylinder(r= main_dia/2 - jig_rim, h=20);
 514 }
 515
 516 module Jig(){ ////toplevel
 517   difference(){
 518     union(){
 519       translate([0,0, -side_height]){
 520         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 521       }
 522       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 523         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 524     }
 525     translate([0,0, -side_height-1])
 526       cylinder(r= main_dia/2, h= side_height + 1);
 527     SavingHole();
 528     translate([0,0, -rivet_posn])
 529       rotate([90, 0,0])
 530       translate([0,0, -100])
 531       cylinder(r= jig_hole_dia/2, h = 200);
 532   }
 533 }
 534
 535 module CoverPrint(){ ////toplevel
 536   rotate([0,180,0]) Cover();
 537 }
 538
 539 module CoverTest2(){ ////toplevel
 540   difference(){
 541     Cover();
 542     SavingHole();
 543   }
 544 }
 545
 546 module CoverTest1(){ ////toplevel
 547   difference(){
 548     CoverTest2();
 549     difference(){
 550       for (r= [ 40, 147 ]){
 551         rotate([0,0, r]){
 552           translate([0,0, -10]) {
 553             cube([ main_dia*3, main_dia * .53, 18], center=true);
 554           }
 555         }
 556       }
 557 //      translate([ 50, 0, 0 ])
 558 //      cube([ 100,
 559 //             strap_loop_inside + strap_loop_thick*2 + 1,
 560 //             100 ],
 561 //           center=true);
 562     }
 563   }
 564 }
 565
 566 module ImplHeadCupTest(){ ////toplevel
 567   for (r=[0,180])
 568     rotate([0,0,r])
 569       translate([-17,0,0])
 570       ImplHeadCup();
 571 }
 572
 573 module SomeStrap(width, cut_width=0){
 574   // children(0) is to add, (1) subtract
 575   difference(){
 576     union(){
 577       cylinder(r=sm_outer_rad, h=width);
 578       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 579                            smc_max_y,
 580                            sm_closure_cnr,
 581                            width);
 582       children(0);
 583     }
 584     translate([0,0,-1])
 585       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 586     translate(smc_pos)
 587       StrapMountBolt(10, width);
 588     translate(smc_pos)
 589       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 590     children(1);
 591   }
 592 }
 593
 594 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 595   // positioned relative to smc_pos
 596   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 597              smc_bolt_y,
 598              strap_width/2]){
 599     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 600       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 601     }
 602     translate([ -sm_bolt_shaft/2, 0,0 ])
 603       rotate([0,-90,0])
 604       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 605                h=smc_bolt_nut_eff_thick + l_delta);
 606     translate([ sm_bolt_shaft/2, 0,0 ])
 607       rotate([0,90,0])
 608       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 609   }
 610 }
 611
 612 module StrapMountProtrusion(half_x, max_y, cnr, width){
 613   translate(smc_pos){
 614     linear_extrude(height=width, convexity=10){
 615       hull(){
 616         for (m = [0,1]) mirror([m,0,0]) {
 617           translate([-(half_x - cnr), max_y - cnr])
 618             circle(r=cnr);
 619           translate([-half_x, -sm_inner_rad])
 620             square([1,1]);
 621         }
 622       }
 623     }
 624   }
 625 }
 626
 627 module StrapMount(){ ////toplevel
 628   SomeStrap(sm_main_width){
 629     rotate([0,0,180]){
 630       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 631                            strap_loop_thick,
 632                            sm_closure_cnr,
 633                            sm_main_width);
 634       translate(smc_pos +
 635                 [0,0, sm_main_width] +
 636                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 637         StrapLoop();
 638     }
 639     union(){ };
 640   }
 641 }
 642
 643 module WallScrewHoleSlot(){ ////toplevel
 644   ds = [-1,+1] * wm_screw_slot/2;
 645   linextr_x_yz(-(wm_thick + 1), 1) {
 646     hull(){
 647       for (d = ds)
 648         translate([d, 0])
 649           circle(r = wm_screw_dia/2);
 650     }
 651   }
 652   hull(){
 653     for (d = ds){
 654       translate([0, d, 0]){
 655         linextr_x_yz(0, 1)
 656           circle(r = wm_screw_head/2);
 657         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 658           circle(r = wm_screw_dia/2);
 659       }
 660     }
 661   }
 662 }
 663
 664 module WallMountMounts(){
 665   linextr(0, wm_z_max){
 666     translate([ -sm_outer_rad, 0 ])
 667       rectfromto([ 0, -wm_y_max ],
 668                  [ wm_thick, wm_y_slot1_max ]);
 669   }
 670 }
 671 module WallMountScrewHoles(){
 672   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 673     translate([ 0, wm_y_slotc_screw, 0 ])
 674       WallScrewHoleSlot();
 675     translate([ 0, -wm_y_slotc_screw, 0 ])
 676       rotate([90,0,0])
 677       WallScrewHoleSlot();
 678   }
 679 }
 680
 681 module WallMount(){ ////toplevel
 682   SomeStrap(sm_main_width, wm_z_max + 2){
 683     WallMountMounts();
 684     WallMountScrewHoles();
 685   }
 686 }
 687
 688 module WallMountBaseRingCut(){
 689   circle(r = wmb_mount_cut_rad);
 690 }
 691
 692 module WallMountBaseMounts(){
 693   linextr(0, wmb_z_max) {
 694     difference(){
 695       rectfromto([ -sm_outer_rad, -wmb_y_mount_max ],
 696                  [ wmb_x_outer,   +wmb_y_mount_max ]);
 697       WallMountBaseRingCut();
 698     }
 699   }
 700 }
 701
 702 // screws, nuts, slots for nuts to go down into
 703 module WallMountBaseScrewsEtc(){ ////toplevel
 704   for (my=[0,1]) {
 705     mirror([0, my, 0]) {
 706       translate([wmb_x_screw, 0, wmb_z_screw]) {
 707         linextr_y_xz(wmb_y_screw_end,
 708                      wmb_y_screw_end + 100) // XXX change 100
 709           circle(r = wmb_screw_dia/2);
 710         linextr_y_xz(wmb_y_screw_end + web_screw_len,
 711                      wmb_y_screw_end + 100) // XXX change 100
 712           circle(r = wmb_screw_head_dia/2);
 713         linextr_y_xz(wmb_y_nut_min,
 714                      wmb_y_nut_min + wmb_nut_th) {
 715           hull(){
 716             rotate(30)
 717               circle(r = wmb_nut_rad, $fn = 6);
 718             translate([0, 100]) // XXX change 100
 719               square(wmb_nut_across, center=true);
 720           }
 721         }
 722       }
 723     }
 724   }
 725 }
 726
 727 module WallMountForBase(){ ////toplevel
 728   SomeStrap(sm_main_width, wm_z_max + 2){
 729     union(){
 730       WallMountMounts();
 731       WallMountBaseMounts();
 732     }
 733     union(){
 734       WallMountScrewHoles();
 735       WallMountBaseScrewsEtc();
 736     }
 737   }
 738 }
 739
 740 module WallMountBase(){ ////toplevel
 741   difference(){
 742     union(){
 743       linextr(wmbb_z_min, wmb_z_max) {
 744         difference(){
 745           for (my = [0,1]) {
 746             mirror([0, my]) {
 747               rectfromto([ -sm_outer_rad, wmbb_y_max - wmb_mount_y_width ],
 748                          [ wmbb_x_outer, wmbb_y_max ]);
 749             }
 750           }
 751           WallMountBaseRingCut();
 752         }
 753       }
 754     }
 755
 756     // cutaway for mount part
 757     linextr(-wmb_mount_gap_z, wmb_z_max+1) {
 758       for (my = [0,1]) {
 759         mirror([0, my])
 760           rectfromto([ -sm_outer_rad-1, wmb_y_mount_max + wmb_mount_gap_xy ],
 761                      [ wmb_x_outer + wmb_mount_gap_xy, 1 ]);
 762       }
 763     }
 764
 765     WallMountBaseScrewsEtc();
 766   }
 767 }
 768
 769 module WallMountForBaseDemo(){ ////toplevel
 770   WallMountForBase();
 771   color("blue") WallMountBase();
 772   %WallMountBaseScrewsEtc();
 773 }
 774
 775 module CatchAssemblyCoreProfile(){
 776   difference(){
 777     union(){
 778       hull(){
 779         translate(cpp3) circle(r= catch_cr3);
 780         polygon([ cpp3,
 781                   cpp2r,
 782                   cpp5,
 783                   cpph,
 784                   cppd
 785                   ]);
 786       }
 787       polygon([cppD,
 788                cppC,
 789                cpp9,
 790                cpp10,
 791                cpp11,
 792                cpp4,
 793                cpp2r,
 794                cpp2d,
 795                cppA,
 796                cppE
 797                ]);
 798       translate(cpp8) circle(r= catch_cr);
 799     }
 800     hull(){
 801       translate(cpp4) circle(r= catch_cr);
 802       translate(cpp5) circle(r= catch_cr);
 803       translate(cpp7) circle(r= catch_cr);
 804       polygon([cpp4,
 805                cppg,
 806                cpph,
 807                cpp10,
 808                cpp11,
 809                ]);
 810     }
 811     translate(cpp2) circle(r= catch_cr);
 812   }
 813   // if cpp11 is above cpp10, the subtracted hull above
 814   // can go down too far.  Ensure we do not cut off below cppy6.
 815   polygon([ cppE,
 816             cppD,
 817             cpp9,
 818             [ cpp9[0],            cppy6 ],
 819             [ cpp7[0] - catch_cr, cppy6 ],
 820             cpp2d
 821             ]);
 822 }
 823
 824 module CatchTipProfile(dy){
 825   ddy = [0,dy];
 826   intersection(){
 827     translate(cppF){
 828       difference(){
 829 //      circle(r = dist2d(cppF, cppd));
 830         //circle(r = dist2d(cppF, cppa));
 831       }
 832     }
 833     polygon([ cppa,
 834               cppi + ddy,
 835               cppd + ddy,
 836               cppc,
 837               cppb ]);
 838   }
 839 }
 840
 841 module CatchHeadProfile(){
 842   polygon([ cppd,
 843             cppd,
 844             cppi,
 845             cppf,
 846             cppe,
 847             cpph ]);
 848 }
 849
 850
 851 module CatchCore(){ /////toplevel
 852   linear_extrude(height=catch_strap_thick, convexity=10)
 853     CatchAssemblyCoreProfile();
 854
 855   hull(){
 856     linear_extrude(height=catch_head_th, convexity=10)
 857       CatchTipProfile(0);
 858     linear_extrude(height=catch_tip_th, convexity=10)
 859       CatchTipProfile(catch_tip_th - catch_head_th);
 860   }
 861
 862   linear_extrude(height=catch_head_th, convexity=10)
 863     CatchHeadProfile();
 864
 865   translate(concat(cppB,[0])) hull(){
 866     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 867       sphere(r = catch_knob_dia/2);
 868     cylinder(r = catch_knob_dia/2, h = 0.1);
 869   }
 870 }
 871
 872 module CatchPreDistort(){ /////toplevel
 873   scale(100 / sm_inner_rad)
 874     rotate([90,0,0])
 875     CatchCore();
 876 }
 877
 878 module CatchAssembly(){ /////toplevel
 879   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 880     translate([0,0, catch_assembly_dy])
 881     scale(sm_inner_rad / 100)
 882     import(str("poster-tube-lid,CatchPostDistort-fa",
 883                (coarse ? 20 : 3),
 884                ".stl"),
 885            convexity=20);
 886
 887   SomeStrap(catch_strap_width){
 888     union(){ }
 889     union(){
 890       translate([-200, -200, -200])
 891         cube([400, 200, 400]);
 892     }
 893   }
 894 }
 895
 896 module CatchDemo(){ /////toplevel
 897   color("blue") translate([0,0,
 898                            -catch_assembly_dy
 899              ])
 900     CatchAssembly();
 901   translate([0,0,+side_height
 902              ])
 903     Cover();
 904 }
 905
 906 module CatchDemoS(){ /////toplevel
 907   color("blue") translate([0,0,
 908              -catch_assembly_dy
 909              ])
 910     CatchAssembly();
 911   intersection(){
 912     translate([0,0,+side_height
 913                ])
 914       Cover();
 915     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 916   }
 917   color("black")
 918     translate([0,-33,0])
 919     cube([6.15, 2,2], center=true);
 920 }
 921
 922 module CatchPinProfileDemo(){ /////toplevel
 923   translate([0, 0 * -bayo_behind,0]) {
 924     echo("G ",
 925          bayo_n[0] - bayo_e[0]);
 926     color("blue") translate([0,0,
 927                              +1,
 928                ]) {
 929       CatchAssemblyCoreProfile();
 930       CatchHeadProfile();
 931     }
 932     translate([0,0,10])
 933       color("red")
 934       CatchTipProfile(0);
 935
 936     polygon(bayo_polygon, convexity=10);
 937
 938     // adhoc show a position
 939     color("purple")
 940     translate(concat(
 941                      cppa,
 942                      10
 943                      )) difference(){ circle(2.5); circle(2.0); }
 944
 945  }
 946 }
 947
 948 //ProfilesDemo();
 949 //BayonetCutout();
 950 //MainProfile();
 951 //Cover();
 952 //Jig();
 953 //CoverTest();