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 = 1.25;
  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 = 80;
  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 brace_end_shorter = 0.3;
  38
  39 jig_thick = 1.4;
  40 jig_hole_dia = 3.0;
  41 jig_rim = 5;
  42 jig_mark = 5;
  43
  44 // calculated
  45
  46 bayo_entry_x = bayo_entry;
  47 bayo_entry_z = bayo_entry;
  48 bayo_inramp_x = bayo_entry;
  49 bayo_inramp_z = bayo_entry;
  50
  51 oring_mid_dia = oring_bore + oring_thick;
  52 oring_outer_dia = oring_mid_dia + oring_thick;
  53
  54 oring_oblate = (1 - oring_compress);
  55
  56 oring_y_rad = oring_thick/2 * oring_oblate;
  57 oring_x_rad = oring_thick/2 / oring_oblate;
  58
  59 seal_thick = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  60
  61 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  62 side_thick = rivet_tall + over_rivet_wall;
  63
  64 top_z = top_thick + seal_thick;
  65
  66 bayo_entry = bayo_behind / 3.0;
  67 bayo_top_z = bayo_behind + rivet_thick + bayo_above_gap;
  68 bayo_entry_ramp = bayo_entry + bayo_interf;
  69
  70 rivet_entry_width = rivet_width + side_rivet_gap;
  71
  72 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
  73
  74 $fs=0.5;
  75 $fa=1;
  76
  77 // bayonet definition
  78
  79 bayo_a = [ bayo_entry_x, 0 ];
  80 bayo_p = [ 0, bayo_entry_z ];
  81 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
  82 bayo_m = [ bayo_inramp_x, bayo_behind ];
  83 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
  84 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
  85 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
  86 bayo_i = bayo_j + [ rivet_width, 0 ];
  87 bayo_h = [ bayo_i[0], bayo_behind + rivet_thick
  88                       + bayo_above_gap + bayo_interf ];
  89 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
  90
  91 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
  92 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
  93 bayo_c = bayo_d + [0,-5];
  94 bayo_b = bayo_a + [0,-5];
  95
  96 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
  97
  98 bayo_polygon = [ bayo_a,
  99                  bayo_b,
 100                  bayo_c,
 101                  bayo_d,
 102                  bayo_e,
 103                  bayo_f,
 104                  bayo_g,
 105                  bayo_h,
 106                  bayo_i,
 107                  bayo_j,
 108                  bayo_k,
 109                  bayo_l,
 110                  bayo_m,
 111                  bayo_n,
 112                  bayo_p ];
 113
 114 echo(bayo_polygon);
 115
 116 module MainProfile(){
 117   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 118   difference(){
 119     union(){
 120       translate(main_cnr_pos){
 121         intersection(){
 122           difference(){
 123             circle(r = main_cnr);
 124             circle(r = main_cnr * 0.5);
 125           }
 126           square([10,10]);
 127         }
 128       }
 129       polygon([[ -11,                   seal_thick        ],
 130                [ -11,                   top_z             ],
 131                [ main_cnr_pos[0],       top_z             ],
 132                [ side_thick,            main_cnr_pos[1]   ],
 133                [ side_thick,            -side_height      ],
 134                [ side_taper,            -side_height      ],
 135                [ 0,                     -rivet_posn       ],
 136                [ 0,                     seal_thick        ],
 137                ],
 138               convexity=10);
 139     }
 140     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 141       hull(){
 142       translate([ 0, oring_y_rad ])
 143         scale([ 1/oring_oblate, oring_oblate ])
 144         circle(oring_thick/2);
 145       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 146         circle(oring_thick/2);
 147     }
 148   }
 149 }
 150
 151 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 152   // nom_rad > real_rad
 153   rotate([0,0, atan2(offset, nom_rad) ]){
 154     intersection(){
 155       translate([-offset, -10, 0])
 156         rotate([90,0,0])
 157         linear_extrude(height= nom_rad*2)
 158         children(0);
 159       translate([0,0, -25])
 160         cylinder(h=50, r= real_rad);
 161       translate([0,0, -25])
 162         linear_extrude(height= 50)
 163         polygon([ [ 0,0 ],
 164                   [ -slice_size, -real_rad*2 ],
 165                   [ +slice_size, -real_rad*2 ] ]);
 166     }
 167   }
 168 }
 169
 170 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 171   offs = [ for (i=[ x_min :
 172                     slice_size :
 173                     x_max + slice_size ]) i ];
 174   echo (offs);
 175   for (off=offs)
 176     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 177     children(0);
 178 }
 179
 180 module BayonetCutout(){
 181   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 182                 main_dia/2 + side_thick,
 183                 main_dia/2 + rivet_tall)
 184     polygon(bayo_polygon, convexity=10);
 185 }
 186
 187 module ProfilesDemo(){ ////toplevel
 188   translate([-20,0]) MainProfile();
 189   polygon(bayo_polygon, convexity=10);
 190 }
 191
 192 module Cover(){ ////toplevel
 193   render() difference(){
 194     union(){
 195       rotate_extrude(convexity=10)
 196         translate([main_dia/2, 0])
 197         MainProfile();
 198       translate([0,0, seal_thick])
 199         cylinder(h= top_thick, r = main_dia/2 - 10);
 200     }
 201     for (r=[0,180])
 202       rotate([0,0, r])
 203         translate([0,0, -side_height])
 204         BayonetCutout();
 205     for (r=[0 : 60 : 179]) {
 206       rotate([0,0, r]) {
 207         height = top_thick - brace_above_below*2;
 208         translate([0,0, seal_thick + brace_above_below + height/2 ])
 209         cube(center=true, [ oring_bore - brace_end_shorter,
 210                             brace_hole_width, height ]);
 211       }
 212     }
 213   }
 214 }
 215
 216 module SavingHole(){
 217   translate([0,0, -10])
 218     cylinder(r= main_dia/2 - jig_rim, h=20);
 219 }
 220
 221 module Jig(){ ////toplevel
 222   difference(){
 223     union(){
 224       translate([0,0, -side_height]){
 225         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 226       }
 227       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 228         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 229     }
 230     translate([0,0, -side_height-1])
 231       cylinder(r= main_dia/2, h= side_height + 1);
 232     SavingHole();
 233     translate([0,0, -rivet_posn])
 234       rotate([90, 0,0])
 235       translate([0,0, -100])
 236       cylinder(r= jig_hole_dia/2, h = 200);
 237   }
 238 }
 239
 240 module CoverTest2(){ ////toplevel
 241   difference(){
 242     Cover();
 243     SavingHole();
 244   }
 245 }
 246
 247 module CoverTest1(){ ////toplevel
 248   difference(){
 249     CoverTest2();
 250     translate([0,0, -10])
 251       cube([ main_dia*3, main_dia * .85, 20], center=true);
 252   }
 253 }
 254
 255 //ProfilesDemo();
 256 //BayonetCutout();
 257 //MainProfile();
 258 //Cover();
 259 //Jig();
 260 //CoverTest();