poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 main_dia = 71.2 + 0.50 - 2.26;
   4 top_minthick_middle = 4;
   5 top_minthick_by_oring = 2.5;
   6 top_middle_dr = 11;
   7
   8 main_cnr = 4.0;
   9
  10 rivet_posn = 6.0;
  11 rivet_thick = 1.67;
  12 rivet_width = 4.15 + 1.0;
  13 rivet_tall = 5.51 + 0.49;
  14
  15 over_rivet_wall = 0.5;
  16 side_rivet_gap = 1.5;
  17
  18 bayo_interf = 1.25;
  19 bayo_behind = 3.5;
  20 bayo_interf_width = 2.0;
  21 bayo_interf_slope = 0.75;
  22
  23 oring_thick = 5.0;
  24 oring_bore = 62.0;
  25
  26 oring_upper_embed_angle = 80;
  27 oring_compress = 0.1; // proportion
  28
  29 side_taper = 1.0;
  30
  31 bayo_above_gap = 1.0;
  32
  33 bayo_entry = bayo_behind/3;
  34
  35 bayo_slice_size = 1;
  36
  37 brace_hole_width = 1.0;
  38 brace_above_below = 1.2;
  39 brace_end_shorter = 0.3;
  40
  41 jig_thick = 1.4;
  42 jig_hole_dia = 3.0;
  43 jig_rim = 5;
  44 jig_mark = 5;
  45
  46 // calculated
  47
  48 bayo_entry_x = bayo_entry;
  49 bayo_entry_z = bayo_entry;
  50 bayo_inramp_x = bayo_entry;
  51 bayo_inramp_z = bayo_entry;
  52
  53 oring_mid_dia = oring_bore + oring_thick;
  54 oring_outer_dia = oring_mid_dia + oring_thick;
  55
  56 oring_oblate = (1 - oring_compress);
  57
  58 oring_y_rad = oring_thick/2 * oring_oblate;
  59 oring_x_rad = oring_thick/2 / oring_oblate;
  60
  61 seal_thick = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  62
  63 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  64 side_thick = rivet_tall + over_rivet_wall;
  65
  66 top_thick = max(top_minthick_middle,
  67                 top_minthick_by_oring + oring_y_rad);
  68
  69 top_z = top_thick + seal_thick;
  70
  71 middle_bot_z = top_z - top_minthick_middle;
  72
  73 bayo_entry = bayo_behind / 3.0;
  74 bayo_top_z = bayo_behind + rivet_thick + bayo_above_gap;
  75 bayo_entry_ramp = bayo_entry + bayo_interf;
  76
  77 rivet_entry_width = rivet_width + side_rivet_gap;
  78
  79 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
  80
  81 $fs=0.5;
  82 $fa=1;
  83
  84 // bayonet definition
  85
  86 bayo_a = [ bayo_entry_x, 0 ];
  87 bayo_p = [ 0, bayo_entry_z ];
  88 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
  89 bayo_m = [ bayo_inramp_x, bayo_behind ];
  90 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
  91 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
  92 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
  93 bayo_i = bayo_j + [ rivet_width, 0 ];
  94 bayo_h = [ bayo_i[0], bayo_behind + rivet_thick
  95                       + bayo_above_gap + bayo_interf ];
  96 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
  97
  98 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
  99 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 100 bayo_c = bayo_d + [0,-5];
 101 bayo_b = bayo_a + [0,-5];
 102
 103 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 104
 105 bayo_polygon = [ bayo_a,
 106                  bayo_b,
 107                  bayo_c,
 108                  bayo_d,
 109                  bayo_e,
 110                  bayo_f,
 111                  bayo_g,
 112                  bayo_h,
 113                  bayo_i,
 114                  bayo_j,
 115                  bayo_k,
 116                  bayo_l,
 117                  bayo_m,
 118                  bayo_n,
 119                  bayo_p ];
 120
 121 echo(bayo_polygon);
 122
 123 module MainProfile(){
 124   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 125   difference(){
 126     union(){
 127       translate(main_cnr_pos){
 128         intersection(){
 129           difference(){
 130             circle(r = main_cnr);
 131             circle(r = main_cnr * 0.5);
 132           }
 133           square([10,10]);
 134         }
 135       }
 136       polygon([[ -top_middle_dr,        middle_bot_z      ],
 137                [ -top_middle_dr,        top_z             ],
 138                [ main_cnr_pos[0],       top_z             ],
 139                [ side_thick,            main_cnr_pos[1]   ],
 140                [ side_thick,            -side_height      ],
 141                [ side_taper,            -side_height      ],
 142                [ 0,                     -rivet_posn       ],
 143                [ 0,                     seal_thick        ],
 144                [ -oring_x_rad,          seal_thick        ],
 145                ],
 146               convexity=10);
 147     }
 148     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 149       hull(){
 150       translate([ 0, oring_y_rad ])
 151         scale([ 1/oring_oblate, oring_oblate ])
 152         circle(oring_thick/2);
 153       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 154         circle(oring_thick/2);
 155     }
 156   }
 157 }
 158
 159 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 160   // nom_rad > real_rad
 161   rotate([0,0, atan2(offset, nom_rad) ]){
 162     intersection(){
 163       translate([-offset, -10, 0])
 164         rotate([90,0,0])
 165         linear_extrude(height= nom_rad*2)
 166         children(0);
 167       translate([0,0, -25])
 168         cylinder(h=50, r= real_rad);
 169       translate([0,0, -25])
 170         linear_extrude(height= 50)
 171         polygon([ [ 0,0 ],
 172                   [ -slice_size, -real_rad*2 ],
 173                   [ +slice_size, -real_rad*2 ] ]);
 174     }
 175   }
 176 }
 177
 178 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 179   offs = [ for (i=[ x_min :
 180                     slice_size :
 181                     x_max + slice_size ]) i ];
 182   echo (offs);
 183   for (off=offs)
 184     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 185     children(0);
 186 }
 187
 188 module BayonetCutout(){
 189   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 190                 main_dia/2 + side_thick,
 191                 main_dia/2 + rivet_tall)
 192     polygon(bayo_polygon, convexity=10);
 193 }
 194
 195 module ProfilesDemo(){ ////toplevel
 196   translate([-10,0]) MainProfile();
 197   translate([+10,0]) polygon(bayo_polygon, convexity=10);
 198 }
 199
 200 module Cover(){ ////toplevel
 201   render() difference(){
 202     union(){
 203       rotate_extrude(convexity=10)
 204         translate([main_dia/2, 0])
 205         MainProfile();
 206       translate([0,0, middle_bot_z])
 207         cylinder(h= top_minthick_middle, r = main_dia/2 - top_middle_dr + 1);
 208     }
 209     for (r=[0,180])
 210       rotate([0,0, r])
 211         translate([0,0, -side_height])
 212         BayonetCutout();
 213     for (r=[0 : 60 : 179]) {
 214       rotate([0,0, r]) {
 215         height = top_thick - brace_above_below*2;
 216         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 217         cube(center=true, [ oring_bore - brace_end_shorter,
 218                             brace_hole_width, height ]);
 219       }
 220     }
 221   }
 222 }
 223
 224 module SavingHole(){
 225   translate([0,0, -10])
 226     cylinder(r= main_dia/2 - jig_rim, h=20);
 227 }
 228
 229 module Jig(){ ////toplevel
 230   difference(){
 231     union(){
 232       translate([0,0, -side_height]){
 233         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 234       }
 235       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 236         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 237     }
 238     translate([0,0, -side_height-1])
 239       cylinder(r= main_dia/2, h= side_height + 1);
 240     SavingHole();
 241     translate([0,0, -rivet_posn])
 242       rotate([90, 0,0])
 243       translate([0,0, -100])
 244       cylinder(r= jig_hole_dia/2, h = 200);
 245   }
 246 }
 247
 248 module CoverTest2(){ ////toplevel
 249   difference(){
 250     Cover();
 251     SavingHole();
 252   }
 253 }
 254
 255 module CoverTest1(){ ////toplevel
 256   difference(){
 257     CoverTest2();
 258     translate([0,0, -10])
 259       cube([ main_dia*3, main_dia * .85, 20], center=true);
 260   }
 261 }
 262
 263 //ProfilesDemo();
 264 //BayonetCutout();
 265 //MainProfile();
 266 //Cover();
 267 //Jig();
 268 //CoverTest();