chiark / gitweb /
poster-tube-lid: catch: wip rework entirely
[reprap-play.git] / poster-tube-lid.scad
1 // -*- C -*-
2
3 coarse = false;
4
5 main_dia = 71.2 + 0.50 - 2.26;
6 top_thick_middle = 4;
7 top_thick_by_oring = 3.0;
8 top_middle_dr = 11;
9
10 main_cnr = 6.0;
11
12 min_wall = 3;
13
14 rivet_posn = 6.0 + 0.30;
15 rivet_thick = 1.67;
16 rivet_width = 4.15 + 1.0;
17 rivet_tall = 5.51 + 1.49;
18
19 over_rivet_wall = 1.0;
20 side_rivet_gap = 1.5;
21 inside_rivet_gap = 1.5;
22
23 bayo_interf = 0.30;
24 bayo_behind = 3.5;
25 bayo_interf_width = 2.0;
26 bayo_interf_slope = 0.5;
27
28 oring_thick = 5.0;
29 oring_bore = 62.0;
30
31 oring_upper_embed_angle = 80;
32 oring_compress = 0.1; // proportion
33 oring_compress_more = 0.2;
34
35 oring_rm_beside = 8;
36 oring_rm_scale = 2.0;
37 oring_rm_angle = 20;
38
39 side_taper = 1.0;
40
41 bayo_gap = 6.0;
42
43 bayo_entry = bayo_behind/3;
44
45 bayo_slice_size = coarse ? 5 : 1;
46
47 brace_hole_width = 1.0;
48 brace_above_below = 1.2;
49 brace_end_shorter = 0.3;
50
51 jig_thick = 1.4;
52 jig_hole_dia = 3.0;
53 jig_rim = 5;
54 jig_mark = 5;
55
56 strap_hoop_thick = 6;
57 strap_hoop_inside = 10;
58 strap_hoop_strlen = 10;
59 strap_hoop_elevation = 45;
60
61 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
62 sm_main_thick = 2.0;
63 sm_main_width = 20;
64
65 sm_bolt_dia = 3.5 + 0.1;
66 sm_bolt_shaft = 21.9;
67 sm_bolt_head_dia = 6.94 + 1.0;
68 sm_bolt_head_thick = 2.14;
69 sm_bolt_nut_width = 5.89 + 0.25;
70 sm_bolt_nut_thick = 3.68;
71 sm_bolt_tighten_allow = 2.0;
72
73 sm_bolt_y_clear = 0.75;
74 sm_bolt_y_over = 0.5;
75
76 sm_closure_cnr = 3.0;
77
78 catch_stem_h = 3;
79 catch_stem_len = 50;
80 catch_stem_th = 3;
81
82 catch_pin_slop = 0.25; // each side, and above
83 catch_stalk_above_gap = 1.5;
84 catch_stalk_eff_bend_rad = catch_stem_len * 0.75;
85
86 catch_stalk_base_width = 15;
87
88 catch_knob_dia = 6;
89 catch_knob_above_gap = 8;
90 catch_knob_height = 6;
91
92 catch_stem_below_gap = 1.0;
93 catch_stem_beside_gap = 2.0;
94 catch_pin_gap = 0.5;
95 catch_hook_slope = 0.15;
96
97 // calculated
98
99 TAU = PI*2;
100
101 bayo_entry_x = bayo_entry;
102 bayo_entry_z = bayo_entry;
103 bayo_inramp_x = bayo_entry;
104 bayo_inramp_z = bayo_entry;
105
106 oring_mid_dia = oring_bore + oring_thick;
107 oring_outer_dia = oring_mid_dia + oring_thick;
108
109 oring_oblate = (1 - oring_compress);
110
111 oring_y_rad = oring_thick/2 * oring_oblate;
112 oring_x_rad = oring_thick/2 / oring_oblate;
113
114 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
115
116 side_height = rivet_posn + bayo_behind + rivet_thick/2;
117 side_thick = rivet_tall + over_rivet_wall;
118
119 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
120
121 middle_bot_z = top_z - top_thick_middle;
122
123 bayo_entry = bayo_behind / 3.0;
124 bayo_top_z = bayo_behind + bayo_gap;
125
126 bayo_nom_rad = main_dia/2 + side_thick;
127 bayo_real_rad = main_dia/2 + rivet_tall;
128
129 rivet_entry_width = rivet_width + side_rivet_gap;
130
131 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
132
133 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
134 handling_angle = 45;
135
136 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
137 sm_outer_rad = sm_inner_rad + sm_main_thick;
138
139 smc_pos = [ 0, sm_inner_rad, 0 ];
140
141 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
142 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
143
144 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
145 smc_max_y = smc_bolt_y + sm_bolt_y_over
146   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
147 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
148   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
149
150 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
151 catch_strap_width = sm_main_width;
152 catch_strap_thick = sm_main_thick;
153 catch_stem_end_h = catch_stem_h;
154 catch_pin_width = (rivet_entry_width * sm_inner_rad / bayo_nom_rad)
155                    - catch_pin_gap;
156
157 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
158
159 $fs= coarse ? 2.5 : 0.5;
160 $fa= coarse ? 5 : 1;
161
162 include <poster-tube-lid-parametric.scad>
163
164 // bayonet definition
165
166 bayo_a = [ bayo_entry_x, 0 ];
167 bayo_p = [ 0, bayo_entry_z ];
168 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
169 bayo_m = [ bayo_inramp_x, bayo_behind ];
170 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
171 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
172 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
173 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
174 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
175 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
176
177 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
178 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
179 bayo_c = bayo_d + [0,-5];
180 bayo_b = bayo_a + [0,-5];
181
182 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
183
184 bayo_polygon = [ bayo_a,
185                  bayo_b,
186                  bayo_c,
187                  bayo_d,
188                  bayo_e,
189                  bayo_f,
190                  bayo_g,
191                  bayo_h,
192                  bayo_i,
193                  bayo_j,
194                  bayo_k,
195                  bayo_l,
196                  bayo_m,
197                  bayo_n,
198                  bayo_p ];
199
200 echo(bayo_polygon);
201
202 // CATCH
203
204 //cppy6 = -catch_strap_width * 2/3;
205
206 cppxC = 0.34 * sm_inner_rad * TAU;
207
208 // catch pin
209
210 cppa = bayo_f + [1,-1] * catch_pin_slop;
211 cppb = bayo_g + [1,-1] * catch_pin_slop;
212 cppd = [ bayo_n[0] - catch_pin_slop, -catch_stalk_above_gap ];
213 cppc = [ cppd[0], cppb[1] ];
214 cpph = cppd + [0,-1] * catch_stem_h;
215 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
216 cppf = [ cppa[0], cppe[1] ];
217 cppg = [ cppa[0], cpph[1] ];
218 cppB = 0.5 * (cppf + cppe);
219
220 // catch assembly depression below pin
221
222 cppy6 = cppB[1] - (catch_knob_dia/2
223                    + (cppc[1] - cppd[1])
224                    + catch_stem_below_gap);
225 cpp7 = [ cppB[0], cppy6 + catch_cr ];
226 cpp11 = cpp7 + [1,0] * catch_cr;
227 cppy9 = cppy6 + catch_strap_width * 1/3;
228 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
229 cpp8 = cpp9 + [0,-1] * catch_cr;
230 cpp10 = cpp8 + [-1,0] * catch_cr;
231 cppC = [ cppxC, cpp9[1] ];
232 cppD = cppC + [0,-1] * catch_strap_width;
233
234 // catch assembly stalk and so on
235
236 cppF = [ cppg[0] - catch_stem_stalk_eff_bend_rad, cppd[1] ];
237 cpp4 = [ cppg[0] - catch_stem_lenm, cppd[1] ] + [1,-1] * catch_cr;
238 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
239 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
240 cpp3 = [ cpp2[0] + catch_cr * 2, cppd[1] - catch_cr ];
241 cppA = [ -cppxC, cpp9[1] ];
242 cppE = [ cppA[0], cppD[1] ];
243
244
245 module MainProfile(){
246   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
247   difference(){
248     union(){
249       translate(main_cnr_pos){
250         intersection(){
251           difference(){
252             circle(r = main_cnr);
253             circle(r = main_cnr * 0.5);
254           }
255           square([10,10]);
256         }
257       }
258       polygon([[ -top_middle_dr,        middle_bot_z      ],
259                [ -top_middle_dr,        top_z             ],
260                [ main_cnr_pos[0],       top_z             ],
261                [ side_thick,            main_cnr_pos[1]   ],
262                [ side_thick,            -side_height      ],
263                [ side_taper,            -side_height      ],
264                [ 0,                     -rivet_posn       ],
265                [ 0,                     by_oring_z        ],
266                [ -oring_x_rad,          by_oring_z        ],
267                ],
268               convexity=10);
269     }
270     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
271       hull(){
272       translate([ 0, oring_y_rad ])
273         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
274         circle(oring_thick/2);
275       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
276         circle(oring_thick/2);
277     }
278   }
279 }
280
281 module StrapHoopProfile(){
282   circle(r = strap_hoop_thick/2);
283 }
284
285 module StrapHoop(){ ////toplevel
286   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
287   extralen = strap_hoop_thick * 5;
288
289   intersection(){
290     rotate([strap_hoop_elevation, 0,0]){
291       for (x= [ -1, +1 ] * bigrad) {
292         translate([x, -extralen, 0])
293           rotate([-90,0,0])
294           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
295                          convexity=10)
296           StrapHoopProfile();
297       }
298       translate([0, strap_hoop_strlen, 0]){
299         intersection(){
300           rotate_extrude(convexity=10)
301             translate([bigrad, 0,0])
302             StrapHoopProfile();
303           translate([0,50,0])
304             cube([100,100,100], center=true);
305         }
306       }
307     }
308     translate([0, 50, 0])
309       cube(100, center=true);
310   }
311 }
312
313 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
314   // nom_rad > real_rad
315   rotate([0,0, atan2(offset, nom_rad) ]){
316     intersection(){
317       translate([-offset, -10, 0])
318         rotate([90,0,0])
319         linear_extrude(height= nom_rad*2)
320         children(0);
321       translate([0,0, -25])
322         cylinder(h=50, r= real_rad);
323       translate([0,0, -25])
324         linear_extrude(height= 50)
325         polygon([ [ 0,0 ],
326                   [ -slice_size, -real_rad*2 ],
327                   [ +slice_size, -real_rad*2 ] ]);
328     }
329   }
330 }
331
332 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
333   offs = [ for (i=[ x_min :
334                     slice_size :
335                     x_max + slice_size ]) i ];
336   echo (offs);
337   for (off=offs)
338     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
339     children(0);
340 }
341
342 module BayonetCutout(){
343   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
344                 bayo_nom_rad, 
345                 bayo_real_rad)
346     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
347     polygon(bayo_polygon, convexity=10);
348 }
349
350 module ProfilesDemo(){ ////toplevel
351   translate([-10,0]) MainProfile();
352   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
353 }
354
355 module LimitForHandling(){ ////toplevel
356   hull() for (r=[0,180])
357     rotate([0,0,r]) {
358       for (rs=[-1,+1]) {
359         for (xd=[0,1]) {
360           rotate([0,0, rs * handling_angle/2]) {
361             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
362                        main_dia/2 + side_thick - main_cnr,
363                        top_z - main_cnr]) {
364               mirror([0,0,1])
365                 cylinder(r= main_cnr, h=50);
366               sphere(main_cnr);
367             }
368           }
369         }
370       } 
371     }
372   hull() rotate_extrude(){
373     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
374       circle(r = main_cnr);
375       mirror([0,1]) square([ main_cnr, 50 ]);
376     }
377   }
378   //cylinder(r= handling_dia/2, h=20);
379 }
380
381 module Cover(){ ////toplevel
382   render() difference(){
383     intersection(){
384       union(){
385         rotate_extrude(convexity=10)
386           translate([main_dia/2, 0])
387           MainProfile();
388         translate([0,0, middle_bot_z])
389           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
390       }
391       LimitForHandling();
392     }
393     for (r=[0,180]){
394       rotate([0,0, r])
395         translate([0,0, -side_height])
396         BayonetCutout();
397       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
398         translate([0,
399                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
400                    oring_y_rad * 1.5])
401         rotate([-oring_rm_angle, 0, 0])
402         mirror([0,0,1])
403         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
404     }
405     for (r=[0 : 60 : 179]) {
406       rotate([0,0, r]) {
407         height = top_thick_middle - brace_above_below*2;
408         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
409         cube(center=true, [ oring_bore - brace_end_shorter,
410                             brace_hole_width, height ]);
411       }
412     }
413   }
414   for (r=[0,180])
415     rotate([0,0,r])
416       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
417                  -implheadcup_large_dia * .0,
418                  middle_bot_z + 0.1])
419       ImplHeadCup();
420 //  translate(strap_hoop_thick * [-0.5, 0, +1])
421 //    translate([handling_dia/2, 0, -side_height])
422 //    rotate([0,180,0]) rotate([0,0,90])
423 //    StrapHoop();
424 }
425
426 module SavingHole(){
427   translate([0,0, -10])
428     cylinder(r= main_dia/2 - jig_rim, h=20);
429 }
430
431 module Jig(){ ////toplevel
432   difference(){
433     union(){
434       translate([0,0, -side_height]){
435         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
436       }
437       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
438         cube([jig_mark_rad*2, jig_mark, jig_mark]);
439     }
440     translate([0,0, -side_height-1])
441       cylinder(r= main_dia/2, h= side_height + 1);
442     SavingHole();
443     translate([0,0, -rivet_posn])
444       rotate([90, 0,0])
445       translate([0,0, -100])
446       cylinder(r= jig_hole_dia/2, h = 200);
447   }
448 }
449
450 module CoverTest2(){ ////toplevel
451   difference(){
452     Cover();
453     SavingHole();
454   }
455 }
456
457 module CoverTest1(){ ////toplevel
458   difference(){
459     CoverTest2();
460     difference(){
461       for (r= [ 40, 147 ]){
462         rotate([0,0, r]){
463           translate([0,0, -10]) {
464             cube([ main_dia*3, main_dia * .53, 18], center=true);
465           }
466         }
467       }
468 //      translate([ 50, 0, 0 ])
469 //      cube([ 100,
470 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
471 //             100 ],
472 //           center=true);
473     }
474   }
475 }
476
477 module ImplHeadCupTest(){ ////toplevel
478   for (r=[0,180])
479     rotate([0,0,r])
480       translate([-17,0,0])
481       ImplHeadCup();
482 }
483
484 module SomeStrap(){
485   // children(0) is to add, (1) subtract
486   difference(){
487     union(){
488       cylinder(r=sm_outer_rad, h=sm_main_width);
489       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
490                            smc_max_y,
491                            sm_closure_cnr);
492       children(0);
493     }
494     translate([0,0,-1])
495       cylinder(r=sm_inner_rad, h=sm_main_width+2);
496     translate(smc_pos)
497       StrapMountBolt(10);
498     translate(smc_pos)
499       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
500     children(1);
501   }
502 }
503
504 module StrapMountBolt(l_delta){ ///toplevel
505   // positioned relative to smc_pos
506   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
507              smc_bolt_y,
508              sm_main_width/2]){
509     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
510       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
511     }
512     translate([ -sm_bolt_shaft/2, 0,0 ])
513       rotate([0,-90,0])
514       cylinder($fn=6, r=smc_bolt_nut_dia/2,
515                h=smc_bolt_nut_eff_thick + l_delta);
516     translate([ sm_bolt_shaft/2, 0,0 ])
517       rotate([0,90,0])
518       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
519   }
520 }
521
522 module StrapMountProtrusion(half_x, max_y, cnr){
523   translate(smc_pos){
524     linear_extrude(height=sm_main_width, convexity=10){
525       hull(){
526         for (m = [0,1]) mirror([m,0,0]) {
527           translate([-(half_x - cnr), max_y - cnr])
528             circle(r=cnr);
529           translate([-half_x, -sm_inner_rad])
530             square([1,1]);
531         }
532       }
533     }
534   }
535 }
536
537 module StrapMount(){ ////toplevel
538   SomeStrap(){
539     rotate([0,0,180]){
540       StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
541                            strap_hoop_thick,
542                            sm_closure_cnr);
543       translate(smc_pos +
544                 [0,0, sm_main_width] +
545                 strap_hoop_thick * [ 0, 0.5, -1.0 ])
546         StrapHoop();
547     }
548     union(){ };
549   }
550 }
551
552 module CatchCoreProfile(){ ////toplevel
553   hull(){
554     translate(cppB) circle(r= catch_knob_dia/2);
555     polygon([cpp4,
556              cppB,
557              cpp3]);
558   }
559   translate(cpp8)
560     circle(catch_cr);
561   polygon([
562            cpp4,
563            cppB,
564            cpp3,
565            cpp2,
566            cpp1,
567            cpp12,
568            ]);
569   difference(){
570     polygon([ cpp4,
571               cpp3,
572               cpp12,
573               cppA,
574               cppE,
575               cppD,
576               cppC,
577               cpp9,
578               cpp10,
579               cpp11,
580               cpp7,
581               cpp5,
582               ], convexity=10);
583     hull(){
584       translate(cpp7) circle(r= catch_cr);
585       polygon([ cpp7,
586                 cpp5,
587                 cpp11 ]);
588     }
589     hull(){
590       translate(cpp6) circle(catch_cr);
591       polygon([ cppA,
592                 cpp0,
593                 cpp1 ]);
594     }
595   }
596 }
597
598 module CatchCore(){ /////toplevel
599   linear_extrude(height=catch_strap_thick, convexity=10)
600     CatchCoreProfile();
601
602   translate(concat(cppB,[0])) hull(){
603     translate([0,0, catch_knob_height - catch_knob_dia/2])
604       sphere(r = catch_knob_dia/2);
605     cylinder(r = catch_knob_dia/2, h = 0.1);
606   }
607 }
608
609 module CatchPreDistort(){ /////toplevel
610   scale(100 / sm_inner_rad)
611     rotate([90,0,0])
612     CatchCore();
613 }
614
615 module CatchAssembly(){ /////toplevel
616   rotate([0,0, -0.5 * (cpp1[0] + cpp2[0]) / sm_inner_rad * 360/TAU])
617     translate([0,0, catch_strap_width])
618     scale(sm_inner_rad / 100)
619     import(str("poster-tube-lid,CatchPostDistort-fa",
620                (coarse ? 20 : 3),
621                ".stl"),
622            convexity=20);
623
624   SomeStrap(){
625     union(){ }
626     union(){
627       translate([-200, -200, -200])
628         cube([400, 200, 400]);
629     }
630   }
631 }
632
633 module CatchDemo(){ /////toplevel
634   color("blue") translate([0,0,
635              -catch_strap_width
636              -cpp0[1]
637              ])
638     CatchAssembly();
639   translate([0,0,+side_height
640              ])
641     Cover();
642 }
643
644 module CatchDemoS(){ /////toplevel
645   color("blue") translate([0,0,
646              -catch_strap_width
647              -cpp0[1]
648              ])
649     CatchAssembly();
650   intersection(){
651     translate([0,0,+side_height
652                ])
653       Cover();
654     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
655   }
656   color("black")
657     translate([0,-33,0])
658     cube([6.15, 2,2], center=true);
659 }
660
661 module CatchPinProfileDemo(){ /////toplevel
662   echo("G ",
663        cpp2[0] - cpp1[0],
664        bayo_n[0] - bayo_e[0]);
665   color("blue") translate([-cpp2[0],
666                            -cpp2[1],
667                            +1,
668              ])
669     CatchCoreProfile();
670   polygon(bayo_polygon, convexity=10);
671 }
672
673 //ProfilesDemo();
674 //BayonetCutout();
675 //MainProfile();
676 //Cover();
677 //Jig();
678 //CoverTest();