4 include <commitid.scad>
24 interlock_fine = 0.66;
26 interlock_fine_slope = 1.0;
27 interlock_fine_lenslop = 1.0;
33 machine_rear_to_front = 85;
35 machine_rear_profile = [
51 machine_front_profile = [
66 cutout_l_end_y_front_slop = 0.5;
67 cutout_l_end_y_rear_slop = 0.5;
68 cutout_l_end_x_slop = 0.25;
71 cutout_l_end_y = machine_rear_to_front;
72 cutout_l_end_curve = 1;
73 cutout_l_end_y_total = cutout_l_end_y
74 + cutout_l_end_y_front_slop + cutout_l_end_y_rear_slop;
76 tile02_tr = [-250, 0];
79 cutout_tile01_y = 170 - 147 + cutout_l_end_y_front_slop;
80 cutout_tile11_x = cutout_l_end_x + cutout_l_end_curve;
81 cutout_tile11_y = cutout_l_end_y_total - cutout_tile01_y;
83 // front and rear curves
87 rearcurve_strt_len = 52;
89 rearcurve_z_slop = 0.75;
91 rearcurve_avoid_y = 35;
93 rearcurve_double_inrad = 26.10 + 8.04;
99 frontcurve_side_skew = 3.5 / 72;
100 frontcurve_avoid_y = 70;
101 frontcurve_z_slop = 0.75;
103 frontcurve_strt_len = 60;
104 frontcurve_dualcurve_angle = 90 - 65;
110 ply_edge_hole_dist = ply_edge_min + ply_hole_dia/2;
112 echo(str("HOLES IN PLY ctr dist from PLY edge = ", ply_edge_hole_dist));
114 hole_slop = (ply_hole_dia - post_dia)/2;
115 tile_hard_edge_hole_dist = ply_edge_hole_dist + hole_slop;
117 echo(str("HOLES IN PLY ctr dist from TILE HARD edge = ",
118 tile_hard_edge_hole_dist));
120 echo(str("HOLES IN PLY ctr dist from TILE ROUND edge = ",
121 tile_hard_edge_hole_dist + round_edge_rad));
123 thehd = [ tile_hard_edge_hole_dist, tile_hard_edge_hole_dist ];
125 thehd_tl = [ -thehd_tr[0], thehd_tr[1] ];
126 thehd_bl = -thehd_tr;
127 thehd_br = -thehd_tl;
129 tablet_z_slop = rearcurve_z_slop;
131 interlock_rad = interlock_dia/2;
132 interlock_negative_rad = interlock_rad + 0.125;
134 interlock_sq_adj = 0.2; // arbitrary
136 first_front = machine_front_profile[len(machine_front_profile)-1];
138 m4_define(`POST_TCROSSSZ',
139 `2*( tile_hard_edge_hole_dist - test_edge + 1 )')
144 cylinder(r= post_dia/2, h= tile_th + ply_th - post_shorter);
145 translate([0,0, tile_th]) {
146 cylinder(r= screw_big_dia/2, h= screw_big_len);
147 cylinder(r= screw_dia/2, h= ply_th, $fn=20);
151 translate([0,0, tile_th/2]) {
152 cube([post_dia, POST_TCROSSSZ, tile_th], center=true);
153 cube([POST_TCROSSSZ, post_dia, tile_th], center=true);
159 module Posts(posts) {
161 translate(concat(p, [0]))
166 module TileBase(botleft, topright){
167 size = topright - botleft;
168 botleft_post = botleft + thehd_tr;
169 topright_post = topright + thehd_bl;
172 translate(concat(botleft, [0]))
173 cube(concat(size, [tile_th]));
175 cidsz = topright_post-botleft_post
176 + [-post_dia,-post_dia]
178 cidszr = [ min(cidsz[0],50), min(cidsz[1],50) ];
179 echo("CID",cidsz,cidszr);
180 translate( concat(botleft_post, [ -tile_th ])
181 + 0.5 * [ post_dia, post_dia, 0 ]
182 + 0.5 * concat( cidsz - cidszr, [ 0 ]) )
183 Commitid_BestCount_M(cidszr);
186 crossoff = tile_hard_edge_hole_dist + POST_TCROSSSZ/2;
187 cidsz = [ thehd[0], size[1] - 2*crossoff ];
188 cidszr = [ cidsz[0], min(cidsz[1], 50) ];
189 translate( concat(botleft + [0, crossoff] + (cidsz-cidszr)/2, [0]) )
190 Commitid_BestCount(cidszr);
193 translate(concat(botleft + [test_edge,test_edge], [test_tile_th]))
194 cube(concat(size - [test_edge,test_edge]*2, [tile_th]));
195 translate(concat(botleft_post, [-1]))
196 cube(concat(topright_post-botleft_post, [tile_th+2]));
198 shufflesz = max(test_edge, tile_hard_edge_hole_dist)*2;
201 cube(shufflesz, center=true);
208 m4_dnl INREFFRAME(left_cnr, right_cnr, morevars) { body; }
209 m4_define(`INREFFRAME',`
210 length_vec = ($2) - ($1);
211 length = dist2d([0,0], length_vec);
212 length_uvec = length_vec / length;
213 ortho_uvec = [ -length_uvec[1], length_uvec[0] ];
214 m = [ [ length_uvec[0], ortho_uvec[0], 0, ($1)[0], ],
215 [ length_uvec[1], ortho_uvec[1], 0, ($1)[1], ],
222 m4_dnl INREFFRAME(left_cnr, right_cnr, morevars)
223 m4_dnl INREFFRAME_EDGE { body; }
224 m4_define(`INREFFRAME_EDGE',`
225 translate([0,0, -round_edge_rad])
228 module RoundEdge(left_cnr, right_cnr) {
229 INREFFRAME(left_cnr, right_cnr)
233 cylinder(r= round_edge_rad, h= length, $fn=50);
234 translate([-1, 0, -20])
235 cube([length+2, 20, 20]);
240 m4_define(`ROUNDCORNER_VARS',`
244 bigr= round_cnr_rad - round_edge_rad;
245 l_uvec = unitvector2d(left_cnr - this_cnr);
246 r_uvec = unitvector2d(right_cnr - this_cnr);
247 lp1 = left_cnr + clockwise2d(l_uvec) * bigr;
248 lp2 = this_cnr + clockwise2d(l_uvec) * bigr;
249 lp3 = this_cnr - clockwise2d(r_uvec) * bigr;
250 lp4 = right_cnr - clockwise2d(r_uvec) * bigr;
251 ctr = line_intersection_2d(lp1,lp2,lp3,lp4);
252 ctr3 = concat(ctr,[0])
255 module RoundCorner_selector(ci, adj) {
257 echo("RCS",l_uvec,ctr);
259 INREFFRAME(this_cnr, right_cnr) {
260 cube(bigr*2 + adj, center=true);
263 %translate(concat(ctr,[0])) circle(1);
266 INREFFRAME(this_cnr, right_cnr) {
267 // %translate([ -bigr,-bigr,0 ])
268 // cube([bigr*2 + adj, bigr*3, bigr*2]);
272 INREFFRAME(this_cnr, left_cnr) {
273 %translate([ -bigr,-bigr,0 ])
279 module RoundCornerCut(ci) {
280 // ci should be [this_cnr, right_cnr, left_cnr]
281 // where right_cnr is to the right (ie, anticlockwise)
284 RoundCorner_selector(ci, -0.1);
286 cylinder(center=true, h=20, r= bigr);
290 module RoundCornerAdd(ci) {
293 RoundCorner_selector(ci, +0.1);
296 rotate_extrude(convexity=10, $fn=50)
299 circle(r= round_edge_rad, $fn=50);
308 module InterlockLobePlan(negative) {
309 r = negative ? interlock_negative_rad : interlock_rad;
310 ymir = negative ? 0 : 1;
314 translate([thehd[0], 0]){
318 translate([-dx, -0.1])
319 square([ dx*2, r/2 + 0.1 ]);
321 translate([ xi*dx, r ])
329 module InterlockEdgePlan(negative, nlobes, length, dosquare=true) {
330 for (lobei = [ 0 : nlobes-1 ]) {
331 lobex = (length - thehd[0]*2) * (lobei ? lobei / (nlobes-1) : 0);
332 translate([lobex, 0, 0]) {
333 InterlockLobePlan(negative);
339 slotshorter = negative ? -0.1 : interlock_fine_lenslop;
340 mirror([0, negative])
341 translate([slotshorter, iadj])
342 square([length - slotshorter*2, interlock_fine + iadj*2]);
346 module InterlockEdge(left_cnr, right_cnr, negative=0, nlobes=2) {
347 plusth = negative * 1.0;
348 protr = interlock_fine + interlock_sq_adj;
351 z1 = -tile_th/2 - protr / interlock_fine_slope;
352 z3 = -tile_th/2 + protr / interlock_fine_slope;
354 negsign = negative ? -1 : +1;
355 yprotr = negsign * protr;
357 INREFFRAME(left_cnr, right_cnr) {
358 for (vsect = [ // zs0 zs1 ys0, ys1
359 [ -tile_th-plusth, plusth, 0, 0],
360 [ z1, z2, 0, yprotr],
361 [ z2, z3, yprotr, 0],
371 [ 0,1, -sl, -ys0 + negsign*interlock_sq_adj ],
375 linear_extrude(height=zsd, convexity=10)
376 InterlockEdgePlan(negative, nlobes, length, !!ysd);
381 function TestPiece_holes2corners(holes) =
382 [ holes[0] + thehd_bl,
385 holes[0] + thehd_tl ];
387 module TestPiece1(){ ////toplevel
391 corners = TestPiece_holes2corners(holes);
392 rcs = [corners[0], corners[1]];
395 TileBase(corners[0], corners[2]);
397 RoundEdge(corners[0], corners[1]);
398 RoundEdge(corners[3], corners[0]);
400 InterlockEdge(corners[1], corners[2], 1, nlobes=1);
406 module TestPiece2(){ ////toplevel
410 corners = TestPiece_holes2corners(holes);
411 TileBase(corners[0], corners[2]);
413 RoundEdge(corners[0], corners[1]);
414 InterlockEdge(corners[3], corners[0], 0, nlobes=1);
417 module TestDemo(){ ////toplevel
418 translate([ -thehd[0], 0 ])
421 translate([ +thehd[0] + demo_slop, 0 ])
425 module Machine_Arm(){
426 ysz = cutout_l_end_y_total;
427 // assume the round end is arc of a circle
428 chordlen = dist2d([0,0], [ cutout_l_end_y, cutout_l_end_curve ]);
429 endrad = cutout_l_end_y / cutout_l_end_curve * chordlen;
431 translate([0,0,-30]) linear_extrude(height=60) {
432 translate(tile01_tr + [0, (-cutout_tile01_y + cutout_tile11_y)/2]) {
434 translate([-50, -ysz/2])
436 translate([ endrad - cutout_tile11_x - cutout_l_end_x_slop, 0 ])
437 circle(r=endrad, $fa=0.01,$fd=5);
443 module Machine_Profile(){
444 first_rear = machine_rear_profile[0];
445 below_point = 0.5 * ( first_rear + first_front ) + [ 0, -10 ];
446 pol = concat( machine_rear_profile,
448 machine_front_profile);
449 skew_angle = atan2( first_front[1] - first_rear[1],
450 first_front[0] - first_rear[0] );
451 //echo(below_point, pol, skew_angle);
456 rotate([0,0, -skew_angle ]){
457 //translate( - first_front )
465 module Machine_NewRearProfile(){
466 // figures copied out of xfig edit boxes
467 // best not to edit the posbox size if poss - just move it
468 posbox = 10 * ([7.2333,-14.1267] - [-16.2289,40.0289]); // box, Green
469 sideline = -10 * ([-6.2400,13.5600] - [-2.4467,28.2556]); // line, Blue
470 scaleline = 10 * dist2d([-1.1911,-20.4800], [-11.2600,4.0578]); // Green2
471 scaleline_mm = 12+5+10+5+3;
472 sh = -[abs(posbox[0]), abs(posbox[1])];
473 rot = atan2(-sideline[0], sideline[1]);
474 sc = scaleline_mm / scaleline;
475 //echo("SH",sh,rot,sc);
476 scale(sc) rotate(rot) translate(sh){
477 import("sewing-table-rear-profile.dxf", convexity=10); // spline, Pink3
481 module Machine_NewRearCurve(){
482 slant = atan2(4,210-10);
484 translate([0,0, rearcurve_double_inrad]) rotate([slant,0,0]){
485 translate([ rearcurve_double_inrad,
487 -rearcurve_double_inrad + 10 ]){
488 rotate([180,0,0]) rotate([0,0,90]) linear_extrude(height=30){
490 Machine_NewRearProfile();
491 translate([0,-100]) Machine_NewRearProfile();
495 rotate([0,90,0]) rotate([90,0,0]) {
497 rotate_extrude(convexity=10, $fn=64)
499 translate([ 0, -rearcurve_double_inrad ])
500 Machine_NewRearProfile();
501 translate([0,0,-500])
502 cube([500,500,1000]);
505 translate([1,0,-rearcurve_double_inrad])
506 rotate([0,-90,0]) rotate([0,0,-90])
507 linear_extrude(height= rearcurve_strt_len + 1)
508 Machine_NewRearProfile();
512 module Machine_RearProfile(){ ////toplevel
515 translate([ -200 + machine_rear_to_front/2, -100 ]) {
521 module Machine_FrontProfile(){
524 translate([ machine_rear_to_front/2, -100 ]) {
530 module Machine_Curves(){ ////toplevel
531 translate([ tile01_tr[0] - cutout_l_end_x + rearedge_len,
535 translate([ -reartablet_x,
537 -reartablet_z + tablet_z_slop])
539 cube([ reartablet_x+1,
543 translate([ tile01_tr[0] - cutout_l_end_x + rearedge_len,
545 frontcurve_z_slop ]){
546 translate([ 0, -first_front[0] , 0 ])
547 multmatrix([[1, -frontcurve_side_skew, 0, 0],
551 translate([ 0, first_front[0] , 0 ])
553 rotate([0,-90,0])rotate([0,0,-90]){
554 linear_extrude(height= 200)
555 Machine_FrontProfile();
558 translate([ rearcurve_strt_len,
561 Machine_NewRearCurve();
566 module Machine(){ ////toplevel
571 module MachineEnvelope(){
573 p_arm_bl = [-cutout_tile11_x, -cutout_tile01_y];
574 y_arm_t = cutout_tile11_y;
575 p_crv_fl = p_arm_bl + [rearedge_len, -frontcurve_avoid_y];
576 y_crv_b = y_arm_t + rearcurve_avoid_y;
578 translate([0,0,-50]) linear_extrude(height= 100){
579 translate(p_arm_bl) square([400, y_arm_t] - p_arm_bl);
580 translate(p_crv_fl) square([400, y_crv_b] - p_crv_fl);
584 function Rectangle_corners(c0, sz) =
585 // returns the corners of a rectangle from c0 to c0+sz
586 // if sz is positive, the corners are anticlockwise starting with c0
589 c0 + [ sz[0], sz[1] ],
592 function Rectangle_corners2posts(c) =
598 module Rectangle_TileBase(c) { TileBase(c[0], c[2]); }
600 function Posts_interpolate_one(c0,c1) = [c0, (c0+c1)/2, c1];
603 m4_dnl c is from Rectangle_corners and
604 m4_dnl ix is a corner number
605 m4_dnl expands to two comma-separated corners:
606 m4_dnl that denoted by ix, and the next one anticlockwise
607 m4_define(`R_EDGE',`$1[$2],$1[(($2)+1)%4]')
609 module FitTest_general(c0,sz, dobrace=false){
610 c = Rectangle_corners(c0, sz);
614 Rectangle_TileBase(c);
616 translate(concat(c0, [-brace[2] + 0.1])){
618 cube(concat(sz,[brace[2]]) - [5,0,0]);
619 translate(brace + [0,0, -25])
620 cube(concat(sz, [50]) - brace*2 + [10,0,0]);
624 RoundEdge(R_EDGE(c,1));
630 module FitTest_Entire(){ ////toplevel
631 FitTest_general([-40,-80], [275,180], dobrace=true);
634 module FitTest_RearCurve(){ ////toplevel
635 FitTest_general([110,0], [170,100]);
638 module Tile02(){ ////toplevel
640 c0 = tile02_tr + -sz;
641 c = Rectangle_corners(c0, sz);
642 posts = Rectangle_corners2posts(c);
646 Rectangle_TileBase(c);
648 RoundEdge(R_EDGE(c,0));
649 RoundEdge(R_EDGE(c,3));
650 InterlockEdge(R_EDGE(c,2), 0);
652 InterlockEdge(R_EDGE(c,1), 1);
658 module Tile12(){ ////toplevel
660 c0 = tile02_tr + [-sz[0], 0];
661 c = Rectangle_corners(c0, sz);
662 posts = Rectangle_corners2posts(c);
666 Rectangle_TileBase(c);
668 RoundEdge(R_EDGE(c,2));
669 RoundEdge(R_EDGE(c,3));
671 InterlockEdge(R_EDGE(c,0), 1);
672 InterlockEdge(R_EDGE(c,1), 1);
678 tile_01_11_cnr = tile01_tr + [-cutout_tile11_x, 0];
679 tile_11_10_cnr = tile01_tr + [0, cutout_tile11_y];
680 tile_01_00_cnr = tile01_tr - [0, cutout_tile01_y];
682 module Tile11(){ ////toplevel
684 c0 = tile01_tr + [-sz[0],0];
685 c = Rectangle_corners(c0, sz);
686 cnr_posts = Rectangle_corners2posts(c);
688 Posts_interpolate_one(cnr_posts[0],
689 cnr_posts[1] - [cutout_tile11_x, 0]),
690 [ cnr_posts[1] + [0, cutout_tile11_y],
696 Rectangle_TileBase(c);
698 RoundEdge(R_EDGE(c,2));
699 InterlockEdge(R_EDGE(c,3));
701 InterlockEdge(c[0], tile_01_11_cnr, 1);
702 InterlockEdge(tile_11_10_cnr, c[2], 1);
707 module Tile01(){ ////toplevel
709 c0 = tile01_tr + -sz;
710 c = Rectangle_corners(c0, sz);
711 cnr_posts = Rectangle_corners2posts(c);
713 Posts_interpolate_one(R_EDGE(cnr_posts,0)),
714 [ cnr_posts[2] + [0, -cutout_tile01_y] ],
715 Posts_interpolate_one(cnr_posts[2] - [cutout_tile11_x, 0],
720 Rectangle_TileBase(c);
722 RoundEdge(R_EDGE(c,0));
723 InterlockEdge(tile_01_11_cnr, c[3]);
724 InterlockEdge(R_EDGE(c,3));
726 InterlockEdge(c[1], tile_01_00_cnr, 1);
731 module Tile10(){ ////toplevel
733 c0 = tile01_tr + [0,0];
734 c = Rectangle_corners(c0, sz);
735 cnr_posts = Rectangle_corners2posts(c);
736 cty = cutout_tile11_y;
737 rcy = cty + rearcurve_avoid_y;
738 posts = [ cnr_posts[0] + [ 0, cty ],
739 cnr_posts[1] + [ -sz[0] + rearedge_len - cutout_l_end_x, cty ],
740 cnr_posts[1] + [ 0, rcy ],
746 Rectangle_TileBase(c);
748 RoundEdge(R_EDGE(c,1));
749 RoundEdge(R_EDGE(c,2));
750 InterlockEdge(c[3], tile_11_10_cnr);
758 module Tile00(){ ////toplevel
760 c0 = tile01_tr + [0,-sz[1]];
761 c = Rectangle_corners(c0, sz);
763 // the edge c[1]..c[2] needs a diagonal chunk, from c1bis to c2bis
764 c2bis = [ -cutout_l_end_x + rearedge_len + frontcurve_strt_len, c[2][1] ];
767 (c[2][0] - c2bis[0]) * tan(90 - frontcurve_dualcurve_angle) ];
769 cnr_posts = Rectangle_corners2posts(c);
770 cty = cutout_tile01_y;
771 rcy = cty + frontcurve_avoid_y;
772 posts = [ cnr_posts[0],
774 cnr_posts[2] + [ 0, -rcy ],
775 cnr_posts[2] + [ -sz[0] + rearedge_len - cutout_l_end_x, -cty ],
776 cnr_posts[3] + [ 0, -cty ]
783 Rectangle_TileBase(c);
785 RoundEdge(R_EDGE(c,0));
786 RoundEdge(c[1], c1bis);
787 InterlockEdge(tile_01_00_cnr, c[0]);
790 translate([0,0,-20]) linear_extrude(height=40) {
791 polygon([ c1bis, c1bis + [50,0], c2bis + [50,0], c2bis ]);
794 RoundEdge(c1bis, c2bis);
799 RoundCornerAdd([c1bis,c2bis,c[1]]);
802 module FitTest_FrontCurve(){ ////toplevel
807 translate([0,0,-8]) linear_extrude(height=18) {
808 translate(p0) square(sz);
813 module RoundCornerDemo_plat(cnr){
814 mirror([0,0,1]) linear_extrude(height=1) polygon(cnr);
817 module RoundCornerDemo(){ ////toplevel
818 cnr = [ [0,0], [15,0], [-10,12] ];
819 translate([0,25,0]) RoundCornerDemo_plat(cnr);
820 translate([25,0,0]) RoundCornerAdd(cnr);
821 translate([-25,0,0]) RoundCornerCut(cnr);
822 translate([0,-25,0]) RoundCorner_selector(cnr, 0);
824 RoundCornerDemo_plat(cnr);
830 module Demo(){ ////toplevel
831 translate(demo_slop*[-2,1]) color("blue") Tile12();
832 translate(demo_slop*[-2,0]) color("red") Tile02();
833 translate(demo_slop*[-2,1]) color("orange") Tile11();
834 translate(demo_slop*[-2,0]) color("purple") Tile01();
835 translate(demo_slop*[-3,1]) color("blue") Tile10();
836 translate(demo_slop*[-3,0]) color("red") Tile00();
845 //Machine_NewRearProfile();
846 //Machine_NewRearCurve();