// -*- C -*- coarse = false; main_dia = 71.2 + 0.50 - 2.26; top_thick_middle = 4; top_thick_by_oring = 3.0; top_middle_dr = 11; main_cnr = 6.0; min_wall = 3; rivet_posn = 6.0 + 0.30; rivet_thick = 1.67; rivet_width = 4.15 + 1.0; rivet_tall = 5.51 + 1.49; over_rivet_wall = 1.0; side_rivet_gap = 1.5; inside_rivet_gap = 1.5; bayo_interf = 0.30; bayo_behind = 3.5; bayo_interf_width = 2.0; bayo_interf_slope = 0.5; oring_thick = 5.0; oring_bore = 62.0; oring_upper_embed_angle = 80; oring_compress = 0.1; // proportion oring_compress_more = 0.2; oring_rm_beside = 8; oring_rm_scale = 2.0; oring_rm_angle = 20; side_taper = 1.0; bayo_gap = 6.0; bayo_entry = bayo_behind/3; bayo_slice_size = coarse ? 5 : 1; brace_hole_width = 1.0; brace_above_below = 1.2; brace_end_shorter = 0.3; jig_thick = 1.4; jig_hole_dia = 3.0; jig_rim = 5; jig_mark = 5; strap_hoop_thick = 6; strap_hoop_inside = 10; strap_hoop_strlen = 10; strap_hoop_elevation = 45; sm_inner_circum = 218 - 1.90 - 1.00 - 0.50; sm_main_thick = 2.0; sm_main_width = 20; sm_bolt_dia = 3.5 + 0.1; sm_bolt_shaft = 21.9; sm_bolt_head_dia = 6.94 + 1.0; sm_bolt_head_thick = 2.14; sm_bolt_nut_width = 5.89 + 0.25; sm_bolt_nut_thick = 3.68; sm_bolt_tighten_allow = 2.0; sm_bolt_y_clear = 0.75; sm_bolt_y_over = 0.5; sm_closure_cnr = 3.0; // calculated TAU = PI*2; bayo_entry_x = bayo_entry; bayo_entry_z = bayo_entry; bayo_inramp_x = bayo_entry; bayo_inramp_z = bayo_entry; oring_mid_dia = oring_bore + oring_thick; oring_outer_dia = oring_mid_dia + oring_thick; oring_oblate = (1 - oring_compress); oring_y_rad = oring_thick/2 * oring_oblate; oring_x_rad = oring_thick/2 / oring_oblate; by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle)); side_height = rivet_posn + bayo_behind + rivet_thick/2; side_thick = rivet_tall + over_rivet_wall; top_z = top_thick_by_oring + oring_y_rad + by_oring_z; middle_bot_z = top_z - top_thick_middle; bayo_entry = bayo_behind / 3.0; bayo_top_z = bayo_behind + bayo_gap; rivet_entry_width = rivet_width + side_rivet_gap; jig_mark_rad = jig_mark + main_dia/2 + jig_thick; handling_dia = oring_bore + oring_thick*2 + min_wall*2; handling_angle = 45; sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU; sm_outer_rad = sm_inner_rad + sm_main_thick; smc_pos = [ 0, sm_inner_rad, 0 ]; smc_bolt_nut_dia = sm_bolt_nut_width / cos(30); smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow; smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear; smc_max_y = smc_bolt_y + sm_bolt_y_over + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2); smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2; $fs= coarse ? 2.5 : 0.5; $fa= coarse ? 5 : 1; include // bayonet definition bayo_a = [ bayo_entry_x, 0 ]; bayo_p = [ 0, bayo_entry_z ]; bayo_n = [ 0, bayo_behind-bayo_inramp_z ]; bayo_m = [ bayo_inramp_x, bayo_behind ]; bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope, 1 ]; bayo_k = bayo_l + [ bayo_interf_width, 0 ]; bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ]; bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ]; bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ]; bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ]; bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0]; bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0]; bayo_c = bayo_d + [0,-5]; bayo_b = bayo_a + [0,-5]; bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ]; bayo_polygon = [ bayo_a, bayo_b, bayo_c, bayo_d, bayo_e, bayo_f, bayo_g, bayo_h, bayo_i, bayo_j, bayo_k, bayo_l, bayo_m, bayo_n, bayo_p ]; echo(bayo_polygon); module MainProfile(){ main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr; difference(){ union(){ translate(main_cnr_pos){ intersection(){ difference(){ circle(r = main_cnr); circle(r = main_cnr * 0.5); } square([10,10]); } } polygon([[ -top_middle_dr, middle_bot_z ], [ -top_middle_dr, top_z ], [ main_cnr_pos[0], top_z ], [ side_thick, main_cnr_pos[1] ], [ side_thick, -side_height ], [ side_taper, -side_height ], [ 0, -rivet_posn ], [ 0, by_oring_z ], [ -oring_x_rad, by_oring_z ], ], convexity=10); } translate([ oring_mid_dia/2 - main_dia/2, 0 ]) hull(){ translate([ 0, oring_y_rad ]) scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ]) circle(oring_thick/2); translate([ 0, oring_y_rad*2 - oring_thick/2 ]) circle(oring_thick/2); } } } module StrapHoopProfile(){ circle(r = strap_hoop_thick/2); } module StrapHoop(){ ////toplevel bigrad = strap_hoop_inside/2 + strap_hoop_thick/2; extralen = strap_hoop_thick * 5; intersection(){ rotate([strap_hoop_elevation, 0,0]){ for (x= [ -1, +1 ] * bigrad) { translate([x, -extralen, 0]) rotate([-90,0,0]) linear_extrude(height= extralen + strap_hoop_strlen + 0.1, convexity=10) StrapHoopProfile(); } translate([0, strap_hoop_strlen, 0]){ intersection(){ rotate_extrude(convexity=10) translate([bigrad, 0,0]) StrapHoopProfile(); translate([0,50,0]) cube([100,100,100], center=true); } } } translate([0, 50, 0]) cube(100, center=true); } } module HandlingProfile(){ // translate([ } module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){ // nom_rad > real_rad rotate([0,0, atan2(offset, nom_rad) ]){ intersection(){ translate([-offset, -10, 0]) rotate([90,0,0]) linear_extrude(height= nom_rad*2) children(0); translate([0,0, -25]) cylinder(h=50, r= real_rad); translate([0,0, -25]) linear_extrude(height= 50) polygon([ [ 0,0 ], [ -slice_size, -real_rad*2 ], [ +slice_size, -real_rad*2 ] ]); } } } module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){ offs = [ for (i=[ x_min : slice_size : x_max + slice_size ]) i ]; echo (offs); for (off=offs) RotateProjectSlice(off, slice_size, nom_rad, real_rad) children(0); } module BayonetCutout(){ RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size, main_dia/2 + side_thick, main_dia/2 + rivet_tall) translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0]) polygon(bayo_polygon, convexity=10); } module ProfilesDemo(){ ////toplevel translate([-10,0]) MainProfile(); translate([+10, -side_height]) polygon(bayo_polygon, convexity=10); } module LimitForHandling(){ ////toplevel hull() for (r=[0,180]) rotate([0,0,r]) { for (rs=[-1,+1]) { for (xd=[0,1]) { rotate([0,0, rs * handling_angle/2]) { translate([rs * xd * main_dia/2 * tan(handling_angle/2), main_dia/2 + side_thick - main_cnr, top_z - main_cnr]) { mirror([0,0,1]) cylinder(r= main_cnr, h=50); sphere(main_cnr); } } } } } hull() rotate_extrude(){ translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) { circle(r = main_cnr); mirror([0,1]) square([ main_cnr, 50 ]); } } //cylinder(r= handling_dia/2, h=20); } module Cover(){ ////toplevel render() difference(){ intersection(){ union(){ rotate_extrude(convexity=10) translate([main_dia/2, 0]) MainProfile(); translate([0,0, middle_bot_z]) cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1); } LimitForHandling(); } for (r=[0,180]){ rotate([0,0, r]) translate([0,0, -side_height]) BayonetCutout(); rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))]) translate([0, oring_mid_dia/2 + oring_thick/4 * oring_rm_scale, oring_y_rad * 1.5]) rotate([-oring_rm_angle, 0, 0]) mirror([0,0,1]) cylinder(r = oring_thick/4 * oring_rm_scale, h=20); } for (r=[0 : 60 : 179]) { rotate([0,0, r]) { height = top_thick_middle - brace_above_below*2; translate([0,0, middle_bot_z + brace_above_below + height/2 ]) cube(center=true, [ oring_bore - brace_end_shorter, brace_hole_width, height ]); } } } for (r=[0,180]) rotate([0,0,r]) translate([-implheadcup_large_dia * .5 - implheadcup_thick/2, -implheadcup_large_dia * .0, middle_bot_z + 0.1]) ImplHeadCup(); // translate(strap_hoop_thick * [-0.5, 0, +1]) // translate([handling_dia/2, 0, -side_height]) // rotate([0,180,0]) rotate([0,0,90]) // StrapHoop(); } module SavingHole(){ translate([0,0, -10]) cylinder(r= main_dia/2 - jig_rim, h=20); } module Jig(){ ////toplevel difference(){ union(){ translate([0,0, -side_height]){ cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick); } translate([-jig_mark_rad, 0, jig_thick - jig_mark]) cube([jig_mark_rad*2, jig_mark, jig_mark]); } translate([0,0, -side_height-1]) cylinder(r= main_dia/2, h= side_height + 1); SavingHole(); translate([0,0, -rivet_posn]) rotate([90, 0,0]) translate([0,0, -100]) cylinder(r= jig_hole_dia/2, h = 200); } } module CoverTest2(){ ////toplevel difference(){ Cover(); SavingHole(); } } module CoverTest1(){ ////toplevel difference(){ CoverTest2(); difference(){ for (r= [ 40, 147 ]){ rotate([0,0, r]){ translate([0,0, -10]) { cube([ main_dia*3, main_dia * .53, 18], center=true); } } } // translate([ 50, 0, 0 ]) // cube([ 100, // strap_hoop_inside + strap_hoop_thick*2 + 1, // 100 ], // center=true); } } } module ImplHeadCupTest(){ ////toplevel for (r=[0,180]) rotate([0,0,r]) translate([-17,0,0]) ImplHeadCup(); } module StrapMountBolt(l_delta){ ///toplevel // positioned relative to smc_pos translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2, smc_bolt_y, sm_main_width/2]){ translate([ -sm_bolt_shaft/2-1, 0,0 ]){ rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2); } translate([ -sm_bolt_shaft/2, 0,0 ]) rotate([0,-90,0]) cylinder($fn=6, r=smc_bolt_nut_dia/2, h=smc_bolt_nut_eff_thick + l_delta); translate([ sm_bolt_shaft/2, 0,0 ]) rotate([0,90,0]) cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta); } } module StrapMountProtrusion(half_x, max_y, cnr){ translate(smc_pos){ linear_extrude(height=sm_main_width, convexity=10){ hull(){ for (m = [0,1]) mirror([m,0,0]) { translate([-(half_x - cnr), max_y - cnr]) circle(r=cnr); translate([-half_x, -sm_inner_rad]) square([1,1]); } } } } } module StrapMount(){ ////toplevel difference(){ union(){ cylinder(r=sm_outer_rad, h=sm_main_width); StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr, smc_max_y, sm_closure_cnr); rotate([0,0,180]){ StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick, strap_hoop_thick, sm_closure_cnr); translate(smc_pos + [0,0, sm_main_width] + strap_hoop_thick * [ 0, 0.5, -1.0 ]) StrapHoop(); } } translate([0,0,-1]) cylinder(r=sm_inner_rad, h=sm_main_width+2); translate(smc_pos) StrapMountBolt(10); translate(smc_pos) cube([ sm_bolt_tighten_allow, 40,100 ], center=true); } } //ProfilesDemo(); //BayonetCutout(); //MainProfile(); //Cover(); //Jig(); //CoverTest();