chiark / gitweb /
sleepphone-cable-box: octagonal led
[reprap-play.git] / belt-slot-cut-jig.scad
index aa0f632..543a53f 100644 (file)
@@ -1,15 +1,32 @@
 // -*- C -*-
 
+// todo
+//  various registration marks
+//   protrustions at ends at strap width and middle
+//   grooves on top face at 1/4,1/2,3/4 length and 1/2 width
+
+strap_thick = 3;
+strap_width = 26.75 + 0.7;
+
+jig_interval = 25;
+
+edgewall_width = 3;
 crewpunch_slop = 0.3;
+main_slop = 0.25;
 
 holder_min_wall = 2;
+holder_attach_near_wall = 5;
 
 holder_attach_xsz = 5;
 holder_ctie_width = 4.0 + 0.5;
-holder_ctie_thick = 2.0 + 0.5;
+holder_ctie_thick = 3.0 + 0.5;
 holder_attach_walls = 3;
 holder_attach_roof = 2.5;
 
+holder_corner_round = 2.0;
+
+punch_travel = 8;
+
 // from careful measurement
 
 crewpunch_shape =
@@ -18,28 +35,58 @@ crewpunch_shape =
    [ 10, [1.6, 6.5], [2.1, 12.8] ],
    [ 12, [1.8, 6.6], [2.3, 12.7] ],
    [ 14, [2.1, 6.8], [2.6, 13.0] ],
-   [ 16, [2.4, 6.9], [2.7, 13.2] ]];
+   [ 16, [2.4, 6.9], [2.7, 13.2] ],
+   [ 18, [2.5, 7.0], [2.9, 13.3] ],
+   [ 22, [3.1, 7.1], [3.2, 13.4] ],
+   [ 26, [3.3, 7.2], [3.5, 13.6] ], 
+   ];
 
 crewpunch_shaft_max_y = 7.5;
 
 crewpunch_systematic_size_error = +0.36;
 
-crewpunch_min_y = 4.7 - crewpunch_systematic_size_error;
-
 crewpunch_smallest_shape = crewpunch_shape[0];
 crewpunch_biggest_shape = crewpunch_shape[len(crewpunch_shape)-1];
 
+crewpunch_skew_angle = 3.5; //degrees
+crewpunch_skew_yoff = +1.1; //mm
+
 // computed
 
+punch_dx = 0.5 * (-crewpunch_biggest_shape[2][0]
+                 +crewpunch_biggest_shape[2][1]);
+punch_dy = 0.5 * (+crewpunch_biggest_shape[1][1]
+                 -crewpunch_biggest_shape[1][0]) + crewpunch_skew_yoff;
+
 attach_ysz = holder_attach_walls*2 + holder_ctie_width;
-holder_front_wall = crewpunch_shaft_max_y - crewpunch_biggest_shape[1][1]
-  + attach_ysz;
 
 holder_block_zsz = crewpunch_biggest_shape[0] - crewpunch_smallest_shape[0];
 holder_xsz = crewpunch_biggest_shape[2][0] + crewpunch_biggest_shape[2][1] +
   holder_min_wall*2;
-holder_ysz = crewpunch_biggest_shape[1][0] + crewpunch_biggest_shape[1][1] +
-  holder_min_wall + holder_front_wall;
+
+holder_skewangle_yextra = holder_xsz/2 * sin(abs(crewpunch_skew_angle));
+
+holder_max_y = punch_dy + crewpunch_biggest_shape[1][0] + holder_min_wall
+  + crewpunch_systematic_size_error + holder_skewangle_yextra;
+
+holder_attach_max_y = punch_dy
+  - max(crewpunch_biggest_shape[1][1], crewpunch_shaft_max_y)
+  - crewpunch_systematic_size_error - holder_skewangle_yextra;
+
+holder_block_min_y = punch_dy
+  - crewpunch_biggest_shape[1][1] - holder_attach_near_wall +
+  - crewpunch_systematic_size_error - holder_skewangle_yextra;
+
+holder_all_min_y = holder_attach_max_y - attach_ysz;
+
+jig_max_y = max(holder_max_y + main_slop, strap_width/2) + edgewall_width;
+jig_min_y = min(holder_all_min_y - main_slop, -strap_width/2) - edgewall_width;
+
+jig_main_zsz = holder_block_zsz + punch_travel;
+
+// common stuff
+
+include <belt-cut-jig-common.scad>
 
 // objects
 
@@ -53,7 +100,7 @@ module CrewPunch(){
            mirror([xind?1:0,0,0]) mirror([0,yind?0:1,0]){
              translate([-0.1,-0.1,-0.1])
                cube([0.1 + layer[2][xind] + ourslop,
-                     0.1 + layer[1][yind] + ourslop,
+                     0.1 + layer[1][1-yind] + ourslop,
                      0.2]);
            }
       }
@@ -61,25 +108,88 @@ module CrewPunch(){
   }
 }
 
-module PunchHolder(){
-  offset = holder_attach_xsz + holder_min_wall;
-  difference(){
-    translate([0,offset,0])
-      cube([holder_xsz, holder_ysz - offset, holder_block_zsz]);
-    translate([crewpunch_biggest_shape[2][1] + holder_min_wall,
-              crewpunch_biggest_shape[1][0] + holder_front_wall,
-              -crewpunch_smallest_shape[0]])
-      CrewPunch();
+module MaybeRoundedCube(sizes, roundedness){
+  if (roundedness > 0) {
+    translate([roundedness, roundedness, 0]){
+      minkowski(){
+       cube([sizes[0] - roundedness*2,
+             sizes[1] - roundedness*2,
+             sizes[2]]);
+       cylinder(h=0.05, r=roundedness, $fn=20);
+      }
+    }
+  } else {
+    cube(sizes);
   }
-  difference(){
-    translate([holder_xsz/2 - holder_attach_xsz/2, 0, 0])
-      cube([holder_attach_xsz,
-           attach_ysz,
-           holder_block_zsz + holder_ctie_thick + holder_attach_roof + 1]);
-    translate([-30, holder_attach_walls, holder_block_zsz + 0.1])
-      cube([60, holder_ctie_width, holder_ctie_thick]);
+}
+
+module PunchHolder(cutouts=true){
+  roundedness = cutouts ? holder_corner_round : 0;
+    difference(){
+      translate([-holder_xsz/2, holder_block_min_y, 0])
+       MaybeRoundedCube([holder_xsz,
+                         holder_max_y - holder_block_min_y,
+                         holder_block_zsz],
+                        roundedness);
+      if (cutouts)
+       rotate([0,0,-crewpunch_skew_angle])
+       translate([punch_dx,
+                  punch_dy,
+                  -crewpunch_smallest_shape[0]])
+         CrewPunch();
+    }
+    difference(){
+      translate([-holder_attach_xsz/2, holder_all_min_y, 0])
+       MaybeRoundedCube([holder_attach_xsz,
+                         attach_ysz,
+                         holder_block_zsz + punch_travel
+                         + holder_ctie_thick + holder_attach_roof + 1],
+                        roundedness);
+      if (cutouts)
+       translate([-30,
+                  holder_all_min_y + holder_attach_walls,
+                  holder_block_zsz + punch_travel])
+         cube([60, holder_ctie_width, holder_ctie_thick]);
+    }
+}
+
+module OneJigCutout(){
+  minkowski(){
+    cube([main_slop*2, main_slop*2, 50], center=true);
+    PunchHolder(false);
   }
 }
-       
+
+module JigT(){ ////toplevel
+  JigPrint();
+}
+
+module PunchHolderT(){ ////toplevel
+  PunchHolder(true);
+}
+
+module Demo(){ ////toplevel
+  %PunchHolder();
+  Jig();
+}
+
+module Kit(){ ////toplevel
+  JigT();
+  rotate([0,0,-45]){
+    translate([(jig_iters-1)*jig_interval/2,
+              jig_min_y - holder_max_y - 5,
+              0])
+      PunchHolder();
+  }
+}
+
 //CrewPunch();
-PunchHolder();
+//PunchHolder();
+//PunchHolder(false);
+//OneJig();
+//Jig();
+Demo();
+//JigT();
+//RegistrationProtrusion();
+//PunchHolderT();
+//Kit();