belt-slot-cut-jig: for test prints

[reprap-play.git] / belt-slot-cut-jig.scad

diff --git a/belt-slot-cut-jig.scad b/belt-slot-cut-jig.scad
index 3f59f9725d7f74255b23208b41528d9eb579ec5d..6a5175be1624fb1345e33000ab6b600225d5c677 100644 (file)
--- a/belt-slot-cut-jig.scad
+++ b/belt-slot-cut-jig.scad
@@ -1,5 +1,186 @@
 // -*- 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
+
+crewpunch_slop = 0.3;
+
+holder_min_wall = 2;
+holder_attach_near_wall = 3;
+
+holder_attach_xsz = 5;
+holder_ctie_width = 4.0 + 0.5;
+holder_ctie_thick = 2.0 + 0.5;
+holder_attach_walls = 3;
+holder_attach_roof = 2.5;
+
+jig_interval = 25;
+strap_width = 25;
+strap_thick = 3;
+edgewall_width = 3;
+
+punch_travel = 8;
+
+main_slop = 0.5;
+
+jig_max_len = 160; // print diagonally
+//jig_max_len = 30;
+
+registrationgroove_width = 0.8;
+registrationgroove_depth = 1.2;
+
+// from careful measurement
+
+crewpunch_shape =
+  [[  6, [0.6, 6.0], [1.6, 12.3] ],
+   [  8, [1.1, 6.2], [1.9, 12.5] ],
+   [ 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] ]];
+
+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];
+
+// computed
+
+attach_ysz = holder_attach_walls*2 + holder_ctie_width;
+holder_front_all = 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;
+crewpunch_biggest_y =
+  crewpunch_biggest_shape[1][0] + crewpunch_biggest_shape[1][1];
+holder_ysz = crewpunch_biggest_y + holder_min_wall + holder_front_all;
+
+attach_offset = 0.5 * (holder_front_all - holder_attach_near_wall);
+
+jig_main_zsz = holder_block_zsz + punch_travel;
+
+jig_ends_extra = 2;
+
+//jig_iters = (jig_max_len - jig_ends_extra) / jig_interval;
+jig_iters=2;
+echo(jig_iters);
+
+// objects
+
 module CrewPunch(){
-  
+  ourslop = crewpunch_slop - crewpunch_systematic_size_error;
+  hull(){
+    for(layer=crewpunch_shape){
+      translate([0,0, layer[0]]){
+       for(xind=[0,1]) //translate([xind?0:1,0,0])
+         for(yind=[0,1]) //translate([0,yind?0.5:0,0])
+           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,
+                     0.2]);
+           }
+      }
+    }
+  }
+}
+
+module PunchHolder(cutouts=true){
+  translate([-holder_xsz/2,
+            -holder_ysz + holder_min_wall + crewpunch_biggest_y/2,
+            0]){
+    difference(){
+      translate([0,attach_offset,0])
+       cube([holder_xsz, holder_ysz - attach_offset, holder_block_zsz]);
+      if (cutouts)
+       translate([crewpunch_biggest_shape[2][1] + holder_min_wall,
+                  crewpunch_biggest_shape[1][0] + holder_front_all,
+                  -crewpunch_smallest_shape[0]])
+         CrewPunch();
+    }
+    difference(){
+      translate([holder_xsz/2 - holder_attach_xsz/2, 0, 0])
+       cube([holder_attach_xsz,
+             attach_ysz,
+             holder_block_zsz + punch_travel
+             + holder_ctie_thick + holder_attach_roof + 1]);
+      if (cutouts)
+       translate([-30,
+                  holder_attach_walls,
+                  holder_block_zsz + punch_travel])
+         cube([60, holder_ctie_width, holder_ctie_thick]);
+    }
+  }
+}
+
+module RegistrationGroove(l){
+  // runs along the +ve X axis for length l but at correct z pos
+  translate([0, 0, jig_main_zsz + 0.1]) {
+    rotate([90,0,90])
+      linear_extrude(height=l)
+      polygon([[-registrationgroove_width/2, 0],
+              [ +registrationgroove_width/2, 0],
+              [ 0, -registrationgroove_depth ]]);
+  }
+}
+
+module OneJig(){
+  difference(){
+    translate([-(jig_interval/2 + 1),
+              -(strap_width/2 + edgewall_width) - attach_offset,
+              -strap_thick])
+      cube([jig_interval + 2,
+           strap_width + edgewall_width*2 + attach_offset,
+           jig_main_zsz + strap_thick]);
+    minkowski(){
+      cube([main_slop*2, main_slop*2, 50], center=true);
+      PunchHolder(false);
+    }
+    translate([-100, -strap_width/2, -10])
+      cube([200, strap_width, 10]);
+   translate([-100,0,0])
+     RegistrationGroove(200);
+   for (xfrac=[-1/4,0,+1/4])
+     translate([jig_interval * xfrac, -100, 0])
+       rotate([0,0,90])
+       RegistrationGroove(200);
+  }
 }
+
+module Jig(){
+  for (i=[0:jig_iters-1]) {
+    translate([jig_interval * i, 0, 0])
+      OneJig();
+  }
+}
+
+module JigT(){ ////toplevel
+  rotate([180,0,0])
+    Jig();
+}
+
+module PunchHolderT(){ ////toplevel
+  PunchHolder(true);
+}
+
+module Demo(){
+  %PunchHolder();
+  Jig();
+}
+
+//CrewPunch();
+//PunchHolder();
+//PunchHolder(false);
+//OneJig();
+//Jig();
+//Demo();
+//JigT();
+//PunchHolderT();