lock-inframe-bracket: formal toplevels

[reprap-play.git] / lock-inframe-bracket.scad

diff --git a/lock-inframe-bracket.scad b/lock-inframe-bracket.scad
index 4c5bd8355aab4589336d570aa656bb33e0248ae1..376662eb0d55bcab7b0f8c5e8b70e6cf9ae53dc1 100644 (file)
--- a/lock-inframe-bracket.scad
+++ b/lock-inframe-bracket.scad
@@ -1,37 +1,65 @@
 // -*- C -*-
 
-tube_dia = 27.5 + 0.5;
+// use shell thickness 1.50
+// use fill density 40%
+
+include <funcs.scad>
+
+tube_dia = 27.5 + 1.625;
 lock_w = 42.5 + 0.5;
 lock_d = 28.0 + 0.5;
 main_h = 45.0;
 backflange_d = 12;
+lockshaft_dia = 14.35;
 
-lockshaft_r = [5, 5];
 cliprecess_h = 16;
 total_h = 45;
 
-back_gap = 7;
-main_th = 2.5;
+back_gap = 12.5;
+main_th = 3.50;
+tube_th = 4.00;
+
 midweb_d = 3;
-clip_th = 2.5;
+clip_th = 3.5;
 clip_gap = 2.5;
 clip_d = 22.0;
 
 mountscrew_dia = 4 + 0.5;
-clipbolt_dia = 5 + 0.5;
+clipbolt_dia = 5 + 0.6;
+
+backflange_th = 4.5;
+
+$fn=50;
+
+join_cr = 9;
 
-backflange_th = 3.5;
+tube_rear_extra_th = 1;
+
+divide_shaft_w = 1.75;
+divide_shaft_l = 1.5;
+divide_head_dx = 1.75;
+divide_head_th = 1.5;
+divide_gap = 0.50;
+divide_heads = 2;
+
+divide_angle = 26;
+divide_fudge_r = 4.75;
+divide_around = 3.5;
+
+backflange_angle = 20;
 
 // calculated
 
+lockshaft_r = [1, 1] * lockshaft_dia / 2;
 front_th = main_th;
-tube_th = main_th;
 
 tube_or = tube_dia/2 + tube_th;
 back_ohw = back_gap/2 + backflange_th;
 backflange_ymin = tube_or+backflange_d;
 
 lock_0y = tube_dia/2 + lock_d/2 + midweb_d;
+lock_0x = lock_w/2 - lock_d/2;
+lock_0 = [lock_0x,lock_0y];
 
 lock_or = [lock_w, lock_d]/2 + [front_th,front_th];
 
@@ -46,24 +74,99 @@ module oval(sz){ // sz[0] > sz[1]
   }
 }
 
+module JoinCircs(jr){
+  // http://mathworld.wolfram.com/Circle-CircleIntersection.html
+  R = tube_or + join_cr;
+  r = lock_or[1] + join_cr;
+  d = dist2d( [0,0], lock_0 );
+  x = (d*d - r*r + R*R) / (2*d);
+  y = sqrt( R*R - x*x );
+
+  echo(lock_0x, lock_0y, R,r, d, x,y);
+
+  for (m=[0,1]) {
+    mirror([m,0]) {
+      rotate(atan2(lock_0y, lock_0x)) {
+       translate([x,-y])
+         circle(r= jr);
+      }
+    }
+  }
+}
+
+module DividePlan(xl=10){
+  w = divide_shaft_w;
+  g = divide_gap;
+  l = divide_shaft_l + g;
+  t = divide_head_th + g;
+  dx = divide_head_dx;
+  for (m=[0,1]) mirror([m,0]) {
+    translate([w, 0]) square([xl, g]);
+    for (i=[0:divide_heads-1]) {
+      translate([w, i*(l + t)]) {
+       translate([0, 0]) square([g, l + g]);
+       translate([0, l]) square([divide_head_dx + g, g]);
+       translate([dx, l]) square([g, t + g]);
+       translate([0, l + t])
+         square([divide_head_dx + g, g]);
+      }
+    }
+    translate([-0.1, (l + t) * divide_heads])
+      square([w + g, g]);
+  }
+}
+
+module DividePlanInPlace(xl=10){
+  rotate([0,0, -divide_angle])
+    translate([ -tube_dia/2 -tube_th/2 - divide_fudge_r, 0])
+    DividePlan(xl);
+}
+
 module MainPlan(){
   difference(){
     union(){
-      circle(r = tube_or);
-      translate([-back_ohw,0]) mirror([0,1])
-       square([back_ohw*2, backflange_ymin]);
-    }
-    circle(r = tube_dia/2);
-    translate([-back_gap/2,1]) mirror([0,1])
-      square([back_gap, backflange_ymin+2]);
-  }
-  translate([0, lock_0y]){
-    difference(){
-      union(){
-       oval(lock_or);
+      difference(){
+       union(){
+         hull(){
+           for (t=[0, tube_rear_extra_th])
+             translate([0, -t])
+               circle(r = tube_or);
+         }
+         rotate([0,0, backflange_angle])
+           translate([-back_ohw,0]) mirror([0,1])
+           square([back_ohw*2, backflange_ymin]);
+
+         translate([0, lock_0y]){
+           oval(lock_or);
+         }
+
+         hull(){
+           JoinCircs(0.01);
+           polygon([[0,0], lock_0, [-lock_0[0], lock_0[1]]]);
+         }
+       }
+
+       rotate([0,0, backflange_angle])
+         translate([-back_gap/2,1]) mirror([0,1])
+         square([back_gap, backflange_ymin+2]);
+
+       JoinCircs(join_cr);
       }
+
+      hull(){
+       minkowski(){
+         DividePlanInPlace(0.1);
+         circle(divide_around);
+       }
+      }
+    }
+    translate([0, lock_0y]){
       oval([lock_w/2, lock_d/2]);
     }
+
+    circle(r = tube_dia/2);
+
+    DividePlanInPlace();
   }
 }
 
@@ -73,7 +176,11 @@ clip_ymin = cliprecess_ymax - total_h;
 clip_ogap = clip_gap + clip_th*2;
 
 module ClipElevationPositive(){
-  oval(lockshaft_or);
+  hull(){
+    oval(lockshaft_or);
+    translate([0, -lockshaft_or[1] * sqrt(2)])
+      square(center=true, 0.5);
+  }
   translate([-lockshaft_or[0], 0])
     square([lockshaft_or[0]*2, cliprecess_ymax]);
   translate([-clip_ogap/2, 0]) mirror([0,1]) square([clip_ogap, -clip_ymin]);
@@ -118,7 +225,7 @@ module ThroughHoles(){
   }
 
   ThroughHole( clipbolt_dia/2,
-              lock_0y + lock_d/2 + clip_d/2,
+              lock_0y + lock_d/2 + clip_d/2 + front_th/2,
               total_h - cliprecess_h - clip_th - clip_d/2 );
 }
 
@@ -132,16 +239,44 @@ module MainPositive(){
   }
 }
 
-module Bracket(){
+module Bracket(){ ////toplevel
   difference(){
     MainPositive();
     ThroughHoles();
   }
 }
 
+module TestTopEdge(){ ////toplevel
+  intersection(){
+    translate([0,0, -total_h])
+      translate([0,0, 4])
+      Bracket();
+    translate([-200,-200,0])
+      cube([400,400,100]);
+  }
+}
+
+module TestClipBoltHole(){ ////toplevel
+  intersection(){
+    union(){
+      translate([0, 0, -5])
+       Bracket();
+      translate([-4, lock_0y + lock_d/2 + 1, 0])
+       cube([8, 4, 1.5]);
+    }
+    translate([-200, lock_0y + lock_d/2 + 0.1])
+      cube([400, 400, total_h-20]);
+  }
+}
+
 //MainPlan();
+//ClipElevationPositive();
 //ClipElevation();
 //MainPositive();
 //%ThroughHoles();
+//TestTopEdge();
+//TestClipBoltHole();
+//DividePlan();
+
+//Bracket();
 
-Bracket();