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 75c9a52e8f05f75f44ba327486bdcc46bb905a27..376662eb0d55bcab7b0f8c5e8b70e6cf9ae53dc1 100644 (file)
--- a/lock-inframe-bracket.scad
+++ b/lock-inframe-bracket.scad
@@ -1,5 +1,8 @@
 // -*- C -*-
 
+// use shell thickness 1.50
+// use fill density 40%
+
 include <funcs.scad>
 
 tube_dia = 27.5 + 1.625;
@@ -12,9 +15,9 @@ lockshaft_dia = 14.35;
 cliprecess_h = 16;
 total_h = 45;
 
-back_gap = 10;
-main_th = 2.5;
-tube_th = 2.25;
+back_gap = 12.5;
+main_th = 3.50;
+tube_th = 4.00;
 
 midweb_d = 3;
 clip_th = 3.5;
@@ -22,13 +25,28 @@ clip_gap = 2.5;
 clip_d = 22.0;
 
 mountscrew_dia = 4 + 0.5;
-clipbolt_dia = 5 + 0.1;
+clipbolt_dia = 5 + 0.6;
 
-backflange_th = 3.5;
+backflange_th = 4.5;
 
 $fn=50;
 
-join_cr = 5;
+join_cr = 9;
+
+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
 
@@ -56,7 +74,8 @@ module oval(sz){ // sz[0] > sz[1]
   }
 }
 
-module JoinCirc(jr){
+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 );
@@ -65,42 +84,89 @@ module JoinCirc(jr){
 
   echo(lock_0x, lock_0y, R,r, d, x,y);
 
-  rotate(atan2(lock_0y, lock_0x)) {
-    translate([x,-y])
-      circle(r= jr);
+  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]);
-
-      translate([0, lock_0y]){
-       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(){
-       for (m=[0,1])
-         mirror([m,0])
-           JoinCirc(0.01);
-       polygon([[0,0], lock_0, [-lock_0[0], lock_0[1]]]);
+       minkowski(){
+         DividePlanInPlace(0.1);
+         circle(divide_around);
+       }
       }
     }
-
-    circle(r = tube_dia/2);
-    translate([-back_gap/2,1]) mirror([0,1])
-      square([back_gap, backflange_ymin+2]);
-
     translate([0, lock_0y]){
       oval([lock_w/2, lock_d/2]);
     }
 
-    for (m=[0,1])
-      mirror([m,0])
-       JoinCirc(join_cr);
+    circle(r = tube_dia/2);
+
+    DividePlanInPlace();
   }
 }
 
@@ -173,14 +239,14 @@ module MainPositive(){
   }
 }
 
-module Bracket(){ //// toplevel
+module Bracket(){ ////toplevel
   difference(){
     MainPositive();
     ThroughHoles();
   }
 }
 
-module TestTopEdge(){ //// toplevel
+module TestTopEdge(){ ////toplevel
   intersection(){
     translate([0,0, -total_h])
       translate([0,0, 4])
@@ -190,7 +256,7 @@ module TestTopEdge(){ //// toplevel
   }
 }
 
-module TestClipBoltHole(){ //// toplevel
+module TestClipBoltHole(){ ////toplevel
   intersection(){
     union(){
       translate([0, 0, -5])
@@ -210,5 +276,7 @@ module TestClipBoltHole(){ //// toplevel
 //%ThroughHoles();
 //TestTopEdge();
 //TestClipBoltHole();
+//DividePlan();
 
 //Bracket();
+