Revert "Revert "poster-tube-lid: drop StrapHoop from Cover""

[reprap-play.git] / pattress-boxes-3-cover.scad

diff --git a/pattress-boxes-3-cover.scad b/pattress-boxes-3-cover.scad
index 1fb88b0ef9ddb08de540bfc07102bbe04a49160b..7c1d4b892cf63d56ddcb2d6e9afc36a5b30d1e34 100644 (file)
--- a/pattress-boxes-3-cover.scad
+++ b/pattress-boxes-3-cover.scad
@@ -8,7 +8,7 @@ lid_fatbox_overlap = 12;
 
 lid_thinbox_h = 9;
 lid_fatbox_h = 24;
-lid_fatbox_switches_h = 6+2;
+lid_fatbox_switches_h = 6+4;
 
 lid_max_switches_w = 70;
 lid_switches_y_slop = 3;
@@ -16,6 +16,8 @@ lid_switches_y_slop = 3;
 total_len = 260;
 thinbox_len = 87;
 
+rail_overlap = 8;
+
 lid_top_wall = 1.5;
 lid_front_wall = 1.5;
 lid_side_wall = 1.5;
@@ -28,13 +30,15 @@ peg_inner_dia = 3.5;
 peg_top_thick = 1;
 peg_straight_len = 3;
 
-peg_inner_slop = 0.2;
-peg_outer_slop = 0.1;
+$peg_inner_slop = 0.75;
+$peg_outer_slop = -0.9;
+$peg_outer_slop_engage = 0.1;
 
 peg_slope = 1;
 
 lid_side_slop = 0.5;
 lid_rail_behindslop = 0.5;
+lid_rail_strongwall = 2.5;
 
 // computed
 
@@ -51,32 +55,37 @@ lid_seatline_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;
 
 lid_seatline_h = lid_fatbox_switches_h;
 
-echo(lid_seatline_w);
-
 peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;
 
-echo(peg_main_height);
+thinbox_front_z = lid_fatbox_switches_h + lid_fatbox_h - lid_thinbox_h;
+
+raillen = patbox_side/2 + rail_overlap;
 
 module LidSideProfile(){
   polygon([[-lid_top_wall,     lid_inner_max_h],
-          [lid_inner_kink[0], lid_inner_max_h],
-          [lid_inner_kink[1], lid_inner_min_h],
+          [min(lid_inner_kink[0],total_len), lid_inner_max_h],
+          [min(lid_inner_kink[1],total_len), lid_inner_min_h],
           [total_len,         lid_inner_min_h],
           [total_len,         -lid_front_wall],
           [-lid_top_wall,     -lid_front_wall]]);
 }
 
-module RailProfile(){
-  yt_base = lid_seatline_h + lid_fatbox_h - lid_thinbox_h;
+module RailProfile(lslop=0.1){
+  yt_base = thinbox_front_z;
   yt = yt_base - lid_rail_behindslop;
-  pegx = (lid_inner_w - patbox_centres)/2;
+  pegx = (lid_inner_w_nom - patbox_centres)/2;
+  sw = lid_rail_strongwall;
   
-  polygon([[-0.1,                  yt],
+  polygon([[-lslop,                  yt],
           [pegx - peg_main_dia/2, yt],
           [pegx - peg_main_dia/2, yt_base - peg_straight_len],
-          [-0.1,
+          [sw,
            yt_base - peg_straight_len - (pegx - peg_main_dia/2)/peg_slope
-          -0.1]]);
+           +sw],
+          [sw,
+           lid_seatline_h - 1],
+          [-lslop,
+           lid_seatline_h - 1]]);
 }
 
 module LidSide(){
@@ -102,27 +111,54 @@ module LidSide(){
   // rail
   rotate([90,0,90])
     translate([0,0,-0.1])
-    linear_extrude(height=100.1) //todo
+    linear_extrude(height=raillen+0.1) //todo
     RailProfile();
+
+  // rail end
+  translate([raillen, 0,0])
+    intersection(){
+      rotate_extrude($fn=50)
+       RailProfile(lslop=0);
+      translate([0, 25-0.1, 0])
+       cube(50, center=true);
+    }
+}
+
+module Lid(){ ////toplevel
+  for (m=[0,1])
+    mirror([0,m,0])
+      translate([0, -lid_inner_w/2, 0]) LidSide();
 }
 
 module PegProfile(){
-  polygon([[-peg_engage_depth, (peg_engage_dia - peg_outer_slop)/2],
-          [0,                 (peg_engage_dia - peg_outer_slop)/2],
-          [0,                 (peg_main_dia - peg_outer_slop)/2],
-          [peg_straight_len,  (peg_main_dia - peg_outer_slop)/2],
-          [peg_main_height,   (peg_max_dia - peg_outer_slop)/2],
-          [peg_main_height+peg_top_thick, (peg_max_dia - peg_outer_slop)/2],
-          [peg_main_height+peg_top_thick, (peg_inner_dia + peg_inner_slop)/2],
-          [-peg_engage_depth,  (peg_inner_dia + peg_inner_slop)/2]]);
+  polygon([[-peg_engage_depth, (peg_engage_dia - $peg_outer_slop_engage)/2],
+          [0,                 (peg_engage_dia - $peg_outer_slop_engage)/2],
+          [0,                 (peg_main_dia - $peg_outer_slop)/2],
+          [peg_straight_len,  (peg_main_dia - $peg_outer_slop)/2],
+          [peg_main_height,   (peg_max_dia - $peg_outer_slop)/2],
+          [peg_main_height+peg_top_thick, (peg_max_dia - $peg_outer_slop)/2],
+          [peg_main_height+peg_top_thick, (peg_inner_dia + $peg_inner_slop)/2],
+          [-peg_engage_depth,  (peg_inner_dia + $peg_inner_slop)/2]]);
 }
 
-module Peg(){
+module Peg(){ ////toplevel
+  echo($peg_outer_slop_engage);
   rotate_extrude($fn=50)
     rotate([0,0,-90])
     PegProfile();
 }
 
+module Pegs(){ ////toplevel
+  baseslop = 0.1;
+  dslops = [0, -0.5, -1.0, -1.5];
+  stride = peg_max_dia + 4;
+  for (i=[0:len(dslops)-1]) {
+    translate([i*stride,0,0])
+      assign($peg_outer_slop_engage= baseslop + dslops[i])
+      Peg();
+  }
+}
+
 module AtFixingCentres(){
   for (fc=[-1,+1]) {
     translate([patbox_side/2 + fc*patbox_centres/2,
@@ -143,8 +179,8 @@ module TopPattressBox(){
 }
 
 module Demo(){
-  translate([0, -lid_inner_w/2, 0]) LidSide();
-  translate([0,0, lid_fatbox_h])
+  Lid();
+  translate([0,0, thinbox_front_z])
     rotate([0,180,0]) translate([0, -patbox_side/2, 0])
     rotate([0,0,90]) union(){
       %TopPattressBox();
@@ -157,6 +193,9 @@ module Demo(){
 //LidSide();
 //PegProfile();
 //Peg();
+//Pegs();
 //TopPattressBox();
 //RailProfile();
-Demo();
+//Demo();
+//Lid();
+//translate([0,0,-lid_fatbox_switches_h]) Lid();