poster-tube-lid: catch stalk base outer curve same centre as inner

[reprap-play.git] / poster-tube-lid.scad

diff --git a/poster-tube-lid.scad b/poster-tube-lid.scad
index c6a0144ae89d83b43c9063020ed98eaea8444927..d4210a2d5d298e40bb70badfecf1eab2c8d21676 100644 (file)
--- a/poster-tube-lid.scad
+++ b/poster-tube-lid.scad
@@ -77,7 +77,7 @@ sm_bolt_y_over = 0.5;
 
 sm_closure_cnr = 3.0;
 
-catch_stalk_h = 3;
+catch_stalk_h = 4.5;
 catch_stalk_len = 50;
 catch_head_th = 3;
 
@@ -86,10 +86,11 @@ catch_pin_slop_x_extra = 0.0; // only on one side
 catch_stalk_above_gap = 1.5;
 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 
-catch_stalk_base_width = 15;
+catch_strap_width = 12;
+catch_stalk_base_width = catch_stalk_h;
 
 catch_knob_dia = 6;
-catch_knob_above_gap = 8;
+catch_knob_above_gap = 5;
 catch_knob_height = 5;
 
 catch_stalk_below_gap = 1.0;
@@ -149,7 +150,6 @@ smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 
 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
-catch_strap_width = sm_main_width;
 catch_strap_thick = sm_main_thick;
 
 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
@@ -199,8 +199,6 @@ echo(bayo_polygon);
 
 // CATCH
 
-//cppy6 = -catch_strap_width * 2/3;
-
 cppxC = 0.41 * sm_inner_rad * TAU;
 
 // catch pin
@@ -239,13 +237,15 @@ cppD = cppC + [0,-1] * catch_strap_width;
 
 // catch assembly stalk and so on
 
+catch_cr3 = catch_cr + catch_stalk_h;
+
 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 cpp2r = cpp2 + [1,0] * catch_cr;
 cpp2d = cpp2 + [0,-1] * catch_cr;
-cpp3 = [ cpp2[0] + catch_cr * 2, cppd[1] - catch_cr ];
+cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 cppA = [ -cppxC, cpp9[1] ];
 cppE = [ cppA[0], cppD[1] ];
 
@@ -491,31 +491,32 @@ module ImplHeadCupTest(){ ////toplevel
       ImplHeadCup();
 }
 
-module SomeStrap(){
+module SomeStrap(width){
   // children(0) is to add, (1) subtract
   difference(){
     union(){
-      cylinder(r=sm_outer_rad, h=sm_main_width);
+      cylinder(r=sm_outer_rad, h=width);
       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
                           smc_max_y,
-                          sm_closure_cnr);
+                          sm_closure_cnr,
+                          width);
       children(0);
     }
     translate([0,0,-1])
-      cylinder(r=sm_inner_rad, h=sm_main_width+2);
+      cylinder(r=sm_inner_rad, h=width+2);
     translate(smc_pos)
-      StrapMountBolt(10);
+      StrapMountBolt(10, width);
     translate(smc_pos)
       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
     children(1);
   }
 }
 
-module StrapMountBolt(l_delta){ ///toplevel
+module StrapMountBolt(l_delta, strap_width){ ///toplevel
   // positioned relative to smc_pos
   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
             smc_bolt_y,
-            sm_main_width/2]){
+            strap_width/2]){
     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
     }
@@ -529,9 +530,9 @@ module StrapMountBolt(l_delta){ ///toplevel
   }
 }
 
-module StrapMountProtrusion(half_x, max_y, cnr){
+module StrapMountProtrusion(half_x, max_y, cnr, width){
   translate(smc_pos){
-    linear_extrude(height=sm_main_width, convexity=10){
+    linear_extrude(height=width, convexity=10){
       hull(){
        for (m = [0,1]) mirror([m,0,0]) {
          translate([-(half_x - cnr), max_y - cnr])
@@ -545,7 +546,7 @@ module StrapMountProtrusion(half_x, max_y, cnr){
 }
 
 module StrapMount(){ ////toplevel
-  SomeStrap(){
+  SomeStrap(sm_main_width){
     rotate([0,0,180]){
       StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
                           strap_hoop_thick,
@@ -563,7 +564,7 @@ module CatchAssemblyCoreProfile(){
   difference(){
     union(){
       hull(){
-       translate(cpp3) circle(r= catch_cr);
+       translate(cpp3) circle(r= catch_cr3);
        polygon([ cpp3,
                  cpp2r,
                  cpp5,
@@ -597,6 +598,15 @@ module CatchAssemblyCoreProfile(){
     }
     translate(cpp2) circle(r= catch_cr);
   }
+  // if cpp11 is above cpp10, the subtracted hull above
+  // can go down too far.  Ensure we do not cut off below cppy6.
+  polygon([ cppE,
+           cppD,
+           cpp9,
+           [ cpp9[0],            cppy6 ],
+           [ cpp7[0] - catch_cr, cppy6 ],
+           cpp2d
+           ]);
 }
 
 module CatchHeadProfile(){
@@ -651,7 +661,7 @@ module CatchAssembly(){ /////toplevel
               ".stl"),
           convexity=20);
 
-  SomeStrap(){
+  SomeStrap(catch_strap_width){
     union(){ }
     union(){
       translate([-200, -200, -200])