round_edge_rad = 2.0;
+round_cnr_rad = 10;
+
interlock_dia = 10;
+interlock_fine = 0.66;
+
+interlock_fine_slope = 1.0;
+interlock_fine_lenslop = 1.0;
+
+demo_slop = 0.1;
+
+// cutout
+
+machine_rear_to_front = 85;
+
+machine_rear_profile = [
+ [ - 0, -0.00 ],
+ [ - 2, -0.10 ],
+ [ - 4, -0.20 ],
+ [ - 5, -0.30 ],
+ [ - 6, -0.40 ],
+ [ - 7, -0.50 ],
+ [ - 8, -0.75 ],
+ [ - 10, -1.50 ],
+ [ - 12, -2.25 ],
+ [ - 14, -3.25 ],
+ [ - 16, -4.25 ],
+ [ - 18, -5.75 ],
+ [ - 20, -8.00 ]
+ ];
+
+machine_front_profile = [
+ [ 128, -3.70, ],
+ [ 124, -2.90, ],
+ [ 120, -2.45, ],
+ [ 116, -2.10, ],
+ [ 112, -1.80, ],
+ [ 108, -1.55, ],
+ [ 104, -1.25, ],
+ [ 100, -1.00, ],
+ [ 96, -0.80, ],
+ [ 92, -0.65, ],
+ [ 88, -0.55, ],
+ [ 84, -0.50, ]
+ ];
+
+cutout_l_end_y_front_slop = 0.5;
+cutout_l_end_y_rear_slop = 0.5;
+cutout_l_end_x_slop = 0.25;
+
+cutout_l_end_x = 22;
+cutout_l_end_y = machine_rear_to_front;
+cutout_l_end_curve = 1;
+cutout_l_end_y_total = cutout_l_end_y
+ + cutout_l_end_y_front_slop + cutout_l_end_y_rear_slop;
+
+tile02_tr = [-250, 0];
+tile01_tr = [ 0, 0];
+
+cutout_tile01_y = 170 - 147 + cutout_l_end_y_front_slop;
+cutout_tile11_x = cutout_l_end_x + cutout_l_end_curve;
+cutout_tile11_y = cutout_l_end_y_total - cutout_tile01_y;
+
+// front and rear curves
+
+rearedge_len = 170;
+
+rearcurve_strt_len = 52;
+
+rearcurve_z_slop = 0.75;
+
+rearcurve_avoid_y = 35;
+
+rearcurve_double_inrad = 26.10 + 8.04;
+
+reartablet_z = 2.54;
+reartablet_x = 5 + 1;
+reartablet_y = 5;
+
+frontcurve_side_skew = 3.5 / 72;
+frontcurve_avoid_y = 70;
+frontcurve_z_slop = 0.75;
// calculated
+TEST = false;
+
ply_edge_hole_dist = ply_edge_min + ply_hole_dia/2;
echo(str("HOLES IN PLY ctr dist from PLY edge = ", ply_edge_hole_dist));
interlock_rad = interlock_dia/2;
interlock_negative_rad = interlock_rad + 0.125;
+interlock_sq_adj = 0.2; // arbitrary
+
+first_front = machine_front_profile[len(machine_front_profile)-1];
+
+m4_define(`POST_TCROSSSZ',
+ `2*( tile_hard_edge_hole_dist - test_edge + 1 )')
+
module Post(){
mirror([0,0,1]) {
difference(){
cylinder(r= screw_dia/2, h= ply_th, $fn=20);
}
}
+ if (TEST) {
+ translate([0,0, tile_th/2]) {
+ cube([post_dia, POST_TCROSSSZ, tile_th], center=true);
+ cube([POST_TCROSSSZ, post_dia, tile_th], center=true);
+ }
+ }
}
}
mirror([0,0,1])
translate(concat(botleft, [0]))
cube(concat(size, [tile_th]));
- translate( concat(botleft_post, [-tile_th])
- + 0.5 * [ post_dia, post_dia, 0 ] )
- Commitid_BestCount_M( topright_post-botleft_post
- + [-post_dia,-post_dia]
- + [0, thehd[1]]);
+ if (!TEST) {
+ translate( concat(botleft_post, [ -tile_th ])
+ + 0.5 * [ post_dia, post_dia, 0 ] )
+ Commitid_BestCount_M( topright_post-botleft_post
+ + [-post_dia,-post_dia]
+ + [0, thehd[1]]);
+ }
+ if (TEST) {
+ crossoff = tile_hard_edge_hole_dist + POST_TCROSSSZ/2;
+ cidsz = [ size[0] - 2*crossoff, thehd[1] ];
+ translate( concat(botleft + [crossoff, 0] + cidsz, [0]) )
+ rotate([0,0,180])
+ Commitid_BestCount(cidsz);
+ difference(){
+ mirror([0,0,1]) {
+ translate(concat(botleft + [test_edge,test_edge], [test_tile_th]))
+ cube(concat(size - [test_edge,test_edge]*2, [tile_th]));
+ translate(concat(botleft_post, [-1]))
+ cube(concat(topright_post-botleft_post, [tile_th+2]));
+ }
+ minkowski(){
+ Machine();
+ cube(max(test_edge, tile_hard_edge_hole_dist)*2, center=true);
+ }
+ }
+ }
}
}
}
}
-module RoundLeftCorner(this_cnr, right_cnr) {
+module RoundCornerCut(ci) {
+ // ci should be [this_cnr, right_cnr]
+ // where right_cnr is to the right (ie, anticlockwise)
+ this_cnr = ci[0];
+ right_cnr = ci[1];
+ offr= round_cnr_rad - round_edge_rad;
INREFFRAME(this_cnr, right_cnr) INREFFRAME_EDGE {
difference(){
- sphere(r= round_edge_rad, $fn=60);
- translate([0,0, -20])
- cube([20,20,20]);
+ cube(offr*2 - 0.1, center=true);
+ translate([offr, offr, 0])
+ cylinder(center=true, h=20, r= offr);
+ }
+ }
+}
+
+module RoundCornerAdd(ci) {
+ this_cnr = ci[0];
+ right_cnr = ci[1];
+ bigr = round_cnr_rad - round_edge_rad;
+ INREFFRAME(this_cnr, right_cnr) INREFFRAME_EDGE {
+ intersection(){
+ cube(bigr*2 + 0.1, center=true);
+ translate([bigr, bigr, 0])
+ rotate_extrude(convexity=10, $fn=50)
+ translate([bigr, 0])
+ difference(){
+ circle(r= round_edge_rad, $fn=50);
+ mirror([1,1])
+ square([20,20]);
+ }
}
}
}
-module InterlockLobePlan(r, ymir) {
+module InterlockLobePlan(negative) {
+ r = negative ? interlock_negative_rad : interlock_rad;
+ ymir = negative ? 0 : 1;
+
dx = sqrt(3) * r;
$fn= 80;
translate([thehd[0], 0]){
- mirror([0,ymir,0]){
+ mirror([0,ymir]){
circle(r=r);
difference(){
translate([-dx, -0.1])
}
}
-module InterlockLobeCore(negative=0) {
- r = negative ? interlock_negative_rad : interlock_rad;
- plusth = negative * 1.0;
- ymir = negative ? 0 : 1;
- translate([0, 0, plusth]){
- mirror([0,0,1]){
- linear_extrude(height=tile_th+plusth*2, convexity=10){
- InterlockLobePlan(r, ymir);
- }
+module InterlockEdgePlan(negative, nlobes, length, dosquare=true) {
+ for (lobei = [ 0 : nlobes-1 ]) {
+ lobex = (length - thehd[0]*2) * (lobei ? lobei / (nlobes-1) : 0);
+ translate([lobex, 0, 0]) {
+ InterlockLobePlan(negative);
}
}
-}
-module InterlockLobe(this_cnr, right_cnr, negative=0) {
- INREFFRAME(this_cnr, right_cnr)
- InterlockLobeCore(negative);
+ if (dosquare) {
+ iadj = 0;
+ slotshorter = negative ? -0.1 : interlock_fine_lenslop;
+ mirror([0, negative])
+ translate([slotshorter, iadj])
+ square([length - slotshorter*2, interlock_fine + iadj*2]);
+ }
}
-module InterlockEdge(left_cnr, right_cnr, negative=0) {
- nlobes=2;
+module InterlockEdge(left_cnr, right_cnr, negative=0, nlobes=2) {
+ plusth = negative * 1.0;
+ protr = interlock_fine + interlock_sq_adj;
+
+ z2 = -tile_th/2;
+ z1 = -tile_th/2 - protr / interlock_fine_slope;
+ z3 = -tile_th/2 + protr / interlock_fine_slope;
+
+ negsign = negative ? -1 : +1;
+ yprotr = negsign * protr;
+
INREFFRAME(left_cnr, right_cnr) {
- for (lobei = [ 0 : nlobes-1 ]) {
- lobex = (length - thehd[0]*2) * lobei / (nlobes-1);
- translate([lobex, 0, 0])
- InterlockLobeCore(negative);
+ for (vsect = [ // zs0 zs1 ys0, ys1
+ [ -tile_th-plusth, plusth, 0, 0],
+ [ z1, z2, 0, yprotr],
+ [ z2, z3, yprotr, 0],
+ ]) {
+ zs0 = vsect[0];
+ zs1 = vsect[1];
+ zsd = zs1-zs0;
+ ys0 = vsect[2];
+ ys1 = vsect[3];
+ ysd = ys1-ys0;
+ sl = ysd/zsd;
+ m = [ [ 1,0, 0, 0 ],
+ [ 0,1, -sl, -ys0 + negsign*interlock_sq_adj ],
+ [ 0,0, 1, zs0 ],
+ [ 0,0, 0, 1 ] ];
+ multmatrix(m)
+ linear_extrude(height=zsd, convexity=10)
+ InterlockEdgePlan(negative, nlobes, length, !!ysd);
}
}
}
[ 0, 0]
];
corners = TestPiece_holes2corners(holes);
+ rcs = [corners[0], corners[1]];
difference(){
- TileBase(corners[0], corners[2]);
- InterlockLobe(corners[1], corners[2], 1);
+ union(){
+ TileBase(corners[0], corners[2]);
+ Posts(holes);
+ RoundEdge(corners[0], corners[1]);
+ RoundEdge(corners[3], corners[0]);
+ }
+ InterlockEdge(corners[1], corners[2], 1, nlobes=1);
+ RoundCornerCut(rcs);
}
- Posts(holes);
- RoundEdge(corners[0], corners[1]);
- RoundEdge(corners[3], corners[0]);
- RoundLeftCorner(corners[0], corners[1]);
+ RoundCornerAdd(rcs);
}
module TestPiece2(){ ////toplevel
TileBase(corners[0], corners[2]);
Posts(holes);
RoundEdge(corners[0], corners[1]);
- InterlockLobe(corners[3], corners[0]);
+ InterlockEdge(corners[3], corners[0], 0, nlobes=1);
}
module TestDemo(){ ////toplevel
translate([ -thehd[0], 0 ])
color("blue")
TestPiece1();
- translate([ +thehd[0], 0 ])
+ translate([ +thehd[0] + demo_slop, 0 ])
TestPiece2();
}
+
+module Machine_Arm(){
+ ysz = cutout_l_end_y_total;
+ // assume the round end is arc of a circle
+ chordlen = dist2d([0,0], [ cutout_l_end_y, cutout_l_end_curve ]);
+ endrad = cutout_l_end_y / cutout_l_end_curve * chordlen;
+
+ translate([0,0,-30]) linear_extrude(height=60) {
+ translate(tile01_tr + [0, (-cutout_tile01_y + cutout_tile11_y)/2]) {
+ intersection(){
+ translate([-100, -ysz/2])
+ square([400, ysz]);
+ translate([ endrad - cutout_tile11_x - cutout_l_end_x_slop, 0 ])
+ circle(r=endrad, $fa=0.01,$fd=5);
+ }
+ }
+ }
+}
+
+module Machine_Profile(){
+ first_rear = machine_rear_profile[0];
+ below_point = 0.5 * ( first_rear + first_front ) + [ 0, -10 ];
+ pol = concat( machine_rear_profile,
+ [ below_point ],
+ machine_front_profile);
+ skew_angle = atan2( first_front[1] - first_rear[1],
+ first_front[0] - first_rear[0] );
+ echo(below_point, pol, skew_angle);
+ hull(){
+ for (z=[0,-40]) {
+ translate([0,z]) {
+ //scale([1,5])
+ rotate([0,0, -skew_angle ]){
+ //translate( - first_front )
+ polygon(pol);
+ }
+ }
+ }
+ }
+}
+
+module Machine_RearProfile(){
+ intersection(){
+ Machine_Profile();
+ translate([ -200 + machine_rear_to_front/2, -100 ]) {
+ square([200,200]);
+ }
+ }
+}
+
+module Machine_FrontProfile(){
+ intersection(){
+ Machine_Profile();
+ translate([ machine_rear_to_front/2, -100 ]) {
+ square([200,200]);
+ }
+ }
+}
+
+module Machine_Curves(){ ////toplevel
+ translate([ tile01_tr[0] - cutout_l_end_x + rearedge_len,
+ cutout_tile11_y,
+ 0 ]){
+ //%cube([20,20,20]);
+ translate([ -reartablet_x,
+ -1,
+ -reartablet_z])
+ mirror([0,0,1])
+ cube([ reartablet_x+1,
+ reartablet_y+1,
+ 20 ]);
+ }
+ translate([ tile01_tr[0] - cutout_l_end_x + rearedge_len,
+ cutout_tile11_y,
+ frontcurve_z_slop ]){
+ translate([ 0, -first_front[0] , 0 ])
+ multmatrix([[1, -frontcurve_side_skew, 0, 0],
+ [0, 1, 0, 0],
+ [0, 0, 1, 0],
+ [0, 0, 0, 1]])
+ translate([ 0, first_front[0] , 0 ])
+ mirror([1,0,0]){
+ rotate([0,-90,0])rotate([0,0,-90]){
+ linear_extrude(height= 200)
+ Machine_FrontProfile();
+ }
+ }
+ translate([ rearcurve_strt_len,
+ 0,
+ rearcurve_z_slop ]){
+ translate([ 1,
+ 0,
+ 0
+ ]){
+ rotate([0,-90,0])rotate([0,0,-90]){
+ linear_extrude(height= rearcurve_strt_len + 1)
+ Machine_RearProfile();
+ }
+ }
+ translate([ 0,
+ 0,
+ rearcurve_double_inrad ]) {
+ intersection(){
+ rotate([90,0,0]){
+ rotate_extrude(convexity=10, $fn=32) {
+ rotate([0,0,90]) translate([ 0,
+ -rearcurve_double_inrad ]) {
+ Machine_RearProfile();
+ }
+ }
+ }
+ mirror([0,0,1])
+ translate([0,-75,0]) cube([150,150,150]);
+ }
+ }
+ }
+ }
+}
+
+module Machine(){ ////toplevel
+ Machine_Arm();
+ Machine_Curves();
+}
function Rectangle_corners(c0, sz) =
+ // returns the corners of a rectangle from c0 to c0+sz
+ // if sz is positive, the corners are anticlockwise starting with c0
[ c0 + [ 0, 0 ],
c0 + [ sz[0], 0 ],
c0 + [ sz[0], sz[1] ],
c[2] + thehd_bl,
c[3] + thehd_br ];
+module Rectangle_TileBase(c) { TileBase(c[0], c[2]); }
+
+function Posts_interpolate_one(c0,c1) = [c0, (c0+c1)/2, c1];
+
+m4_dnl R_EDGE(c,ix)
+m4_dnl c is from Rectangle_corners and
+m4_dnl ix is a corner number
+m4_dnl expands to two comma-separated corners:
+m4_dnl that denoted by ix, and the next one anticlockwise
+m4_define(`R_EDGE',`$1[$2],$1[(($2)+1)%4]')
+
module Tile02(){ ////toplevel
sz = [100,170];
- c0 = -sz;
+ c0 = tile02_tr + -sz;
c = Rectangle_corners(c0, sz);
posts = Rectangle_corners2posts(c);
+ rcs = [R_EDGE(c,0)];
difference(){
- TileBase(c[0], c[2]);
+ union(){
+ Rectangle_TileBase(c);
+ Posts(posts);
+ RoundEdge(R_EDGE(c,0));
+ RoundEdge(R_EDGE(c,3));
+ InterlockEdge(R_EDGE(c,2), 0);
+ }
+ InterlockEdge(R_EDGE(c,1), 1);
+ RoundCornerCut(rcs);
}
- Posts(posts);
- RoundEdge(c[0], c[1]);
- RoundEdge(c[3], c[0]);
- RoundLeftCorner(c[0], c[1]);
- InterlockEdge(c[2], c[3], 0, 2);
+ RoundCornerAdd(rcs);
}
module Tile12(){ ////toplevel
sz = [100,250];
- c0 = [-sz[0], 0];
+ c0 = tile02_tr + [-sz[0], 0];
c = Rectangle_corners(c0, sz);
posts = Rectangle_corners2posts(c);
+ rcs = [R_EDGE(c,3)];
+ difference(){
+ union(){
+ Rectangle_TileBase(c);
+ Posts(posts);
+ RoundEdge(R_EDGE(c,2));
+ RoundEdge(R_EDGE(c,3));
+ }
+ InterlockEdge(R_EDGE(c,0), 1);
+ InterlockEdge(R_EDGE(c,1), 1);
+ RoundCornerCut(rcs);
+ }
+ RoundCornerAdd(rcs);
+}
+
+tile_01_11_cnr = tile01_tr + [-cutout_tile11_x, 0];
+tile_11_10_cnr = tile01_tr + [0, cutout_tile11_y];
+tile_01_00_cnr = tile01_tr - [0, cutout_tile01_y];
+
+module Tile11(){ ////toplevel
+ sz = [250,250];
+ c0 = tile01_tr + [-sz[0],0];
+ c = Rectangle_corners(c0, sz);
+ cnr_posts = Rectangle_corners2posts(c);
+ posts = concat(
+ Posts_interpolate_one(cnr_posts[0],
+ cnr_posts[1] - [cutout_tile11_x, 0]),
+ [ cnr_posts[1] + [0, cutout_tile11_y],
+ cnr_posts[2],
+ cnr_posts[3]
+ ]);
+ difference(){
+ union(){
+ Rectangle_TileBase(c);
+ Posts(posts);
+ RoundEdge(R_EDGE(c,2));
+ InterlockEdge(R_EDGE(c,3));
+ }
+ InterlockEdge(c[0], tile_01_11_cnr, 1);
+ InterlockEdge(tile_11_10_cnr, c[2], 1);
+ Machine();
+ }
+}
+
+module Tile01(){ ////toplevel
+ sz = [250,170];
+ c0 = tile01_tr + -sz;
+ c = Rectangle_corners(c0, sz);
+ cnr_posts = Rectangle_corners2posts(c);
+ posts = concat(
+ Posts_interpolate_one(R_EDGE(cnr_posts,0)),
+ [ cnr_posts[2] + [0, -cutout_tile01_y] ],
+ Posts_interpolate_one(cnr_posts[2] - [cutout_tile11_x, 0],
+ cnr_posts[3])
+ );
difference(){
- TileBase(c[0], c[2]);
+ union(){
+ Rectangle_TileBase(c);
+ Posts(posts);
+ RoundEdge(R_EDGE(c,0));
+ InterlockEdge(tile_01_11_cnr, c[3]);
+ InterlockEdge(R_EDGE(c,3));
+ }
+ InterlockEdge(c[1], tile_01_00_cnr, 1);
+ Machine();
+ }
+}
+
+module Tile10(){ ////toplevel
+ sz = [250,250];
+ c0 = tile01_tr + [0,0];
+ c = Rectangle_corners(c0, sz);
+ cnr_posts = Rectangle_corners2posts(c);
+ cty = cutout_tile11_y;
+ rcy = cty + rearcurve_avoid_y;
+ posts = [ cnr_posts[0] + [ 0, cty ],
+ cnr_posts[1] + [ -sz[0] + rearedge_len - cutout_l_end_x, cty ],
+ cnr_posts[1] + [ 0, rcy ],
+ cnr_posts[2],
+ cnr_posts[3] ];
+ rcs = [R_EDGE(c,2)];
+ difference(){
+ union(){
+ Rectangle_TileBase(c);
+ Posts(posts);
+ RoundEdge(R_EDGE(c,1));
+ RoundEdge(R_EDGE(c,2));
+ InterlockEdge(c[3], tile_11_10_cnr);
+ }
+ RoundCornerCut(rcs);
+ Machine();
+ }
+ RoundCornerAdd(rcs);
+}
+
+module Tile00(){ ////toplevel
+ sz = [250,170];
+ c0 = tile01_tr + [0,-sz[1]];
+ c = Rectangle_corners(c0, sz);
+ cnr_posts = Rectangle_corners2posts(c);
+ cty = cutout_tile01_y;
+ rcy = cty + frontcurve_avoid_y;
+ posts = [ cnr_posts[0],
+ cnr_posts[1],
+ cnr_posts[2] + [ 0, -rcy ],
+ cnr_posts[2] + [ -sz[0] + rearedge_len - cutout_l_end_x, -cty ],
+ cnr_posts[3] + [ 0, -cty ]
+ ];
+ rcs = [R_EDGE(c,1)];
+ difference(){
+ union(){
+ Rectangle_TileBase(c);
+ Posts(posts);
+ RoundEdge(R_EDGE(c,0));
+ RoundEdge(R_EDGE(c,1));
+ InterlockEdge(tile_01_00_cnr, c[0]);
+ }
+ RoundCornerCut(rcs);
+ Machine();
}
- Posts(posts);
- RoundEdge(c[2], c[3]);
- RoundEdge(c[3], c[0]);
- RoundLeftCorner(c[2], c[3]);
+ RoundCornerAdd(rcs);
}
module Demo(){ ////toplevel
- color("blue") Tile12();
- color("red") Tile02();
+ translate(demo_slop*[-2,1]) color("blue") Tile12();
+ translate(demo_slop*[-2,0]) color("red") Tile02();
+ translate(demo_slop*[-2,1]) color("orange") Tile11();
+ translate(demo_slop*[-2,0]) color("purple") Tile01();
+ translate(demo_slop*[-3,1]) color("blue") Tile10();
+ translate(demo_slop*[-3,0]) color("red") Tile00();
+ %Machine();
}
//TestPiece1();
//TestPiece2();
//Demo();
+
+//Machine_Profile();
+//Machine_RearProfile();
~ianmdlvl / reprap-play.git / blobdiff