chiark / gitweb /
sewing-table: MachineRear: fixed too slow, other fixes
[reprap-play.git] / sewing-table.scad.m4
index e8f6b7a..b4ec954 100644 (file)
@@ -1,6 +1,7 @@
 // -*- C -*-
 
 include <funcs.scad>
+include <commitid.scad>
 
 ply_th = 18;
 ply_hole_dia = 15;
@@ -17,20 +18,73 @@ screw_big_len = 4.0;
 
 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
+
+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 = 85;
+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;
+
+tile01_tr = [250, 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;
+
+// rear curve
+
+rearedge_len = 170;
+
+rearcurve_rad = 25.4;
+rearcurve_strt_len = 65;
+rearcurve_total_len = 84;
+
+rearcurve_rad_slop = 0.5;
+
+rearcurve_avoid_y = rearcurve_rad + 10;
 
 // calculated
 
+TEST = false;
+
 ply_edge_hole_dist = ply_edge_min + ply_hole_dia/2;
 
-echo(str("HOLES IN PLY ctr dist from edge = ", ply_edge_hole_dist));
+echo(str("HOLES IN PLY ctr dist from PLY edge = ", ply_edge_hole_dist));
 
 hole_slop = (ply_hole_dia - post_dia)/2;
 tile_hard_edge_hole_dist = ply_edge_hole_dist + hole_slop;
+
+echo(str("HOLES IN PLY ctr dist from TILE HARD edge = ",
+        tile_hard_edge_hole_dist));
+
+echo(str("HOLES IN PLY ctr dist from TILE ROUND edge = ",
+        tile_hard_edge_hole_dist + round_edge_rad));
+
 thehd = [ tile_hard_edge_hole_dist, tile_hard_edge_hole_dist ];
+thehd_tr = thehd;
+thehd_tl = [ -thehd_tr[0], thehd_tr[1] ];
+thehd_bl = -thehd_tr;
+thehd_br = -thehd_tl;
 
 interlock_rad = interlock_dia/2;
-interlock_negative_rad = interlock_rad + 0.25;
+interlock_negative_rad = interlock_rad + 0.125;
+
+interlock_sq_adj = 0.2; // arbitrary
 
 module Post(){
   mirror([0,0,1]) {
@@ -41,25 +95,58 @@ module Post(){
        cylinder(r= screw_dia/2, h= ply_th, $fn=20);
       }
     }
+    if (TEST) {
+      tsz = tile_hard_edge_hole_dist - test_edge + 1;
+      translate([0,0, tile_th/2]) {
+       cube([post_dia, tsz*2, tile_th], center=true);
+       cube([tsz*2, post_dia, tile_th], center=true);
+      }
+    }
   }
 }
 
 module Posts(posts) {
   for (p= posts) {
-    translate([p[0], p[1], 0])
+    translate(concat(p, [0]))
       Post();
   }
 }
 
-module TileBase(botleft_post, topright_post){
-  botleft = botleft_post - thehd;
-  size = topright_post - botleft_post + thehd * 2;
-  mirror([0,0,1])
-    translate([botleft[0], botleft[1], 0])
-    cube([size[0], size[1], tile_th]);
+module TileBase(botleft, topright){
+  size = topright - botleft;
+  botleft_post = botleft + thehd_tr;
+  topright_post = topright + thehd_bl;
+  difference(){
+    mirror([0,0,1])
+      translate(concat(botleft, [0]))
+      cube(concat(size, [tile_th]));
+    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) {
+      translate( concat(botleft + [thehd[0], 0], [0]) )
+       Commitid_BestCount([ size[0] - thehd[0]*2, thehd[1] ]);
+      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);
+       }
+      }
+    }
+  }
 }
 
-m4_dnl  INREFFRAME(left_post, right_post, morevars) { body; }
+m4_dnl  INREFFRAME(left_cnr, right_cnr, morevars) { body; }
 m4_define(`INREFFRAME',`
   length_vec = ($2) - ($1);
   length = dist2d([0,0], length_vec);
@@ -73,63 +160,389 @@ m4_define(`INREFFRAME',`
   multmatrix(m)
 ')
 
-m4_dnl  INREFFRAME(left_post, right_post, morevars)
+m4_dnl  INREFFRAME(left_cnr, right_cnr, morevars)
 m4_dnl    INREFFRAME_EDGE { body; }
 m4_define(`INREFFRAME_EDGE',`
-  translate([-thehd[1], -thehd[0], -round_edge_rad])
+  translate([0,0, -round_edge_rad])
 ')
 
-module RoundEdge(left_post, right_post) {
-  INREFFRAME(left_post, right_post,
-             `tlength = length + thehd[1] * 2;') m4_dnl '
+module RoundEdge(left_cnr, right_cnr) {
+  INREFFRAME(left_cnr, right_cnr)
     INREFFRAME_EDGE {
     difference(){
       rotate([0,90,0])
-       cylinder(r= round_edge_rad, h= tlength, $fn=50);
+       cylinder(r= round_edge_rad, h= length, $fn=50);
       translate([-1, 0, -20])
-       cube([tlength+2, 20, 20]);
+       cube([length+2, 20, 20]);
     }
   }
 }
 
-module RoundLeftCorner(this_post, right_post) {
-  INREFFRAME(this_post, right_post) INREFFRAME_EDGE {
+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 InterlockCore(r) {
-  translate([0, -thehd[0], 1]){
-    mirror([0,0,1]){
-      linear_extrude(height=tile_th+2){
-       circle(r=r, $fn=40);
+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]){
+      circle(r=r);
+      difference(){
+       translate([-dx, -0.1])
+         square([ dx*2, r/2 + 0.1 ]);
+       for (xi = [-1, 1]) {
+         translate([ xi*dx, r ])
+           circle(r=r);
+       }
       }
     }
   }
 }
 
-module InterlockNegative(this_post, right_post) {
-  INREFFRAME(this_post, right_post)
-    InterlockCore(interlock_negative_rad);
+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);
+    }
+  }
+
+  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 TestPiece1(){
+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 (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);
+    }
+  }
+}
+
+function TestPiece_holes2corners(holes) =
+  [ holes[0] + thehd_bl,
+    holes[1] + thehd_br,
+    holes[1] + thehd_tr,
+    holes[0] + thehd_tl ];
+
+module TestPiece1(){ ////toplevel
   holes = [ [-100, 0],
            [   0, 0]
            ];
+  corners = TestPiece_holes2corners(holes);
+  rcs = [corners[0], corners[1]];
   difference(){
-    TileBase(holes[0], holes[1]);
-    InterlockNegative(holes[1], holes[1] + [0,1]);
-
+    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);
   }
+  RoundCornerAdd(rcs);
+}
+
+module TestPiece2(){ ////toplevel
+  holes = [ [   0, 0],
+           [  50, 0]
+           ];
+  corners = TestPiece_holes2corners(holes);
+  TileBase(corners[0], corners[2]);
   Posts(holes);
-  RoundEdge(holes[0], holes[1]);
-  RoundEdge(holes[0] + [ 0, 0.1 ], holes[0]);
-  RoundLeftCorner(holes[0], holes[1]);
+  RoundEdge(corners[0], corners[1]);
+  InterlockEdge(corners[3], corners[0], 0, nlobes=1);
 }
 
-TestPiece1();
+module TestDemo(){ ////toplevel
+  translate([ -thehd[0], 0 ])
+    color("blue")
+    TestPiece1();
+  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_Rear(){
+  big_rad = rearcurve_total_len - rearcurve_strt_len + rearcurve_rad;
+  small_rad = rearcurve_rad + rearcurve_rad_slop;
+  translate([ 250 + rearedge_len - cutout_l_end_y + big_rad,
+             cutout_tile11_y,
+             0 ]){
+    translate([ 0,
+               0,
+               -rearcurve_rad
+               ]){
+      rotate([0,-90,0]){
+       rotate([0,0, 360/8/2])
+         cylinder(r = small_rad, h= rearcurve_strt_len);
+      }
+    }
+    translate([ 0,
+               0,
+               big_rad - rearcurve_rad ]) {
+      intersection(){
+       rotate([90,0,0]){
+         rotate_extrude(convexity=10) {
+           translate([ big_rad,
+                       0 ]) {
+             hull(){
+               circle(r= small_rad);
+               translate([200,0])
+                 circle(r= small_rad);
+             }
+           }
+         }
+       }
+       mirror([0,0,1])
+         cube([150,150,150]);
+      }
+    }
+  }
+}
+
+module Machine(){ ////toplevel
+  Machine_Arm();
+  Machine_Rear();
+}
+  
+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] ],
+    c0 + [ 0,     sz[1] ] ];
+
+function Rectangle_corners2posts(c) =
+  [ c[0] + thehd_tr,
+    c[1] + thehd_tl,
+    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;
+  c = Rectangle_corners(c0, sz);
+  posts = Rectangle_corners2posts(c);
+  rcs = [R_EDGE(c,0)];
+  difference(){
+    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);
+  }
+  RoundCornerAdd(rcs);
+}
+
+module Tile12(){ ////toplevel
+  sz = [100,250];
+  c0 = [-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 = [250, 0] + [-cutout_tile11_x, 0];
+tile_11_10_cnr = [250, 0] + [0, cutout_tile11_y];
+
+module Tile11(){ ////toplevel
+  sz = [250,250];
+  c0 = [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();
+  }
+}    
+
+tile_01_00_cnr = [250, 0] + [0, -cutout_tile01_y];
+
+module Tile01(){ ////toplevel
+  sz = [250,170];
+  c0 = [0,-sz[1]];
+  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(){
+    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 = [sz[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] + [ -rearedge_len + cutout_l_end_x, rcy ],
+           cnr_posts[1] + [ 0,                              rcy ],
+           cnr_posts[2],
+           cnr_posts[3] ];
+  difference(){
+    union(){
+      Rectangle_TileBase(c);
+      Posts(posts);
+      RoundEdge(R_EDGE(c,2));
+      //InterlockEdge(tile_01_11_cnr, c[3]);
+      //InterlockEdge(R_EDGE(c,3));
+    }
+    //InterlockEdge(c[1], tile_01_00_cnr, 1);
+    Machine();
+  }
+}
+
+module Demo(){ ////toplevel
+  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();
+  %Machine();
+}
+  
+//TestPiece1();
+//TestPiece2();
+//Demo();