X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=knifeblock.scad;h=7ea6079d580a4221ad95a69e589f6909b885a4ac;hp=53654e58afb241dbf841cd7214c5efd95753852a;hb=216f40cedb6ce16f24f1bcad55a8ecf1f2093f02;hpb=144b5cc39ec1e9fba5330018388a43a1fb9fad6d

diff --git a/knifeblock.scad b/knifeblock.scad
index 53654e5..7ea6079 100644
--- a/knifeblock.scad
+++ b/knifeblock.scad
@@ -3,20 +3,27 @@
 // properties of the knives
 nknives = 3;
 widths = [15.5, 15.8, 19.0];
-handlelenbase = 60;
-handlelendelta = [-10, 0, 0];
-locations = [-35, 0, 40];
+handlelenbase = 75;
+handlelendelta = [-15, 0, 10];
+locations = [-35, 0, 37];
 bladew = 5; // 2.5
-maxhandledepth = 43.5 - 5;
+maxhandledepth = 45;
+
+templatescale = 27.2 / 19.6;
+
+coverlonglen = 120; // xxx
+covershortlen = 70; // xxx
 
 // other tuneables
 front = 5;
-back = 8;
+back = 5;
 height = 50;
 minsidein = 4;
 minsideout = 4;
 
-frontbackslop = 0.5;
+frontbackslop = 0.25;
+
+knifewidthslop = 2.0;
 
 screwbackdepth = 6.0 - 1.0;
 screwdia =       4.0 + 0.5;
@@ -24,24 +31,66 @@ screwcsinkdia =  9.8 + 1.0;
 
 screwabove = 15;
 
+coverthick = 2.4;
+coverside = coverthick;
+
+covertopwing = 15;
+covertopwingbase = 20;
+coveredge = 3;
+
+holesize = 12.5;
+holestrut = 7;
+holeedge = 4;
+
+holeoffx = 0.33;
+holeoffy = 0.23;
+
+pegstem = 3.5;
+peghead = 10;
+pegstemheight = 2;
+pegheight = 9;
+peglen = 12;
+
+recessblockwidth = peghead + pegstem*3;
+recessblockheight = peglen/2 + pegstem*1.5;
+
+pegsloph = 0.5;
+pegslopv = 0.5;
+pegslopl = 0.5;
+
+pegdepthproportion = 0.80;
+
 // computed
+
+function width(k) = widths[k] + knifewidthslop;
+
 side = minsidein + screwcsinkdia + minsideout;
 totaldepth = front + maxhandledepth + back;
 
+minkx = locations[0] -         width(0)        /2;
+maxkx = locations[nknives-1] + width(nknives-1)/2;
+
+minx = minkx - side;
+maxx = maxkx + side;
+
+holepitch = holesize+holestrut;
+
+pegrecess = pegdepthproportion*totaldepth - 0.5*peglen;
+
 module ImportTemplate(w,k,t) {
   fn = str("knifeblock-knives-t",k,t,".dxf");
   echo(fn);
   translate([0,0, -w/2])
     linear_extrude(height=w)
-    import(file=fn, convexity=100);
+    scale(templatescale) import(file=fn, convexity=100);
 }
 
 module Knife(k){
   ImportTemplate(bladew, k,"bl");
   hull(){
-    ImportTemplate(widths[k], k,"hl");
+    ImportTemplate(width(k), k,"hl");
     translate([-100,0,0])
-      ImportTemplate(widths[k], k,"hl");
+      ImportTemplate(width(k), k,"hl");
   }
 }
 
@@ -54,12 +103,8 @@ module DoKnife(k){
 }
 
 module DoKnives(){
-  for (yshift=[-1,1]) {
-    translate([0, yshift * frontbackslop, 0])
-      for (k=[0:nknives-1]) {
-	DoKnife(k);
-      }
-  }
+  for (k=[0:nknives-1])
+    DoKnife(k);
 }
 
 module ScrewHole(){
@@ -71,30 +116,186 @@ module ScrewHole(){
     cylinder(r=screwcsinkdia/2 / (sqrt(3)/2), h=100, $fn=6);
 }
 
-module Block(){
-  minkx = locations[0] -         widths[0]        /2;
-  maxkx = locations[nknives-1] + widths[nknives-1]/2;
+module PegTemplate(apex){
+  for (mx=[0,1]) for (my=[0,1]) {
+      mirror([mx,0,0]) mirror([0,my,0])
+	polygon([[-0.1,      -0.1],
+		 [pegstem/2, -0.1],
+		 [pegstem/2, pegstemheight/2],
+		 [peghead/2, pegheight    /2],
+		 [-0.1,      pegheight    /2 + apex]]);
+    }
+}
+
+module AtSides(){
+  translate([minx,0,0])                 child(0);
+  translate([maxx,0,0]) mirror([1,0,0]) child(1);
+}
 
-  minx = minkx - side;
-  maxx = maxkx + side;
+module BlockPegSlot(){
+  translate([recessblockwidth/2, pegrecess - 0.5*peglen, -height]){
+    rotate([-90,0,0]) linear_extrude(height=totaldepth){
+      PegTemplate(peghead/2 * 1.2);
+    }
+  }
+}
 
+module Block(){
   sidemidx = minsideout + screwcsinkdia/2;
 
   difference(){
-    hull() mirror([0,0,1]) {
-      translate([minx, 0, 0])
-	cube([maxx-minx, totaldepth-front, height]);
-      for (x=[minx + front/2, maxx - front/2])
-	translate([x, -front/2, 0])
-	cylinder(r=front/2, h=height, $fn=30);
+    mirror([0,0,1]) {
+      translate([minx, -front, 0])
+	cube([maxx-minx, totaldepth, height]);
     }
     for (x=[minx + sidemidx, maxx - sidemidx]) {
       translate([x, 0, -screwabove])
 	ScrewHole();
     }
-    DoKnives();
+    for (yshift=[-1,1])
+      translate([0, yshift * frontbackslop, 0])
+	DoKnives();
+    AtSides() { BlockPegSlot(); BlockPegSlot(); }
+  }
+}
+
+module BlockPrint(){ ////toplevel
+  rotate([0,0,90])
+    Block();
+}
+
+module CoverTemplate(){
+  linear_extrude(height=coverthick)
+    polygon([[minx, 0],
+	     [maxx, 0],
+	     [maxx, coverlonglen],
+	     [maxx - coverside, coverlonglen],
+	     [minx, covershortlen]]);
+}
+
+module CoverSide(len){
+  translate([0, 0 ,0]) {
+    rotate([90,0,90])
+      linear_extrude(height=coverside)
+      polygon([[0,                      0],
+	       [0,                      totaldepth],
+	       [covertopwing,           totaldepth],
+	       [covertopwingbase,       coverside + coverthick],
+	       [len - covertopwingbase, coverside + coverthick],
+	       [len - covertopwing,     totaldepth],
+	       [len,                    totaldepth],
+	       [len,                    0]]);
+    cube([recessblockwidth, recessblockheight, totaldepth]);
+  }
+}
+
+module Peg(){
+  echo("peg angle slope (must be <1)",
+       (peghead-pegstem)/(pegheight-pegstemheight));
+  dx = pegsloph;
+  dy = pegslopv;
+  rotate([90,0,0]) {
+    linear_extrude(height=peglen-pegslopl) {
+      intersection(){
+	translate([-dx,-dy,0]) PegTemplate(0);
+	translate([-dx,+dy,0]) PegTemplate(0);
+	translate([+dx,+dy,0]) PegTemplate(0);
+	translate([+dx,-dy,0]) PegTemplate(0);
+      }
+    }
+  }
+}
+
+module CoverPegSlot(coverlen){
+  translate([recessblockwidth/2, 0, -1]){
+    linear_extrude(height= 1 + pegrecess + 0.5*peglen){
+      PegTemplate(0);
+    }
+  }
+}
+
+module HoleRow(){
+  imax = ceil(coverlonglen / holepitch);
+  echo("Holes Y count ", imax);
+  for (i=[0:imax]) {
+    translate([0, (i+0.5)*holepitch, -20])
+      cylinder(r=holesize/2, h=40, $fn=20);
+  }
+}
+
+module HolesScope(){
+  intersection_for (dx=[-1,+1]) {
+    intersection_for (dy=[-1,+1]) {
+      translate([dx * holeedge, dy * holeedge, -5])
+	scale([1,1,10])
+	CoverTemplate();
+    }
+  }
+}
+
+module Holes(){
+  imin = ceil((maxx-minx)/(sqrt(3)*holepitch));
+  echo("Holes X count 2 x", imin);
+  intersection(){
+    translate([holeoffx * holepitch, holeoffy * holepitch, 0]) {
+      for (i=[-imin:2]) {
+	translate([i * sqrt(3) * holepitch, 0, 0]) {
+	  HoleRow();
+	  translate([sqrt(3)/2 * holepitch, -0.5 * holepitch, 0])
+	    HoleRow();
+	}
+      }
+    }
+    HolesScope();
+  }
+}
+
+module CoverCover(){
+  difference(){
+    CoverTemplate();
+    Holes();
+  }
+}
+
+module Cover(){
+  difference(){
+    union(){
+      CoverCover();
+      AtSides() { CoverSide(covershortlen); CoverSide(coverlonglen); }
+    }
+    AtSides() { CoverPegSlot(); CoverPegSlot(); }
+  }
+}
+
+module CoverAligned(){
+  translate([0,-front,-height])
+    rotate([-90,0,0])
+    Cover();
+}
+
+module DemoPeg(){
+  translate([recessblockwidth/2, pegrecess, -height])
+    Peg();
+}
+
+module Demo(){ ////toplevel
+  %Block();
+  DoKnives();
+  color([0,0,1]) CoverAligned();
+  color([1,0,0]) AtSides() { DemoPeg(); DemoPeg(); }
+}
+
+module CoverParts(){ ////toplevel
+  Cover();
+  translate([0, coverlonglen, pegheight/2]) {
+    Peg();
+    translate([-peghead-3, 0,0]) Peg();
   }
 }
 
-rotate([0,0,90])
-  Block();
+//Block();
+//Demo();
+//Cover();
+//CoverParts();
+//Peg();
+//Cover();