X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=knifeblock.scad;h=c1f1869f4b1a07e9a777f9077b0274ccc7478a63;hp=686644a425f86b6b90f603b4dbfb96cb3a328ef0;hb=14f86b26435802ec6292652fc167799e1122ec21;hpb=81a7d329cc21747a71b3609f4dd15c4a16648e71

diff --git a/knifeblock.scad b/knifeblock.scad
index 686644a..c1f1869 100644
--- a/knifeblock.scad
+++ b/knifeblock.scad
@@ -3,41 +3,98 @@
 // 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;
+maxhandledepth = 45;
+
+templatescale = 27.2 / 19.6;
+
+coverlonglen = 120; // xxx
+covershortlen = 70; // xxx
 
 // other tuneables
-side = 5;
 front = 5;
 back = 5;
 height = 50;
+minsidein = 4;
+minsideout = 4;
+
+frontbackslop = 0.25;
+
+knifewidthslop = 2.0;
+
+screwbackdepth = 6.0 - 1.0;
+screwdia =       4.0 + 0.5;
+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;
 
-frontbackslop = 0.5;
+indentdepth = 1;
+indentoutersize = holesize + 2.15;
+indentinnersize = indentoutersize - indentdepth * 3.0;
 
-screwbackdepth = 16;
-screwdia = 3.6;
-screwcsinkdia = 8.7;
+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");
   }
 }
 
@@ -50,27 +107,240 @@ 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(){
+  translate([0,-50,0])
+    rotate([-90,0,0])
+    cylinder(r=screwdia/2, h=150, $fn=40);
+  translate([0, totaldepth-front - screwbackdepth, 0])
+    rotate([90,0,0])
+    cylinder(r=screwcsinkdia/2 / (sqrt(3)/2), h=100, $fn=6);
+}
+
+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);
+}
+
+module BlockPegSlot(){
+  translate([recessblockwidth/2, pegrecess - peglen, -height]){
+    rotate([-90,0,0]) linear_extrude(height=totaldepth){
+      PegTemplate(peghead/2 * 1.2);
+    }
+  }
+}
+
+module DecorativeIndents(){
+  translate([0, -front, 0])
+  rotate([90,0,0])
+  HexGrid(-height, 0, minx,maxx) {
+    hull(){
+      translate([0, 0, -indentdepth])
+	cylinder(r=indentinnersize/2, h=indentdepth, $fn=40);
+      cylinder(r=indentoutersize/2, h=indentdepth, $fn=40);
+    }
   }
 }
 
 module Block(){
-  minkx = locations[0] -         widths[0]        /2;
-  maxkx = locations[nknives-1] + widths[nknives-1]/2;
+  sidemidx = minsideout + screwcsinkdia/2;
+
+  difference(){
+    mirror([0,0,1]) {
+      translate([minx, -front, 0])
+	cube([maxx-minx, totaldepth, height]);
+    }
+    for (x=[minx + sidemidx, maxx - sidemidx]) {
+      translate([x, 0, -screwabove])
+	ScrewHole();
+    }
+    for (yshift=[-1,1])
+      translate([0, yshift * frontbackslop, 0])
+	DoKnives();
+    AtSides() { BlockPegSlot(); BlockPegSlot(); }
+    DecorativeIndents();
+  }
+}
 
-  minx = minkx - side;
-  maxx = maxkx + side;
+module BlockPrint(){ ////toplevel
+  rotate([0,0,90])
+    Block();
+}
+
+module CoverTemplate(){
+  linear_extrude(height=coverthick)
+    polygon([[minx, 0],
+	     [maxx, 0],
+	     [maxx, coverlonglen+0.1],
+	     [maxx - coverside, coverlonglen+0.1],
+	     [minx, covershortlen+0.1]]);
+}
 
+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 HolesScope(){
+  intersection_for (dx=[-1,+1]) {
+    intersection_for (dy=[-1,+1]) {
+      translate([dx * holeedge, dy * holeedge, -5])
+	scale([1,1,10])
+	CoverTemplate();
+    }
+  }
+}
+
+module HexGrid(xa,xb,ya,yb) {
+  imin = floor(xa / holepitch);
+  imax =  ceil(xb / holepitch);
+  jmin = floor(ya / (sqrt(3)*holepitch));
+  jmax =  ceil(yb / (sqrt(3)*holepitch));
+  echo("HexGrid ",imin,imax,jmin,jmax);
+  for (i=[imin:imax]) {
+    for (j=[jmin:jmax]) {
+      translate([(j * sqrt(3) + holeoffx) * holepitch,
+		 (i +     0.5 + holeoffy) * holepitch,
+		 0]) {
+	child();
+	translate([sqrt(3)/2 * holepitch, -0.5 * holepitch, 0])
+	  child();
+      }
+    }
+  }
+}
+
+module Hole(){
+  cylinder(r=holesize/2, h=40, $fn=40);
+}
+
+module Holes(){
+  intersection(){
+    translate([0, 0, -20])
+      HexGrid(0, coverlonglen, minx, maxx)
+      Hole();
+    HolesScope();
+  }
+}
+
+module CoverCover(){
   difference(){
-    translate([minx, -front, 0])
-      mirror([0,0,1])
-      cube([maxx-minx, totaldepth, height]);
-    #DoKnives();
+    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 Pegs(){ ////toplevel
+  Peg();
+  translate([-peghead-3, 0,0]) Peg();
+}
+
+module CoverParts(){ ////toplevel
+  Cover();
+  translate([0, coverlonglen, pegheight/2-pegslopv])
+    Pegs();
+}
+
+module FrontDemo(){ ////toplevel
+  color([1,0,1]) Block();
+  color([1,0,1]) CoverAligned();
+  color([0,0,0]) DoKnives();
+}
+
+module BlockFrontTest(){ ////toplevel
+  intersection(){
+    Block();
+    translate([minx-10, -front-10, -height-10]) {
+      cube([75,14,35]);
+      cube([75,25,13]);
+    }
   }
 }
 
-Block();
+//Block();
+//Demo();
+//Cover();
+//CoverParts();
+//Peg();
+//Cover();
+//Holes();
+//%CoverTemplate();
+//Pegs();