X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=lock-inframe-bracket.scad;h=376662eb0d55bcab7b0f8c5e8b70e6cf9ae53dc1;hp=5b14c9d321d47ebc1103cb09e727689f0afa8759;hb=156db7e3f7e1588b02761647901279164869bbf8;hpb=6c5eea64f002a2e610bcabd9026b869ab3544a4e

diff --git a/lock-inframe-bracket.scad b/lock-inframe-bracket.scad
index 5b14c9d..376662e 100644
--- a/lock-inframe-bracket.scad
+++ b/lock-inframe-bracket.scad
@@ -1,24 +1,65 @@
 // -*- C -*-
 
-tube_dia = 27.5 + 0.5;
+// use shell thickness 1.50
+// use fill density 40%
+
+include <funcs.scad>
+
+tube_dia = 27.5 + 1.625;
 lock_w = 42.5 + 0.5;
 lock_d = 28.0 + 0.5;
 main_h = 45.0;
 backflange_d = 12;
+lockshaft_dia = 14.35;
+
+cliprecess_h = 16;
+total_h = 45;
+
+back_gap = 12.5;
+main_th = 3.50;
+tube_th = 4.00;
 
-back_gap = 7;
-main_th = 2.5;
 midweb_d = 3;
+clip_th = 3.5;
+clip_gap = 2.5;
+clip_d = 22.0;
+
+mountscrew_dia = 4 + 0.5;
+clipbolt_dia = 5 + 0.6;
+
+backflange_th = 4.5;
+
+$fn=50;
+
+join_cr = 9;
+
+tube_rear_extra_th = 1;
+
+divide_shaft_w = 1.75;
+divide_shaft_l = 1.5;
+divide_head_dx = 1.75;
+divide_head_th = 1.5;
+divide_gap = 0.50;
+divide_heads = 2;
+
+divide_angle = 26;
+divide_fudge_r = 4.75;
+divide_around = 3.5;
+
+backflange_angle = 20;
 
 // calculated
 
+lockshaft_r = [1, 1] * lockshaft_dia / 2;
 front_th = main_th;
 
-tube_or = tube_dia/2 + main_th;
-back_ohw = back_gap/2 + main_th;
+tube_or = tube_dia/2 + tube_th;
+back_ohw = back_gap/2 + backflange_th;
 backflange_ymin = tube_or+backflange_d;
 
 lock_0y = tube_dia/2 + lock_d/2 + midweb_d;
+lock_0x = lock_w/2 - lock_d/2;
+lock_0 = [lock_0x,lock_0y];
 
 lock_or = [lock_w, lock_d]/2 + [front_th,front_th];
 
@@ -33,25 +74,209 @@ module oval(sz){ // sz[0] > sz[1]
   }
 }
 
+module JoinCircs(jr){
+  // http://mathworld.wolfram.com/Circle-CircleIntersection.html
+  R = tube_or + join_cr;
+  r = lock_or[1] + join_cr;
+  d = dist2d( [0,0], lock_0 );
+  x = (d*d - r*r + R*R) / (2*d);
+  y = sqrt( R*R - x*x );
+
+  echo(lock_0x, lock_0y, R,r, d, x,y);
+
+  for (m=[0,1]) {
+    mirror([m,0]) {
+      rotate(atan2(lock_0y, lock_0x)) {
+	translate([x,-y])
+	  circle(r= jr);
+      }
+    }
+  }
+}
+
+module DividePlan(xl=10){
+  w = divide_shaft_w;
+  g = divide_gap;
+  l = divide_shaft_l + g;
+  t = divide_head_th + g;
+  dx = divide_head_dx;
+  for (m=[0,1]) mirror([m,0]) {
+    translate([w, 0]) square([xl, g]);
+    for (i=[0:divide_heads-1]) {
+      translate([w, i*(l + t)]) {
+	translate([0, 0]) square([g, l + g]);
+	translate([0, l]) square([divide_head_dx + g, g]);
+	translate([dx, l]) square([g, t + g]);
+	translate([0, l + t])
+	  square([divide_head_dx + g, g]);
+      }
+    }
+    translate([-0.1, (l + t) * divide_heads])
+      square([w + g, g]);
+  }
+}
+
+module DividePlanInPlace(xl=10){
+  rotate([0,0, -divide_angle])
+    translate([ -tube_dia/2 -tube_th/2 - divide_fudge_r, 0])
+    DividePlan(xl);
+}
+
 module MainPlan(){
   difference(){
     union(){
-      circle(r = tube_or);
-      translate([-back_ohw,0]) mirror([0,1])
-	square([back_ohw*2, backflange_ymin]);
+      difference(){
+	union(){
+	  hull(){
+	    for (t=[0, tube_rear_extra_th])
+	      translate([0, -t])
+		circle(r = tube_or);
+	  }
+	  rotate([0,0, backflange_angle])
+	    translate([-back_ohw,0]) mirror([0,1])
+	    square([back_ohw*2, backflange_ymin]);
+
+	  translate([0, lock_0y]){
+	    oval(lock_or);
+	  }
+
+	  hull(){
+	    JoinCircs(0.01);
+	    polygon([[0,0], lock_0, [-lock_0[0], lock_0[1]]]);
+	  }
+	}
+
+	rotate([0,0, backflange_angle])
+	  translate([-back_gap/2,1]) mirror([0,1])
+	  square([back_gap, backflange_ymin+2]);
+
+	JoinCircs(join_cr);
+      }
+
+      hull(){
+	minkowski(){
+	  DividePlanInPlace(0.1);
+	  circle(divide_around);
+	}
+      }
+    }
+    translate([0, lock_0y]){
+      oval([lock_w/2, lock_d/2]);
     }
+
     circle(r = tube_dia/2);
-    translate([-back_gap/2,1]) mirror([0,1])
-      square([back_gap, backflange_ymin+2]);
+
+    DividePlanInPlace();
   }
-  translate([0, lock_0y]){
-    difference(){
-      union(){
-	oval(lock_or);
-      }
-      oval([lock_w/2, lock_d/2]);
+}
+
+lockshaft_or = lockshaft_r + [clip_th,clip_th];
+cliprecess_ymax = cliprecess_h - lockshaft_r[1];
+clip_ymin = cliprecess_ymax - total_h;
+clip_ogap = clip_gap + clip_th*2;
+
+module ClipElevationPositive(){
+  hull(){
+    oval(lockshaft_or);
+    translate([0, -lockshaft_or[1] * sqrt(2)])
+      square(center=true, 0.5);
+  }
+  translate([-lockshaft_or[0], 0])
+    square([lockshaft_or[0]*2, cliprecess_ymax]);
+  translate([-clip_ogap/2, 0]) mirror([0,1]) square([clip_ogap, -clip_ymin]);
+}
+
+module ClipElevationNegative(){
+  hull(){
+    for (y=[0, cliprecess_ymax+1])
+      translate([0, y])
+	oval(lockshaft_r);
+  }
+  translate([-clip_gap/2, 1]) mirror([0,1]) square([clip_gap, 2-clip_ymin]);
+}
+
+module ClipElevation(){
+  difference(){
+    ClipElevationPositive(1);
+    ClipElevationNegative(0);
+  }
+}
+
+module ExtrudeClipElevation(extra=0){
+  translate([0,
+	     lock_0y + lock_d/2 + clip_d + extra,
+	     -clip_ymin])
+    rotate([90,0,0])
+    linear_extrude(height= clip_d + extra*2, convexity=100)
+    children(0);
+}
+
+module ThroughHole(r, y, z) {
+  translate([-50, y, z])
+    rotate([0, 90, 0])
+    cylinder(r=r, h=100, $fn=20);
+}
+
+module ThroughHoles(){
+  for (z=[ 1/4, 3/4 ]) {
+    ThroughHole( mountscrew_dia/2,
+		 -tube_or -0.5*backflange_d,
+		 total_h * z );
+  }
+
+  ThroughHole( clipbolt_dia/2,
+	       lock_0y + lock_d/2 + clip_d/2 + front_th/2,
+	       total_h - cliprecess_h - clip_th - clip_d/2 );
+}
+
+module MainPositive(){
+  difference(){
+    union(){
+      linear_extrude(height=total_h, convexity=100) MainPlan();
+      ExtrudeClipElevation() ClipElevationPositive();
     }
+    ExtrudeClipElevation(1) ClipElevationNegative();
   }
 }
 
-MainPlan();
+module Bracket(){ ////toplevel
+  difference(){
+    MainPositive();
+    ThroughHoles();
+  }
+}
+
+module TestTopEdge(){ ////toplevel
+  intersection(){
+    translate([0,0, -total_h])
+      translate([0,0, 4])
+      Bracket();
+    translate([-200,-200,0])
+      cube([400,400,100]);
+  }
+}
+
+module TestClipBoltHole(){ ////toplevel
+  intersection(){
+    union(){
+      translate([0, 0, -5])
+	Bracket();
+      translate([-4, lock_0y + lock_d/2 + 1, 0])
+	cube([8, 4, 1.5]);
+    }
+    translate([-200, lock_0y + lock_d/2 + 0.1])
+      cube([400, 400, total_h-20]);
+  }
+}
+
+//MainPlan();
+//ClipElevationPositive();
+//ClipElevation();
+//MainPositive();
+//%ThroughHoles();
+//TestTopEdge();
+//TestClipBoltHole();
+//DividePlan();
+
+//Bracket();
+