X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=pattress-boxes-3-cover.scad;h=7c1d4b892cf63d56ddcb2d6e9afc36a5b30d1e34;hp=b30268b2cc8ab1f4f284547e9e0ca4f0c7eaedf6;hb=48c07842b36e40408e661792c77ce63ae92a9ffd;hpb=555a02d54556725cebdab1fc14f781dbff968025

diff --git a/pattress-boxes-3-cover.scad b/pattress-boxes-3-cover.scad
index b30268b..7c1d4b8 100644
--- a/pattress-boxes-3-cover.scad
+++ b/pattress-boxes-3-cover.scad
@@ -1,41 +1,201 @@
 // -*- C -*-
 
-patbox_side = 87 + 0.5;
+patbox_side = 87;
 patbox_centres = 60.3;
 
-lid_box_overlap = 5;
+lid_thinboxbase_overlap = 5;
+lid_fatbox_overlap = 12;
 
 lid_thinbox_h = 9;
 lid_fatbox_h = 24;
-lid_fatbox_switches_h = 6+2;
+lid_fatbox_switches_h = 6+4;
+
+lid_max_switches_w = 70;
+lid_switches_y_slop = 3;
 
 total_len = 260;
 thinbox_len = 87;
 
+rail_overlap = 8;
+
 lid_top_wall = 1.5;
 lid_front_wall = 1.5;
 lid_side_wall = 1.5;
 
+peg_engage_depth = 1;
+peg_engage_dia = 6.5;
+peg_main_dia = 9;
+peg_max_dia = 15;
+peg_inner_dia = 3.5;
+peg_top_thick = 1;
+peg_straight_len = 3;
+
+$peg_inner_slop = 0.75;
+$peg_outer_slop = -0.9;
+$peg_outer_slop_engage = 0.1;
+
+peg_slope = 1;
+
+lid_side_slop = 0.5;
+lid_rail_behindslop = 0.5;
+lid_rail_strongwall = 2.5;
+
 // computed
 
-lid_inner_max_h = lid_box_overlap + lid_fatbox_h + lid_fatbox_switches_h;
-lid_inner_min_h = lid_box_overlap + lid_fatbox_switches_h;
+lid_inner_max_h =
+  lid_thinboxbase_overlap + lid_fatbox_h + lid_fatbox_switches_h;
+lid_inner_min_h = lid_fatbox_overlap + lid_fatbox_switches_h;
 
 lid_inner_kink = [thinbox_len, thinbox_len*2];
 
+lid_inner_w_nom = patbox_side;
+lid_inner_w = lid_inner_w_nom + lid_side_slop * 2;
+
+lid_seatline_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;
+
+lid_seatline_h = lid_fatbox_switches_h;
+
+peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;
+
+thinbox_front_z = lid_fatbox_switches_h + lid_fatbox_h - lid_thinbox_h;
+
+raillen = patbox_side/2 + rail_overlap;
+
 module LidSideProfile(){
   polygon([[-lid_top_wall,     lid_inner_max_h],
-	   [lid_inner_kink[0], lid_inner_max_h],
-	   [lid_inner_kink[1], lid_inner_min_h],
+	   [min(lid_inner_kink[0],total_len), lid_inner_max_h],
+	   [min(lid_inner_kink[1],total_len), lid_inner_min_h],
 	   [total_len,         lid_inner_min_h],
 	   [total_len,         -lid_front_wall],
 	   [-lid_top_wall,     -lid_front_wall]]);
 }
 
+module RailProfile(lslop=0.1){
+  yt_base = thinbox_front_z;
+  yt = yt_base - lid_rail_behindslop;
+  pegx = (lid_inner_w_nom - patbox_centres)/2;
+  sw = lid_rail_strongwall;
+  
+  polygon([[-lslop,                  yt],
+	   [pegx - peg_main_dia/2, yt],
+	   [pegx - peg_main_dia/2, yt_base - peg_straight_len],
+	   [sw,
+	    yt_base - peg_straight_len - (pegx - peg_main_dia/2)/peg_slope
+	    +sw],
+	   [sw,
+	    lid_seatline_h - 1],
+	   [-lslop,
+	    lid_seatline_h - 1]]);
+}
+
 module LidSide(){
+  overlap = [0.1, 0.1, 0.1];
+
+  // main side profile
   rotate([90,0,0])
-  linear_extrude(height= lid_side_wall)
+    linear_extrude(height= lid_side_wall)
     LidSideProfile();
+
+  // seatline
+  translate(-overlap)
+    cube(overlap + [total_len, lid_seatline_w, lid_seatline_h]);
+
+  // lid front
+  translate([-0.1, -0.1, -lid_front_wall])
+    cube([total_len+0.1, lid_inner_w/2 + 0.2, lid_front_wall]);
+
+  // lid top
+  translate([-lid_top_wall, -lid_side_wall, -lid_front_wall])
+    cube([lid_top_wall, lid_inner_w/2 + 10, lid_front_wall + lid_inner_max_h]);
+
+  // rail
+  rotate([90,0,90])
+    translate([0,0,-0.1])
+    linear_extrude(height=raillen+0.1) //todo
+    RailProfile();
+
+  // rail end
+  translate([raillen, 0,0])
+    intersection(){
+      rotate_extrude($fn=50)
+	RailProfile(lslop=0);
+      translate([0, 25-0.1, 0])
+	cube(50, center=true);
+    }
+}
+
+module Lid(){ ////toplevel
+  for (m=[0,1])
+    mirror([0,m,0])
+      translate([0, -lid_inner_w/2, 0]) LidSide();
+}
+
+module PegProfile(){
+  polygon([[-peg_engage_depth, (peg_engage_dia - $peg_outer_slop_engage)/2],
+	   [0,                 (peg_engage_dia - $peg_outer_slop_engage)/2],
+	   [0,                 (peg_main_dia - $peg_outer_slop)/2],
+	   [peg_straight_len,  (peg_main_dia - $peg_outer_slop)/2],
+	   [peg_main_height,   (peg_max_dia - $peg_outer_slop)/2],
+	   [peg_main_height+peg_top_thick, (peg_max_dia - $peg_outer_slop)/2],
+	   [peg_main_height+peg_top_thick, (peg_inner_dia + $peg_inner_slop)/2],
+	   [-peg_engage_depth,  (peg_inner_dia + $peg_inner_slop)/2]]);
+}
+
+module Peg(){ ////toplevel
+  echo($peg_outer_slop_engage);
+  rotate_extrude($fn=50)
+    rotate([0,0,-90])
+    PegProfile();
+}
+
+module Pegs(){ ////toplevel
+  baseslop = 0.1;
+  dslops = [0, -0.5, -1.0, -1.5];
+  stride = peg_max_dia + 4;
+  for (i=[0:len(dslops)-1]) {
+    translate([i*stride,0,0])
+      assign($peg_outer_slop_engage= baseslop + dslops[i])
+      Peg();
+  }
+}
+
+module AtFixingCentres(){
+  for (fc=[-1,+1]) {
+    translate([patbox_side/2 + fc*patbox_centres/2,
+	       patbox_side/2,
+	       0])
+      children();
+  }
+}
+
+module TopPattressBox(){
+  difference(){
+    translate([0,0, -lid_thinbox_h])
+      cube([patbox_side, patbox_side, lid_thinbox_h]);
+    AtFixingCentres(){
+      translate([0,0,-10]) cylinder(r=peg_engage_dia/2, h=20);
+    }
+  }
+}
+
+module Demo(){
+  Lid();
+  translate([0,0, thinbox_front_z])
+    rotate([0,180,0]) translate([0, -patbox_side/2, 0])
+    rotate([0,0,90]) union(){
+      %TopPattressBox();
+      color("blue") AtFixingCentres(){
+	rotate([180,0,0]) Peg();
+      }
+  }
 }
 
-LidSide();
+//LidSide();
+//PegProfile();
+//Peg();
+//Pegs();
+//TopPattressBox();
+//RailProfile();
+//Demo();
+//Lid();
+//translate([0,0,-lid_fatbox_switches_h]) Lid();