X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=poster-tube-lid.scad;h=2e8209f0430e9e3ca591dce15c9d05e35c96275f;hp=33d008f481287cf08c33029577e8d47c1bace1d5;hb=a77f9afd05af6862238596327a76aa1beccd036e;hpb=12ff79d2e9cc2dc14b0e9336daad6144e4b75486 diff --git a/poster-tube-lid.scad b/poster-tube-lid.scad index 33d008f..2e8209f 100644 --- a/poster-tube-lid.scad +++ b/poster-tube-lid.scad @@ -1,47 +1,97 @@ // -*- C -*- +coarse = false; + main_dia = 71.2 + 0.50 - 2.26; -top_thick = 4; +top_thick_middle = 4; +top_thick_by_oring = 3.0; +top_middle_dr = 11; + +main_cnr = 6.0; -main_cnr = 4.0; +min_wall = 3; -rivet_posn = 6.0; +rivet_posn = 6.0 + 0.30; rivet_thick = 1.67; rivet_width = 4.15 + 1.0; -rivet_tall = 5.51 + 0.49; +rivet_tall = 5.51 + 1.49; -over_rivet_wall = 0.5; +over_rivet_wall = 1.0; side_rivet_gap = 1.5; +inside_rivet_gap = 1.5; -bayo_interf = 0.75; +bayo_interf = 0.30; bayo_behind = 3.5; bayo_interf_width = 2.0; -bayo_interf_slope = 0.75; +bayo_interf_slope = 0.5; oring_thick = 5.0; oring_bore = 62.0; -oring_upper_embed_angle = 45; +oring_upper_embed_angle = 80; oring_compress = 0.1; // proportion +oring_compress_more = 0.2; + +oring_rm_beside = 8; +oring_rm_scale = 2.0; +oring_rm_angle = 20; side_taper = 1.0; -bayo_above_gap = 1.0; +bayo_gap = 6.0; bayo_entry = bayo_behind/3; -bayo_slice_size = 1; +bayo_slice_size = coarse ? 5 : 1; brace_hole_width = 1.0; brace_above_below = 1.2; +brace_end_shorter = 0.3; jig_thick = 1.4; jig_hole_dia = 3.0; jig_rim = 5; jig_mark = 5; +strap_hoop_thick = 6; +strap_hoop_inside = 10; +strap_hoop_strlen = 10; +strap_hoop_elevation = 45; + +sm_inner_circum = 218 - 1.90 - 1.00 - 0.50; +sm_main_thick = 2.0; +sm_main_width = 20; + +sm_bolt_dia = 3.5 + 0.1; +sm_bolt_shaft = 21.9; +sm_bolt_head_dia = 6.94 + 1.0; +sm_bolt_head_thick = 2.14; +sm_bolt_nut_width = 5.89 + 0.25; +sm_bolt_nut_thick = 3.68; +sm_bolt_tighten_allow = 2.0; + +sm_bolt_y_clear = 0.75; +sm_bolt_y_over = 0.5; + +sm_closure_cnr = 3.0; + +catch_stem_h = 3; +catch_stem_len = 50; +catch_stem_th = 3; + +catch_knob_dia = 6; +catch_knob_above_gap = 8; +catch_pin_height = 7; + +catch_stem_below_gap = 1.0; +catch_stem_beside_gap = 2.0; +catch_pin_gap = 0.5; +catch_hook_slope = 0.15; + // calculated +TAU = PI*2; + bayo_entry_x = bayo_entry; bayo_entry_z = bayo_entry; bayo_inramp_x = bayo_entry; @@ -50,26 +100,89 @@ bayo_inramp_z = bayo_entry; oring_mid_dia = oring_bore + oring_thick; oring_outer_dia = oring_mid_dia + oring_thick; -oring_y_rad = oring_thick/2 * (1 - oring_compress); -oring_x_rad = oring_thick/2 / (1 - oring_compress); +oring_oblate = (1 - oring_compress); + +oring_y_rad = oring_thick/2 * oring_oblate; +oring_x_rad = oring_thick/2 / oring_oblate; -seal_thick = oring_y_rad * (1 + cos(oring_upper_embed_angle)); +by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle)); side_height = rivet_posn + bayo_behind + rivet_thick/2; side_thick = rivet_tall + over_rivet_wall; -top_z = top_thick + seal_thick; +top_z = top_thick_by_oring + oring_y_rad + by_oring_z; + +middle_bot_z = top_z - top_thick_middle; bayo_entry = bayo_behind / 3.0; -bayo_top_z = bayo_behind + rivet_thick + bayo_above_gap; -bayo_entry_ramp = bayo_entry + bayo_interf; +bayo_top_z = bayo_behind + bayo_gap; + +bayo_nom_rad = main_dia/2 + side_thick; +bayo_real_rad = main_dia/2 + rivet_tall; rivet_entry_width = rivet_width + side_rivet_gap; jig_mark_rad = jig_mark + main_dia/2 + jig_thick; -$fs=0.5; -$fa=1; +handling_dia = oring_bore + oring_thick*2 + min_wall*2; +handling_angle = 45; + +sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU; +sm_outer_rad = sm_inner_rad + sm_main_thick; + +smc_pos = [ 0, sm_inner_rad, 0 ]; + +smc_bolt_nut_dia = sm_bolt_nut_width / cos(30); +smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow; + +smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear; +smc_max_y = smc_bolt_y + sm_bolt_y_over + + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2); +smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr + + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2; + +catch_cr = catch_knob_dia/2 + catch_stem_beside_gap; +catch_strap_width = sm_main_width; +catch_strap_thick = sm_main_thick; +catch_stem_end_h = catch_stem_h; +catch_pin_width = rivet_entry_width - catch_pin_gap; + +cppy6 = -catch_strap_width/2; +cppxC = 0.34 * sm_inner_rad * TAU; +cppB = [ catch_pin_width/2, + cppy6 + + catch_stem_below_gap + + catch_pin_height + + catch_knob_dia/2 ]; +cpp0 = [ 0, + cppB[1] + + catch_knob_dia + + catch_knob_above_gap ]; +cpp12 = cpp0 + [1,0] * (catch_pin_height * catch_hook_slope); +cpp1 = cpp0 + [0,1] * catch_pin_height; +cpp2 = cpp1 + [1,0] * catch_pin_width; +cpp4 = cpp0 + [0,-1] * catch_stem_end_h; +cpp3 = [ cpp2[0], cpp4[1] ]; +cpp5 = [ cpp0[0] - catch_stem_len, + -catch_stem_h ]; +cpp6 = [ cpp5[0], catch_cr ]; +cpp7 = cppB + [1,-1] * catch_knob_dia/2 + + [ catch_stem_beside_gap, -catch_stem_below_gap ] + + [ 0, -catch_pin_height ] + + [-1,1] * catch_cr; +cpp11 = cpp7 + [1,0] * catch_cr; +cpp10 = [ cpp11[0], 0 - catch_cr ]; +cpp8 = cpp10 + [1,0] * catch_cr; +cpp9 = cpp8 + [0,1] * catch_cr; +cppC = [ cppxC, cpp9[1] ]; +cppA = [ -cppxC, 0 ]; +cppD = cppC + [0,-1] * catch_strap_width; +cppE = [ cppA[0], cppD[1] ]; + +$fs= coarse ? 2.5 : 0.5; +$fa= coarse ? 5 : 1; + +include // bayonet definition @@ -80,8 +193,8 @@ bayo_m = [ bayo_inramp_x, bayo_behind ]; bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope, 1 ]; bayo_k = bayo_l + [ bayo_interf_width, 0 ]; bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ]; -bayo_i = bayo_j + [ rivet_width, 0 ]; -bayo_h = [ bayo_i[0], bayo_behind + rivet_thick + bayo_above_gap ]; +bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ]; +bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ]; bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ]; bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0]; @@ -122,17 +235,58 @@ module MainProfile(){ square([10,10]); } } - polygon([[ -11, seal_thick ], - [ -11, top_z ], + polygon([[ -top_middle_dr, middle_bot_z ], + [ -top_middle_dr, top_z ], [ main_cnr_pos[0], top_z ], [ side_thick, main_cnr_pos[1] ], [ side_thick, -side_height ], [ side_taper, -side_height ], [ 0, -rivet_posn ], - [ 0, seal_thick ], + [ 0, by_oring_z ], + [ -oring_x_rad, by_oring_z ], ], convexity=10); } + translate([ oring_mid_dia/2 - main_dia/2, 0 ]) + hull(){ + translate([ 0, oring_y_rad ]) + scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ]) + circle(oring_thick/2); + translate([ 0, oring_y_rad*2 - oring_thick/2 ]) + circle(oring_thick/2); + } + } +} + +module StrapHoopProfile(){ + circle(r = strap_hoop_thick/2); +} + +module StrapHoop(){ ////toplevel + bigrad = strap_hoop_inside/2 + strap_hoop_thick/2; + extralen = strap_hoop_thick * 5; + + intersection(){ + rotate([strap_hoop_elevation, 0,0]){ + for (x= [ -1, +1 ] * bigrad) { + translate([x, -extralen, 0]) + rotate([-90,0,0]) + linear_extrude(height= extralen + strap_hoop_strlen + 0.1, + convexity=10) + StrapHoopProfile(); + } + translate([0, strap_hoop_strlen, 0]){ + intersection(){ + rotate_extrude(convexity=10) + translate([bigrad, 0,0]) + StrapHoopProfile(); + translate([0,50,0]) + cube([100,100,100], center=true); + } + } + } + translate([0, 50, 0]) + cube(100, center=true); } } @@ -167,37 +321,86 @@ module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){ module BayonetCutout(){ RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size, - main_dia/2 + side_thick, - main_dia/2 + rivet_tall) + bayo_nom_rad, + bayo_real_rad) + translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0]) polygon(bayo_polygon, convexity=10); } module ProfilesDemo(){ ////toplevel - translate([-20,0]) MainProfile(); - polygon(bayo_polygon, convexity=10); + translate([-10,0]) MainProfile(); + translate([+10, -side_height]) polygon(bayo_polygon, convexity=10); +} + +module LimitForHandling(){ ////toplevel + hull() for (r=[0,180]) + rotate([0,0,r]) { + for (rs=[-1,+1]) { + for (xd=[0,1]) { + rotate([0,0, rs * handling_angle/2]) { + translate([rs * xd * main_dia/2 * tan(handling_angle/2), + main_dia/2 + side_thick - main_cnr, + top_z - main_cnr]) { + mirror([0,0,1]) + cylinder(r= main_cnr, h=50); + sphere(main_cnr); + } + } + } + } + } + hull() rotate_extrude(){ + translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) { + circle(r = main_cnr); + mirror([0,1]) square([ main_cnr, 50 ]); + } + } + //cylinder(r= handling_dia/2, h=20); } module Cover(){ ////toplevel render() difference(){ - union(){ - rotate_extrude(convexity=10) - translate([main_dia/2, 0]) - MainProfile(); - translate([0,0, seal_thick]) - cylinder(h= top_thick, r = main_dia/2 - 10); + intersection(){ + union(){ + rotate_extrude(convexity=10) + translate([main_dia/2, 0]) + MainProfile(); + translate([0,0, middle_bot_z]) + cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1); + } + LimitForHandling(); } - for (r=[0,180]) + for (r=[0,180]){ rotate([0,0, r]) translate([0,0, -side_height]) BayonetCutout(); + rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))]) + translate([0, + oring_mid_dia/2 + oring_thick/4 * oring_rm_scale, + oring_y_rad * 1.5]) + rotate([-oring_rm_angle, 0, 0]) + mirror([0,0,1]) + cylinder(r = oring_thick/4 * oring_rm_scale, h=20); + } for (r=[0 : 60 : 179]) { rotate([0,0, r]) { - height = top_thick - brace_above_below*2; - translate([0,0, seal_thick + brace_above_below + height/2 ]) - cube(center=true, [ main_dia, brace_hole_width, height ]); + height = top_thick_middle - brace_above_below*2; + translate([0,0, middle_bot_z + brace_above_below + height/2 ]) + cube(center=true, [ oring_bore - brace_end_shorter, + brace_hole_width, height ]); } } } + for (r=[0,180]) + rotate([0,0,r]) + translate([-implheadcup_large_dia * .5 - implheadcup_thick/2, + -implheadcup_large_dia * .0, + middle_bot_z + 0.1]) + ImplHeadCup(); +// translate(strap_hoop_thick * [-0.5, 0, +1]) +// translate([handling_dia/2, 0, -side_height]) +// rotate([0,180,0]) rotate([0,0,90]) +// StrapHoop(); } module SavingHole(){ @@ -234,11 +437,180 @@ module CoverTest2(){ ////toplevel module CoverTest1(){ ////toplevel difference(){ CoverTest2(); - translate([0,0, -10]) - cube([ main_dia*3, main_dia * .85, 20], center=true); + difference(){ + for (r= [ 40, 147 ]){ + rotate([0,0, r]){ + translate([0,0, -10]) { + cube([ main_dia*3, main_dia * .53, 18], center=true); + } + } + } +// translate([ 50, 0, 0 ]) +// cube([ 100, +// strap_hoop_inside + strap_hoop_thick*2 + 1, +// 100 ], +// center=true); + } + } +} + +module ImplHeadCupTest(){ ////toplevel + for (r=[0,180]) + rotate([0,0,r]) + translate([-17,0,0]) + ImplHeadCup(); +} + +module SomeStrap(){ + // children(0) is to add, (1) subtract + difference(){ + union(){ + cylinder(r=sm_outer_rad, h=sm_main_width); + StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr, + smc_max_y, + sm_closure_cnr); + children(0); + } + translate([0,0,-1]) + cylinder(r=sm_inner_rad, h=sm_main_width+2); + translate(smc_pos) + StrapMountBolt(10); + translate(smc_pos) + cube([ sm_bolt_tighten_allow, 40,100 ], center=true); + children(1); + } +} + +module StrapMountBolt(l_delta){ ///toplevel + // positioned relative to smc_pos + translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2, + smc_bolt_y, + sm_main_width/2]){ + translate([ -sm_bolt_shaft/2-1, 0,0 ]){ + rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2); + } + translate([ -sm_bolt_shaft/2, 0,0 ]) + rotate([0,-90,0]) + cylinder($fn=6, r=smc_bolt_nut_dia/2, + h=smc_bolt_nut_eff_thick + l_delta); + translate([ sm_bolt_shaft/2, 0,0 ]) + rotate([0,90,0]) + cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta); + } +} + +module StrapMountProtrusion(half_x, max_y, cnr){ + translate(smc_pos){ + linear_extrude(height=sm_main_width, convexity=10){ + hull(){ + for (m = [0,1]) mirror([m,0,0]) { + translate([-(half_x - cnr), max_y - cnr]) + circle(r=cnr); + translate([-half_x, -sm_inner_rad]) + square([1,1]); + } + } + } + } +} + +module StrapMount(){ ////toplevel + SomeStrap(){ + rotate([0,0,180]){ + StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick, + strap_hoop_thick, + sm_closure_cnr); + translate(smc_pos + + [0,0, sm_main_width] + + strap_hoop_thick * [ 0, 0.5, -1.0 ]) + StrapHoop(); + } + union(){ }; + } +} + +module CatchCoreProfile(){ ////toplevel + hull(){ + translate(cppB) circle(r= catch_knob_dia/2); + polygon([cpp4, + cppB, + cpp3]); + } + translate(cpp8) + circle(catch_cr); + polygon([ + cpp4, + cppB, + cpp3, + cpp2, + cpp1, + cpp12, + ]); + difference(){ + polygon([ cpp4, + cpp3, + cpp12, + cppA, + cppE, + cppD, + cppC, + cpp9, + cpp10, + cpp11, + cpp7, + cpp5, + ], convexity=10); + hull(){ + translate(cpp7) circle(r= catch_cr); + polygon([ cpp7, + cpp5, + cpp11 ]); + } + hull(){ + translate(cpp6) circle(catch_cr); + polygon([ cppA, + cpp0, + cpp1 ]); + } } } +module CatchPreDistort(){ /////toplevel + scale(100 / sm_inner_rad) + rotate([90,0,0]) + linear_extrude(height=catch_strap_thick, convexity=10) + CatchCoreProfile(); +} + +module CatchAssembly(){ /////toplevel + rotate([0,0, -0.5 * (cpp1[0] + cpp2[0]) / sm_inner_rad * 360/TAU]) + translate([0,0, catch_strap_width]) + scale(sm_inner_rad / 100) + import(str("poster-tube-lid,CatchPostDistort-fa", + (coarse ? 20 : 1), + ".stl"), + convexity=20); + + SomeStrap(){ + union(){ } + union(){ + translate([-200, -200, -200]) + cube([400, 200, 400]); + } + } +} + +module CatchDemo(){ /////toplevel + color("blue") translate([0,0, + -catch_strap_width + -cpp0[1] + ]) + CatchAssembly(); + translate([0,0,+side_height + ]) + Cover(); +} + //ProfilesDemo(); //BayonetCutout(); //MainProfile();