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=81120a4a74258a76c7528c65894b9dff9d760762;hp=1b2cb0eb1cd8f68a4dc6bd44c4666856154981e7;hb=7770827b802f785346281246c80a71663ea58938;hpb=6fea359a13f0700f6386b984c759d1cefcd4e107

diff --git a/poster-tube-lid.scad b/poster-tube-lid.scad
index 1b2cb0e..81120a4 100644
--- a/poster-tube-lid.scad
+++ b/poster-tube-lid.scad
@@ -1,54 +1,134 @@
 // -*- C -*-
 
-main_dia = 71.2 + 0.50;
-top_thick = 4;
+coarse = false;
 
-main_cnr = 4.0;
+main_dia = 71.2 + 0.50 - 2.26;
+top_thick_middle = 4;
+top_thick_by_oring = 3.0;
+top_middle_dr = 11;
 
-rivet_posn = 6.0;
+main_cnr = 6.0;
+
+min_wall = 3;
+
+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;
 
-seal_thick = 0.1;
-seal_recess = [ 2.0, 2.0 ]; // recess depth, recess height
+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;
 
 // calculated
 
+TAU = PI*2;
+
 bayo_entry_x = bayo_entry;
 bayo_entry_z = bayo_entry;
 bayo_inramp_x = bayo_entry;
 bayo_inramp_z = bayo_entry;
 
+oring_mid_dia = oring_bore + oring_thick;
+oring_outer_dia = oring_mid_dia + oring_thick;
+
+oring_oblate = (1 - oring_compress);
+
+oring_y_rad = oring_thick/2 * oring_oblate;
+oring_x_rad = oring_thick/2 / oring_oblate;
+
+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;
 
 rivet_entry_width = rivet_width + side_rivet_gap;
 
-$fs=0.5;
-$fa=1;
+jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
+
+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;
+
+$fs= coarse ? 2.5 : 0.5;
+$fa= coarse ? 5 : 1;
+
+include <poster-tube-lid-parametric.scad>
 
 // bayonet definition
 
@@ -59,8 +139,8 @@ 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];
@@ -90,65 +170,309 @@ echo(bayo_polygon);
 
 module MainProfile(){
   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
-  translate(main_cnr_pos){
-    intersection(){
-      difference(){
-	circle(r = main_cnr);
-	circle(r = main_cnr * 0.5);
+  difference(){
+    union(){
+      translate(main_cnr_pos){
+	intersection(){
+	  difference(){
+	    circle(r = main_cnr);
+	    circle(r = main_cnr * 0.5);
+	  }
+	  square([10,10]);
+	}
+      }
+      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,                     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);
+	}
       }
-      square([10,10]);
     }
+    translate([0, 50, 0])
+      cube(100, center=true);
   }
-  polygon([[ -1,                    seal_thick        ],
-	   [ -1,                    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_recess[0] + seal_recess[1]) ],
-	   [ seal_recess[0],        -(seal_recess[0]) ],
-	   [ seal_recess[0],        seal_thick        ],
-	   ]);
-}
-
-module BayonetCutoutSlice(offset){
-  rotate([0,0, atan2(offset, main_dia/2 + side_thick) ]){
+}
+
+module HandlingProfile(){
+//  translate([
+}
+
+module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
+  // nom_rad > real_rad
+  rotate([0,0, atan2(offset, nom_rad) ]){
     intersection(){
       translate([-offset, -10, 0])
 	rotate([90,0,0])
-	linear_extrude(height= main_dia*2)
-	polygon(bayo_polygon);
+	linear_extrude(height= nom_rad*2)
+	children(0);
+      translate([0,0, -25])
+	cylinder(h=50, r= real_rad);
       translate([0,0, -25])
-	cylinder(h=50, r= main_dia/2 + rivet_tall);
-      #translate([0,0, -25])
 	linear_extrude(height= 50)
 	polygon([ [ 0,0 ],
-		  [ -bayo_slice_size, -main_dia ],
-		  [ +bayo_slice_size, -main_dia ] ]);
+		  [ -slice_size, -real_rad*2 ],
+		  [ +slice_size, -real_rad*2 ] ]);
     }
   }
 }
 
-module BayonetCutout(){
-  offs = [ for (i=[ bayo_c[0] :
-		    bayo_slice_size :
-		    bayo_i[0] + bayo_slice_size ]) i ];
+module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
+  offs = [ for (i=[ x_min :
+		    slice_size :
+		    x_max + slice_size ]) i ];
   echo (offs);
-  for (off =offs
-	 
-	 //[ -20 : bayo_slice_size : 20 ]
-       ){
-    translate([ off * 5, 0,0 ])
-    echo(off);
-    BayonetCutoutSlice(off);
+  for (off=offs)
+    RotateProjectSlice(off, slice_size, nom_rad, real_rad)
+    children(0);
+}
+
+module BayonetCutout(){
+  RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
+		main_dia/2 + side_thick, 
+		main_dia/2 + rivet_tall)
+    translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
+    polygon(bayo_polygon, convexity=10);
+}
+
+module ProfilesDemo(){ ////toplevel
+  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(){
+    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]){
+      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_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(){
+  translate([0,0, -10])
+    cylinder(r= main_dia/2 - jig_rim, h=20);
+}
+
+module Jig(){ ////toplevel
+  difference(){
+    union(){
+      translate([0,0, -side_height]){
+	cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
+      }
+      translate([-jig_mark_rad, 0, jig_thick - jig_mark])
+	cube([jig_mark_rad*2, jig_mark, jig_mark]);
+    }
+    translate([0,0, -side_height-1])
+      cylinder(r= main_dia/2, h= side_height + 1);
+    SavingHole();
+    translate([0,0, -rivet_posn])
+      rotate([90, 0,0])
+      translate([0,0, -100])
+      cylinder(r= jig_hole_dia/2, h = 200);
   }
 }
 
-module ProfilesDemo(){
-  translate([-20,0]) MainProfile();
-  polygon(bayo_polygon);
+module CoverTest2(){ ////toplevel
+  difference(){
+    Cover();
+    SavingHole();
+  }
+}
+
+module CoverTest1(){ ////toplevel
+  difference(){
+    CoverTest2();
+    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 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
+  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);
+      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();
+      }
+    }
+    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);
+  }
 }
 
 //ProfilesDemo();
-BayonetCutout();
+//BayonetCutout();
+//MainProfile();
+//Cover();
+//Jig();
+//CoverTest();