poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 // Print, for each end:
   4 //
   5 //   CoverPrint
   6 //   StrapMount
   7 //   CatchAssembly
   8
   9 include <funcs.scad>
  10 include <utils.scad>
  11
  12 coarse = false;
  13 enable_head_cups = false;
  14
  15 main_dia = 71.2 + 0.50 - 2.26;
  16 top_thick_middle = 4;
  17 top_thick_by_oring = 3.0;
  18 top_middle_dr = 11;
  19
  20 main_cnr = 6.0;
  21
  22 min_wall = 3;
  23
  24 rivet_posn = 6.0 + 0.30;
  25 rivet_thick = 1.67;
  26 rivet_width = 4.15 + 1.0;
  27 rivet_tall = 5.51 + 1.49;
  28
  29 over_rivet_wall = 1.0;
  30 side_rivet_gap = 1.5;
  31 inside_rivet_gap = 1.5;
  32
  33 bayo_interf = 0.30;
  34 bayo_behind = 8.5;
  35 bayo_interf_width = 2.0;
  36 bayo_interf_slope = 0.5;
  37
  38 oring_thick = 5.0;
  39 oring_bore = 62.0;
  40
  41 oring_upper_embed_angle = 80;
  42 oring_compress = 0.1; // proportion
  43 oring_compress_more = 0.2;
  44
  45 oring_rm_beside = 8;
  46 oring_rm_scale = 2.0;
  47 oring_rm_angle = 20;
  48
  49 side_taper = 1.0;
  50
  51 bayo_gap = 6.0;
  52
  53 bayo_entry = 1.167;
  54 bayo_inramp = 0.9;
  55
  56 bayo_slice_size = coarse ? 5 : 1;
  57
  58 brace_hole_width = 1.0;
  59 brace_above_below = 1.2;
  60 brace_end_shorter = 0.3;
  61
  62 jig_thick = 1.4;
  63 jig_hole_dia = 3.0;
  64 jig_rim = 5;
  65 jig_mark = 5;
  66
  67 strap_loop_thick = 6;
  68 strap_loop_inside = 10;
  69 strap_loop_strlen = 10;
  70 strap_loop_elevation = 45;
  71
  72 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  73 sm_main_thick = 2.0;
  74 sm_main_width = 20;
  75
  76 sm_bolt_dia = 3.5 + 0.1;
  77 sm_bolt_shaft = 21.0;
  78 sm_bolt_head_dia = 6.94 + 1.0;
  79 sm_bolt_head_thick = 2.14;
  80 sm_bolt_nut_width = 5.89 + 0.25;
  81 sm_bolt_nut_thick = 3.68;
  82 sm_bolt_tighten_allow = 2.0;
  83
  84 sm_bolt_y_clear = 0.75;
  85 sm_bolt_y_over = 0.5;
  86
  87 sm_closure_cnr = 3.0;
  88
  89 wm_thick = 5;
  90 wm_screw_dia = 4.5; // XXX
  91 wm_screwdriver_dia = 6.0; // XXX
  92 wm_screw_around = 4.0; // XXX
  93 wm_screw_slot = 3.5;
  94 wm_screw_head = 7.5; // XXX
  95
  96 wmb_screw_dia = 5;
  97 wmb_screw_head_dia = 10; // XXX
  98 wmb_screw_around_x = 4; // XXX
  99 wmb_screw_around_z = 6; // XXX
 100 wmb_screw_depth_min = 10;
 101 web_screw_len = 15 + 1; // XXX
 102 wmb_nut_across = 8; // XXX
 103 wmb_nut_around_min = 2; // XXX
 104 wmb_nut_behind_min = 5;
 105 wmb_nut_th = 4; // XXX
 106 wmb_mount_wall = 4.5;
 107 wmb_mount_gap_xy = 0.5;
 108 wmb_ring_gap = 1.0;
 109
 110 catch_stalk_h = 4.5;
 111 catch_stalk_len = 50;
 112 catch_tip_th = 4;
 113 catch_head_th = 3;
 114
 115 catch_pin_slop = 0.25; // each side, and above
 116 catch_pin_slop_x_extra = 0.0; // only on one side
 117 catch_stalk_above_gap = 1.5;
 118 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 119
 120 catch_strap_width = 12;
 121 catch_stalk_base_width = 15;
 122
 123 catch_knob_dia = 6;
 124 catch_knob_above_gap = 5;
 125 catch_knob_height = 3.0;
 126
 127 catch_stalk_below_gap = 1.0;
 128 catch_stalk_beside_gap = 2.0;
 129
 130 // calculated
 131
 132 TAU = PI*2;
 133
 134 bayo_entry_x = bayo_entry;
 135 bayo_entry_z = bayo_entry;
 136 bayo_inramp_x = bayo_inramp;
 137 bayo_inramp_z = bayo_inramp;
 138
 139 oring_mid_dia = oring_bore + oring_thick;
 140 oring_outer_dia = oring_mid_dia + oring_thick;
 141
 142 oring_oblate = (1 - oring_compress);
 143
 144 oring_y_rad = oring_thick/2 * oring_oblate;
 145 oring_x_rad = oring_thick/2 / oring_oblate;
 146
 147 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 148
 149 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 150 side_thick = rivet_tall + over_rivet_wall;
 151
 152 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 153
 154 middle_bot_z = top_z - top_thick_middle;
 155
 156 bayo_top_z = bayo_behind + bayo_gap;
 157
 158 bayo_nom_rad = main_dia/2 + side_thick;
 159 bayo_real_rad = main_dia/2 + rivet_tall;
 160
 161 rivet_entry_width = rivet_width + side_rivet_gap;
 162
 163 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 164
 165 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 166 handling_angle = 45;
 167
 168 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 169 sm_outer_rad = sm_inner_rad + sm_main_thick;
 170
 171 wm_main_width = sm_main_width;
 172 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 173                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 174 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 175 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 176 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 177 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 178 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 179 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 180 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 181 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 182 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 183
 184 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
 185 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
 186 wmb_x_screw_plus_around_r = max(
 187                                 wmb_screw_around_x + wmb_screw_dia/2,
 188                                 wmb_nut_around_min + wmb_nut_across/2
 189                                 );
 190 wmb_x_screw = -sm_outer_rad + wmb_x_screw_plus_around_r;
 191 wmb_x_outer = -sm_outer_rad + wmb_x_screw_plus_around_r * 2;
 192 function wmb_screw_thing_y_min(dia) = sqrt(
 193                        pow(wmb_mount_cut_rad, 2) -
 194                        pow(wmb_x_screw + dia/2, 2)
 195                        );
 196 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 197 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2);
 198 wmb_y_mount_max = max(
 199                       wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
 200                       wmb_y_screw_end + wmb_screw_depth_min
 201                       );
 202 wmb_z_screw = max(
 203                   wmb_screw_around_z + wmb_screw_dia/2,
 204                   wmb_nut_around_min + wmb_nut_rad
 205                   );
 206 wmb_z_max = wmb_z_screw * 2;
 207 wmbb_y_max = wmb_y_mount_max + wmb_mount_gap_xy + wmb_mount_wall;
 208 wmbb_x_outer = wmb_x_outer - (wmb_mount_gap_xy + wmb_mount_wall);
 209 wmbb_z_min = -20; // XXX
 210
 211 smc_pos = [ 0, sm_inner_rad, 0 ];
 212
 213 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 214 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 215
 216 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 217 smc_max_y = smc_bolt_y + sm_bolt_y_over
 218   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 219 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 220   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 221
 222 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 223 catch_strap_thick = sm_main_thick;
 224
 225 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 226
 227 $fs= coarse ? 2.5 : 0.5;
 228 $fa= coarse ? 5 : 1;
 229
 230 include <poster-tube-lid-parametric.scad>
 231
 232 // bayonet definition
 233
 234 bayo_a = [ bayo_entry_x, 0 ];
 235 bayo_p = [ 0, bayo_entry_z ];
 236 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 237 bayo_m = [ bayo_inramp_x, bayo_behind ];
 238 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 239 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 240 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 241 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 242 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 243 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 244
 245 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 246 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 247 bayo_c = bayo_d + [0,-5];
 248 bayo_b = bayo_a + [0,-5];
 249
 250 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 251
 252 bayo_polygon = [ bayo_a,
 253                  bayo_b,
 254                  bayo_c,
 255                  bayo_d,
 256                  bayo_e,
 257                  bayo_f,
 258                  bayo_g,
 259                  bayo_h,
 260                  bayo_i,
 261                  bayo_j,
 262                  bayo_k,
 263                  bayo_l,
 264                  bayo_m,
 265                  bayo_n,
 266                  bayo_p ];
 267
 268 echo(bayo_polygon);
 269
 270 // CATCH
 271
 272 cppxC = 0.41 * sm_inner_rad * TAU;
 273
 274 // catch pin
 275
 276 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 277 // radius scaling due to nom and actual radius difference in
 278 // bayo entry construction
 279
 280 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 281 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 282 cppd = [ bayo_n[0]
 283          - catch_pin_slop - catch_pin_slop_x_extra,
 284          -catch_stalk_above_gap ];
 285 cppi = [ cppa[0], cppd[1] ];
 286 cppc = [ cppd[0], cppb[1] ];
 287 cpph = cppd + [0,-1] * catch_stalk_h;
 288 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 289 cppf = [ cppa[0], cppe[1] ];
 290 cppg = [ cppa[0], cpph[1] ];
 291 cppB = 0.5 * (cppf + cppe);
 292
 293 echo("RR", sm_inner_rad / bayo_nom_rad);
 294
 295 // catch assembly depression below pin
 296
 297 cppy6 = cppB[1] - (catch_knob_dia/2
 298                    + (cppc[1] - cppd[1])
 299                    + catch_stalk_below_gap);
 300 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 301 cpp11 = cpp7 + [1,0] * catch_cr;
 302 cppy9 = cppy6 + catch_strap_width * 1/3;
 303 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 304 cpp8 = cpp9 + [0,-1] * catch_cr;
 305 cpp10 = cpp8 + [-1,0] * catch_cr;
 306 cppC = [ cppxC, cpp9[1] ];
 307 cppD = cppC + [0,-1] * catch_strap_width;
 308
 309 // catch assembly stalk and so on
 310
 311 catch_cr3 = catch_cr + catch_stalk_h;
 312
 313 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 314 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 315 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 316 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 317 cpp2r = cpp2 + [1,0] * catch_cr;
 318 cpp2d = cpp2 + [0,-1] * catch_cr;
 319 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 320 cppA = [ -cppxC, cpp9[1] ];
 321 cppE = [ cppA[0], cppD[1] ];
 322
 323 catch_assembly_dy = -cppy9 + catch_strap_width;
 324
 325
 326 module MainProfile(){
 327   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 328   difference(){
 329     union(){
 330       translate(main_cnr_pos){
 331         intersection(){
 332           difference(){
 333             circle(r = main_cnr);
 334             circle(r = main_cnr * 0.5);
 335           }
 336           square([10,10]);
 337         }
 338       }
 339       polygon([[ -top_middle_dr,        middle_bot_z      ],
 340                [ -top_middle_dr,        top_z             ],
 341                [ main_cnr_pos[0],       top_z             ],
 342                [ side_thick,            main_cnr_pos[1]   ],
 343                [ side_thick,            -side_height      ],
 344                [ side_taper,            -side_height      ],
 345                [ 0,                     -rivet_posn       ],
 346                [ 0,                     by_oring_z        ],
 347                [ -oring_x_rad,          by_oring_z        ],
 348                ],
 349               convexity=10);
 350     }
 351     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 352       hull(){
 353       translate([ 0, oring_y_rad ])
 354         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 355         circle(oring_thick/2);
 356       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 357         circle(oring_thick/2);
 358     }
 359   }
 360 }
 361
 362 module StrapLoopProfile(){
 363   circle(r = strap_loop_thick/2);
 364 }
 365
 366 module StrapLoop(){ ////toplevel
 367   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 368   extralen = strap_loop_thick * 5;
 369
 370   intersection(){
 371     rotate([strap_loop_elevation, 0,0]){
 372       for (x= [ -1, +1 ] * bigrad) {
 373         translate([x, -extralen, 0])
 374           rotate([-90,0,0])
 375           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 376                          convexity=10)
 377           StrapLoopProfile();
 378       }
 379       translate([0, strap_loop_strlen, 0]){
 380         intersection(){
 381           rotate_extrude(convexity=10)
 382             translate([bigrad, 0,0])
 383             StrapLoopProfile();
 384           translate([0,50,0])
 385             cube([100,100,100], center=true);
 386         }
 387       }
 388     }
 389     translate([0, 50, 0])
 390       cube(100, center=true);
 391   }
 392 }
 393
 394 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 395   // nom_rad > real_rad
 396   rotate([0,0, atan2(offset, nom_rad) ]){
 397     intersection(){
 398       translate([-offset, -10, 0])
 399         rotate([90,0,0])
 400         linear_extrude(height= nom_rad*2, convexity=50)
 401         children(0);
 402       translate([0,0, -25])
 403         cylinder(h=50, r= real_rad);
 404       translate([0,0, -25])
 405         linear_extrude(height= 50, convexity=50)
 406         polygon([ [ 0,0 ],
 407                   [ -slice_size, -real_rad*2 ],
 408                   [ +slice_size, -real_rad*2 ] ]);
 409     }
 410   }
 411 }
 412
 413 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 414   offs = [ for (i=[ x_min :
 415                     slice_size :
 416                     x_max + slice_size ]) i ];
 417   echo (offs);
 418   for (off=offs)
 419     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 420     children(0);
 421 }
 422
 423 module BayonetCutout(){
 424   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 425                 bayo_nom_rad,
 426                 bayo_real_rad)
 427     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 428     polygon(bayo_polygon, convexity=10);
 429 }
 430
 431 module ProfilesDemo(){ ////toplevel
 432   translate([-10,0]) MainProfile();
 433   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 434 }
 435
 436 module LimitForHandling(){ ////toplevel
 437   hull() for (r=[0,180])
 438     rotate([0,0,r]) {
 439       for (rs=[-1,+1]) {
 440         for (xd=[0,1]) {
 441           rotate([0,0, rs * handling_angle/2]) {
 442             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 443                        main_dia/2 + side_thick - main_cnr,
 444                        top_z - main_cnr]) {
 445               mirror([0,0,1])
 446                 cylinder(r= main_cnr, h=50);
 447               sphere(main_cnr);
 448             }
 449           }
 450         }
 451       }
 452     }
 453   hull() rotate_extrude(convexity=10){
 454     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 455       circle(r = main_cnr);
 456       mirror([0,1]) square([ main_cnr, 50 ]);
 457     }
 458   }
 459   //cylinder(r= handling_dia/2, h=20);
 460 }
 461
 462 module Cover(){ ////toplevel
 463   render() difference(){
 464     intersection(){
 465       union(){
 466         rotate_extrude(convexity=10)
 467           translate([main_dia/2, 0])
 468           MainProfile();
 469         translate([0,0, middle_bot_z])
 470           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 471       }
 472       LimitForHandling();
 473     }
 474     for (r=[0,180]){
 475       rotate([0,0, r])
 476         translate([0,0, -side_height])
 477         BayonetCutout();
 478       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 479         translate([0,
 480                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 481                    oring_y_rad * 1.5])
 482         rotate([-oring_rm_angle, 0, 0])
 483         mirror([0,0,1])
 484         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 485     }
 486     for (r=[0 : 60 : 179]) {
 487       rotate([0,0, r]) {
 488         height = top_thick_middle - brace_above_below*2;
 489         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 490         cube(center=true, [ oring_bore - brace_end_shorter,
 491                             brace_hole_width, height ]);
 492       }
 493     }
 494   }
 495   if (enable_head_cups)
 496     for (r=[0,180])
 497       rotate([0,0,r])
 498         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 499                    -implheadcup_large_dia * .0,
 500                    middle_bot_z + 0.1])
 501         ImplHeadCup();
 502
 503 //  translate(strap_loop_thick * [-0.5, 0, +1])
 504 //    translate([handling_dia/2, 0, -side_height])
 505 //    rotate([0,180,0]) rotate([0,0,90])
 506 //    StrapLoop();
 507 }
 508
 509 module SavingHole(){
 510   translate([0,0, -10])
 511     cylinder(r= main_dia/2 - jig_rim, h=20);
 512 }
 513
 514 module Jig(){ ////toplevel
 515   difference(){
 516     union(){
 517       translate([0,0, -side_height]){
 518         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 519       }
 520       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 521         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 522     }
 523     translate([0,0, -side_height-1])
 524       cylinder(r= main_dia/2, h= side_height + 1);
 525     SavingHole();
 526     translate([0,0, -rivet_posn])
 527       rotate([90, 0,0])
 528       translate([0,0, -100])
 529       cylinder(r= jig_hole_dia/2, h = 200);
 530   }
 531 }
 532
 533 module CoverPrint(){ ////toplevel
 534   rotate([0,180,0]) Cover();
 535 }
 536
 537 module CoverTest2(){ ////toplevel
 538   difference(){
 539     Cover();
 540     SavingHole();
 541   }
 542 }
 543
 544 module CoverTest1(){ ////toplevel
 545   difference(){
 546     CoverTest2();
 547     difference(){
 548       for (r= [ 40, 147 ]){
 549         rotate([0,0, r]){
 550           translate([0,0, -10]) {
 551             cube([ main_dia*3, main_dia * .53, 18], center=true);
 552           }
 553         }
 554       }
 555 //      translate([ 50, 0, 0 ])
 556 //      cube([ 100,
 557 //             strap_loop_inside + strap_loop_thick*2 + 1,
 558 //             100 ],
 559 //           center=true);
 560     }
 561   }
 562 }
 563
 564 module ImplHeadCupTest(){ ////toplevel
 565   for (r=[0,180])
 566     rotate([0,0,r])
 567       translate([-17,0,0])
 568       ImplHeadCup();
 569 }
 570
 571 module SomeStrap(width, cut_width=0){
 572   // children(0) is to add, (1) subtract
 573   difference(){
 574     union(){
 575       cylinder(r=sm_outer_rad, h=width);
 576       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 577                            smc_max_y,
 578                            sm_closure_cnr,
 579                            width);
 580       children(0);
 581     }
 582     translate([0,0,-1])
 583       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 584     translate(smc_pos)
 585       StrapMountBolt(10, width);
 586     translate(smc_pos)
 587       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 588     children(1);
 589   }
 590 }
 591
 592 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 593   // positioned relative to smc_pos
 594   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 595              smc_bolt_y,
 596              strap_width/2]){
 597     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 598       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 599     }
 600     translate([ -sm_bolt_shaft/2, 0,0 ])
 601       rotate([0,-90,0])
 602       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 603                h=smc_bolt_nut_eff_thick + l_delta);
 604     translate([ sm_bolt_shaft/2, 0,0 ])
 605       rotate([0,90,0])
 606       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 607   }
 608 }
 609
 610 module StrapMountProtrusion(half_x, max_y, cnr, width){
 611   translate(smc_pos){
 612     linear_extrude(height=width, convexity=10){
 613       hull(){
 614         for (m = [0,1]) mirror([m,0,0]) {
 615           translate([-(half_x - cnr), max_y - cnr])
 616             circle(r=cnr);
 617           translate([-half_x, -sm_inner_rad])
 618             square([1,1]);
 619         }
 620       }
 621     }
 622   }
 623 }
 624
 625 module StrapMount(){ ////toplevel
 626   SomeStrap(sm_main_width){
 627     rotate([0,0,180]){
 628       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 629                            strap_loop_thick,
 630                            sm_closure_cnr,
 631                            sm_main_width);
 632       translate(smc_pos +
 633                 [0,0, sm_main_width] +
 634                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 635         StrapLoop();
 636     }
 637     union(){ };
 638   }
 639 }
 640
 641 module WallScrewHoleSlot(){ ////toplevel
 642   ds = [-1,+1] * wm_screw_slot/2;
 643   linextr_x_yz(-(wm_thick + 1), 1) {
 644     hull(){
 645       for (d = ds)
 646         translate([d, 0])
 647           circle(r = wm_screw_dia/2);
 648     }
 649   }
 650   hull(){
 651     for (d = ds){
 652       translate([0, d, 0]){
 653         linextr_x_yz(0, 1)
 654           circle(r = wm_screw_head/2);
 655         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 656           circle(r = wm_screw_dia/2);
 657       }
 658     }
 659   }
 660 }
 661
 662 module WallMountMounts(){
 663   linextr(0, wm_z_max){
 664     translate([ -sm_outer_rad, 0 ])
 665       rectfromto([ 0, -wm_y_max ],
 666                  [ wm_thick, wm_y_slot1_max ]);
 667   }
 668 }
 669 module WallMountScrewHoles(){
 670   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 671     translate([ 0, wm_y_slotc_screw, 0 ])
 672       WallScrewHoleSlot();
 673     translate([ 0, -wm_y_slotc_screw, 0 ])
 674       rotate([90,0,0])
 675       WallScrewHoleSlot();
 676   }
 677 }
 678
 679 module WallMount(){ ////toplevel
 680   SomeStrap(sm_main_width, wm_z_max + 2){
 681     WallMountMounts();
 682     WallMountScrewHoles();
 683   }
 684 }
 685
 686 module WallMountBaseRingCut(){
 687   circle(r = wmb_mount_cut_rad);
 688 }
 689
 690 module WallMountBaseMounts(){
 691   linextr(0, wmb_z_max) {
 692     difference(){
 693       rectfromto([ -sm_outer_rad,            -wmb_y_mount_max ],
 694                  [ wmb_x_outer, +wmb_y_mount_max ]);
 695       WallMountBaseRingCut();
 696     }
 697   }
 698 }
 699
 700 // screws, nuts, slots for nuts to go down into
 701 module WallMountBaseScrewsEtc(){ ////toplevel
 702   for (my=[0,1]) {
 703     mirror([0, my, 0]) {
 704       translate([wmb_x_screw, 0, wmb_z_screw]) {
 705         linextr_y_xz(wmb_y_screw_end,
 706                      wmb_y_screw_end + 100) // XXX change 100
 707           circle(r = wmb_screw_dia/2);
 708         linextr_y_xz(wmb_y_screw_end + web_screw_len,
 709                      wmb_y_screw_end + 100) // XXX change 100
 710           circle(r = wmb_screw_head_dia/2);
 711         linextr_y_xz(wmb_y_nut_min,
 712                      wmb_y_nut_min + wmb_nut_th){
 713           hull(){
 714             rotate(30)
 715               circle(r = wmb_nut_rad, $fn = 6);
 716             translate([0, 100]) // XXX change 100
 717               square(wmb_nut_across, center=true);
 718           }
 719         }
 720       }
 721     }
 722   }
 723 }
 724
 725 module WallMountForBase(){ ////toplevel
 726   SomeStrap(sm_main_width, wm_z_max + 2){
 727     union(){
 728       WallMountMounts();
 729       WallMountBaseMounts();
 730     }
 731     union(){
 732       WallMountScrewHoles();
 733       WallMountBaseScrewsEtc();
 734     }
 735   }
 736 }
 737
 738 module WallMountBase(){ ////toplevel
 739   linextr(wmbb_z_min, wmb_z_max) {
 740     difference(){
 741       rectfromto([ 0,            -wmbb_y_max ],
 742                  [ wmbb_x_outer, +wmbb_y_max ]);
 743       WallMountBaseRingCut();
 744     }
 745   }
 746 }
 747
 748 module WallMountForBaseDemo(){ ////toplevel
 749   WallMountForBase();
 750   color("blue") WallMountBase();
 751   %WallMountBaseScrewsEtc();
 752 }
 753
 754 module CatchAssemblyCoreProfile(){
 755   difference(){
 756     union(){
 757       hull(){
 758         translate(cpp3) circle(r= catch_cr3);
 759         polygon([ cpp3,
 760                   cpp2r,
 761                   cpp5,
 762                   cpph,
 763                   cppd
 764                   ]);
 765       }
 766       polygon([cppD,
 767                cppC,
 768                cpp9,
 769                cpp10,
 770                cpp11,
 771                cpp4,
 772                cpp2r,
 773                cpp2d,
 774                cppA,
 775                cppE
 776                ]);
 777       translate(cpp8) circle(r= catch_cr);
 778     }
 779     hull(){
 780       translate(cpp4) circle(r= catch_cr);
 781       translate(cpp5) circle(r= catch_cr);
 782       translate(cpp7) circle(r= catch_cr);
 783       polygon([cpp4,
 784                cppg,
 785                cpph,
 786                cpp10,
 787                cpp11,
 788                ]);
 789     }
 790     translate(cpp2) circle(r= catch_cr);
 791   }
 792   // if cpp11 is above cpp10, the subtracted hull above
 793   // can go down too far.  Ensure we do not cut off below cppy6.
 794   polygon([ cppE,
 795             cppD,
 796             cpp9,
 797             [ cpp9[0],            cppy6 ],
 798             [ cpp7[0] - catch_cr, cppy6 ],
 799             cpp2d
 800             ]);
 801 }
 802
 803 module CatchTipProfile(dy){
 804   ddy = [0,dy];
 805   intersection(){
 806     translate(cppF){
 807       difference(){
 808 //      circle(r = dist2d(cppF, cppd));
 809         //circle(r = dist2d(cppF, cppa));
 810       }
 811     }
 812     polygon([ cppa,
 813               cppi + ddy,
 814               cppd + ddy,
 815               cppc,
 816               cppb ]);
 817   }
 818 }
 819
 820 module CatchHeadProfile(){
 821   polygon([ cppd,
 822             cppd,
 823             cppi,
 824             cppf,
 825             cppe,
 826             cpph ]);
 827 }
 828
 829
 830 module CatchCore(){ /////toplevel
 831   linear_extrude(height=catch_strap_thick, convexity=10)
 832     CatchAssemblyCoreProfile();
 833
 834   hull(){
 835     linear_extrude(height=catch_head_th, convexity=10)
 836       CatchTipProfile(0);
 837     linear_extrude(height=catch_tip_th, convexity=10)
 838       CatchTipProfile(catch_tip_th - catch_head_th);
 839   }
 840
 841   linear_extrude(height=catch_head_th, convexity=10)
 842     CatchHeadProfile();
 843
 844   translate(concat(cppB,[0])) hull(){
 845     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 846       sphere(r = catch_knob_dia/2);
 847     cylinder(r = catch_knob_dia/2, h = 0.1);
 848   }
 849 }
 850
 851 module CatchPreDistort(){ /////toplevel
 852   scale(100 / sm_inner_rad)
 853     rotate([90,0,0])
 854     CatchCore();
 855 }
 856
 857 module CatchAssembly(){ /////toplevel
 858   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 859     translate([0,0, catch_assembly_dy])
 860     scale(sm_inner_rad / 100)
 861     import(str("poster-tube-lid,CatchPostDistort-fa",
 862                (coarse ? 20 : 3),
 863                ".stl"),
 864            convexity=20);
 865
 866   SomeStrap(catch_strap_width){
 867     union(){ }
 868     union(){
 869       translate([-200, -200, -200])
 870         cube([400, 200, 400]);
 871     }
 872   }
 873 }
 874
 875 module CatchDemo(){ /////toplevel
 876   color("blue") translate([0,0,
 877                            -catch_assembly_dy
 878              ])
 879     CatchAssembly();
 880   translate([0,0,+side_height
 881              ])
 882     Cover();
 883 }
 884
 885 module CatchDemoS(){ /////toplevel
 886   color("blue") translate([0,0,
 887              -catch_assembly_dy
 888              ])
 889     CatchAssembly();
 890   intersection(){
 891     translate([0,0,+side_height
 892                ])
 893       Cover();
 894     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 895   }
 896   color("black")
 897     translate([0,-33,0])
 898     cube([6.15, 2,2], center=true);
 899 }
 900
 901 module CatchPinProfileDemo(){ /////toplevel
 902   translate([0, 0 * -bayo_behind,0]) {
 903     echo("G ",
 904          bayo_n[0] - bayo_e[0]);
 905     color("blue") translate([0,0,
 906                              +1,
 907                ]) {
 908       CatchAssemblyCoreProfile();
 909       CatchHeadProfile();
 910     }
 911     translate([0,0,10])
 912       color("red")
 913       CatchTipProfile(0);
 914
 915     polygon(bayo_polygon, convexity=10);
 916
 917     // adhoc show a position
 918     color("purple")
 919     translate(concat(
 920                      cppa,
 921                      10
 922                      )) difference(){ circle(2.5); circle(2.0); }
 923
 924  }
 925 }
 926
 927 //ProfilesDemo();
 928 //BayonetCutout();
 929 //MainProfile();
 930 //Cover();
 931 //Jig();
 932 //CoverTest();