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