poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 coarse = false;
   4
   5 main_dia = 71.2 + 0.50 - 2.26;
   6 top_thick_middle = 4;
   7 top_thick_by_oring = 3.0;
   8 top_middle_dr = 11;
   9
  10 main_cnr = 6.0;
  11
  12 min_wall = 3;
  13
  14 rivet_posn = 6.0 + 0.30;
  15 rivet_thick = 1.67;
  16 rivet_width = 4.15 + 1.0;
  17 rivet_tall = 5.51 + 1.49;
  18
  19 over_rivet_wall = 1.0;
  20 side_rivet_gap = 1.5;
  21 inside_rivet_gap = 1.5;
  22
  23 bayo_interf = 0.30;
  24 bayo_behind = 3.5;
  25 bayo_interf_width = 2.0;
  26 bayo_interf_slope = 0.5;
  27
  28 oring_thick = 5.0;
  29 oring_bore = 62.0;
  30
  31 oring_upper_embed_angle = 80;
  32 oring_compress = 0.1; // proportion
  33 oring_compress_more = 0.2;
  34
  35 oring_rm_beside = 8;
  36 oring_rm_scale = 2.0;
  37 oring_rm_angle = 20;
  38
  39 side_taper = 1.0;
  40
  41 bayo_gap = 6.0;
  42
  43 bayo_entry = bayo_behind/3;
  44
  45 bayo_slice_size = coarse ? 5 : 1;
  46
  47 brace_hole_width = 1.0;
  48 brace_above_below = 1.2;
  49 brace_end_shorter = 0.3;
  50
  51 jig_thick = 1.4;
  52 jig_hole_dia = 3.0;
  53 jig_rim = 5;
  54 jig_mark = 5;
  55
  56 strap_hoop_thick = 6;
  57 strap_hoop_inside = 10;
  58 strap_hoop_strlen = 10;
  59 strap_hoop_elevation = 45;
  60
  61 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  62 sm_main_thick = 2.0;
  63 sm_main_width = 20;
  64
  65 sm_bolt_dia = 3.5 + 0.1;
  66 sm_bolt_shaft = 21.9;
  67 sm_bolt_head_dia = 6.94 + 1.0;
  68 sm_bolt_head_thick = 2.14;
  69 sm_bolt_nut_width = 5.89 + 0.25;
  70 sm_bolt_nut_thick = 3.68;
  71 sm_bolt_tighten_allow = 2.0;
  72
  73 sm_bolt_y_clear = 0.75;
  74 sm_bolt_y_over = 0.5;
  75
  76 sm_closure_cnr = 3.0;
  77
  78 catch_stem_h = 3;
  79 catch_stem_len = 50;
  80 catch_stem_th = 3;
  81
  82 catch_knob_dia = 6;
  83 catch_knob_above_gap = 8;
  84 catch_stem_end_h = 12;
  85 catch_pin_height = 7;
  86
  87 catch_stem_below_gap = 1.0;
  88 catch_stem_beside_gap = 2.0;
  89 catch_pin_gap = 0.5;
  90
  91 // calculated
  92
  93 TAU = PI*2;
  94
  95 bayo_entry_x = bayo_entry;
  96 bayo_entry_z = bayo_entry;
  97 bayo_inramp_x = bayo_entry;
  98 bayo_inramp_z = bayo_entry;
  99
 100 oring_mid_dia = oring_bore + oring_thick;
 101 oring_outer_dia = oring_mid_dia + oring_thick;
 102
 103 oring_oblate = (1 - oring_compress);
 104
 105 oring_y_rad = oring_thick/2 * oring_oblate;
 106 oring_x_rad = oring_thick/2 / oring_oblate;
 107
 108 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 109
 110 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 111 side_thick = rivet_tall + over_rivet_wall;
 112
 113 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 114
 115 middle_bot_z = top_z - top_thick_middle;
 116
 117 bayo_entry = bayo_behind / 3.0;
 118 bayo_top_z = bayo_behind + bayo_gap;
 119
 120 rivet_entry_width = rivet_width + side_rivet_gap;
 121
 122 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 123
 124 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 125 handling_angle = 45;
 126
 127 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 128 sm_outer_rad = sm_inner_rad + sm_main_thick;
 129
 130 smc_pos = [ 0, sm_inner_rad, 0 ];
 131
 132 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 133 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 134
 135 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 136 smc_max_y = smc_bolt_y + sm_bolt_y_over
 137   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 138 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 139   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 140
 141 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
 142
 143 cpp0 = [0,0];
 144 cpp1 = cpp0 + [0,1] * catch_pin_height;
 145 cpp2 = cpp0 + [1,0] * (rivet_entry_width - catch_pin_gap);
 146 cpp3 = cpp2 + [0,-1] * catch_stem_end_h;
 147 cpp4 = cpp2 + [0,-1] * catch_stem_end_h;
 148 cpp5 = [ cpp0[0] - catch_stem_len,
 149          cpp0[1] - (catch_stem_h + catch_cr) ];
 150 cppB = [ 0.5*(cpp1 + cpp2)[0],
 151          cpp1[1] - catch_pin_height - catch_knob_above_gap -
 152          0.5 * catch_knob_dia ];
 153 cpp7 = cppB + [-1,-1] * catch_knob_dia/2
 154             + [ catch_stem_beside_gap, -catch_stem_below_gap ]
 155             + [ 0, -catch_pin_height ]
 156             + [-1,1] * catch_cr;
 157 cpp6 = [ cpp5[0], cpp7[1] ];
 158 cpp8 = [ cpp7[0] + catch_cr*2,
 159          cpp0[0] - catch_cr ];
 160 cppC = cpp8 + [1,1] * catch_cr;
 161 cppA = [ cpp5[0] - catch_cr*2, cpp0[1] ];
 162
 163 $fs= coarse ? 2.5 : 0.5;
 164 $fa= coarse ? 5 : 1;
 165
 166 include <poster-tube-lid-parametric.scad>
 167
 168 // bayonet definition
 169
 170 bayo_a = [ bayo_entry_x, 0 ];
 171 bayo_p = [ 0, bayo_entry_z ];
 172 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 173 bayo_m = [ bayo_inramp_x, bayo_behind ];
 174 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 175 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 176 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 177 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 178 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 179 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 180
 181 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 182 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 183 bayo_c = bayo_d + [0,-5];
 184 bayo_b = bayo_a + [0,-5];
 185
 186 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 187
 188 bayo_polygon = [ bayo_a,
 189                  bayo_b,
 190                  bayo_c,
 191                  bayo_d,
 192                  bayo_e,
 193                  bayo_f,
 194                  bayo_g,
 195                  bayo_h,
 196                  bayo_i,
 197                  bayo_j,
 198                  bayo_k,
 199                  bayo_l,
 200                  bayo_m,
 201                  bayo_n,
 202                  bayo_p ];
 203
 204 echo(bayo_polygon);
 205
 206 module MainProfile(){
 207   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 208   difference(){
 209     union(){
 210       translate(main_cnr_pos){
 211         intersection(){
 212           difference(){
 213             circle(r = main_cnr);
 214             circle(r = main_cnr * 0.5);
 215           }
 216           square([10,10]);
 217         }
 218       }
 219       polygon([[ -top_middle_dr,        middle_bot_z      ],
 220                [ -top_middle_dr,        top_z             ],
 221                [ main_cnr_pos[0],       top_z             ],
 222                [ side_thick,            main_cnr_pos[1]   ],
 223                [ side_thick,            -side_height      ],
 224                [ side_taper,            -side_height      ],
 225                [ 0,                     -rivet_posn       ],
 226                [ 0,                     by_oring_z        ],
 227                [ -oring_x_rad,          by_oring_z        ],
 228                ],
 229               convexity=10);
 230     }
 231     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 232       hull(){
 233       translate([ 0, oring_y_rad ])
 234         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 235         circle(oring_thick/2);
 236       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 237         circle(oring_thick/2);
 238     }
 239   }
 240 }
 241
 242 module StrapHoopProfile(){
 243   circle(r = strap_hoop_thick/2);
 244 }
 245
 246 module StrapHoop(){ ////toplevel
 247   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 248   extralen = strap_hoop_thick * 5;
 249
 250   intersection(){
 251     rotate([strap_hoop_elevation, 0,0]){
 252       for (x= [ -1, +1 ] * bigrad) {
 253         translate([x, -extralen, 0])
 254           rotate([-90,0,0])
 255           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 256                          convexity=10)
 257           StrapHoopProfile();
 258       }
 259       translate([0, strap_hoop_strlen, 0]){
 260         intersection(){
 261           rotate_extrude(convexity=10)
 262             translate([bigrad, 0,0])
 263             StrapHoopProfile();
 264           translate([0,50,0])
 265             cube([100,100,100], center=true);
 266         }
 267       }
 268     }
 269     translate([0, 50, 0])
 270       cube(100, center=true);
 271   }
 272 }
 273
 274 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 275   // nom_rad > real_rad
 276   rotate([0,0, atan2(offset, nom_rad) ]){
 277     intersection(){
 278       translate([-offset, -10, 0])
 279         rotate([90,0,0])
 280         linear_extrude(height= nom_rad*2)
 281         children(0);
 282       translate([0,0, -25])
 283         cylinder(h=50, r= real_rad);
 284       translate([0,0, -25])
 285         linear_extrude(height= 50)
 286         polygon([ [ 0,0 ],
 287                   [ -slice_size, -real_rad*2 ],
 288                   [ +slice_size, -real_rad*2 ] ]);
 289     }
 290   }
 291 }
 292
 293 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 294   offs = [ for (i=[ x_min :
 295                     slice_size :
 296                     x_max + slice_size ]) i ];
 297   echo (offs);
 298   for (off=offs)
 299     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 300     children(0);
 301 }
 302
 303 module BayonetCutout(){
 304   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 305                 main_dia/2 + side_thick,
 306                 main_dia/2 + rivet_tall)
 307     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 308     polygon(bayo_polygon, convexity=10);
 309 }
 310
 311 module ProfilesDemo(){ ////toplevel
 312   translate([-10,0]) MainProfile();
 313   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 314 }
 315
 316 module LimitForHandling(){ ////toplevel
 317   hull() for (r=[0,180])
 318     rotate([0,0,r]) {
 319       for (rs=[-1,+1]) {
 320         for (xd=[0,1]) {
 321           rotate([0,0, rs * handling_angle/2]) {
 322             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 323                        main_dia/2 + side_thick - main_cnr,
 324                        top_z - main_cnr]) {
 325               mirror([0,0,1])
 326                 cylinder(r= main_cnr, h=50);
 327               sphere(main_cnr);
 328             }
 329           }
 330         }
 331       }
 332     }
 333   hull() rotate_extrude(){
 334     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 335       circle(r = main_cnr);
 336       mirror([0,1]) square([ main_cnr, 50 ]);
 337     }
 338   }
 339   //cylinder(r= handling_dia/2, h=20);
 340 }
 341
 342 module Cover(){ ////toplevel
 343   render() difference(){
 344     intersection(){
 345       union(){
 346         rotate_extrude(convexity=10)
 347           translate([main_dia/2, 0])
 348           MainProfile();
 349         translate([0,0, middle_bot_z])
 350           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 351       }
 352       LimitForHandling();
 353     }
 354     for (r=[0,180]){
 355       rotate([0,0, r])
 356         translate([0,0, -side_height])
 357         BayonetCutout();
 358       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 359         translate([0,
 360                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 361                    oring_y_rad * 1.5])
 362         rotate([-oring_rm_angle, 0, 0])
 363         mirror([0,0,1])
 364         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 365     }
 366     for (r=[0 : 60 : 179]) {
 367       rotate([0,0, r]) {
 368         height = top_thick_middle - brace_above_below*2;
 369         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 370         cube(center=true, [ oring_bore - brace_end_shorter,
 371                             brace_hole_width, height ]);
 372       }
 373     }
 374   }
 375   for (r=[0,180])
 376     rotate([0,0,r])
 377       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 378                  -implheadcup_large_dia * .0,
 379                  middle_bot_z + 0.1])
 380       ImplHeadCup();
 381 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 382 //    translate([handling_dia/2, 0, -side_height])
 383 //    rotate([0,180,0]) rotate([0,0,90])
 384 //    StrapHoop();
 385 }
 386
 387 module SavingHole(){
 388   translate([0,0, -10])
 389     cylinder(r= main_dia/2 - jig_rim, h=20);
 390 }
 391
 392 module Jig(){ ////toplevel
 393   difference(){
 394     union(){
 395       translate([0,0, -side_height]){
 396         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 397       }
 398       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 399         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 400     }
 401     translate([0,0, -side_height-1])
 402       cylinder(r= main_dia/2, h= side_height + 1);
 403     SavingHole();
 404     translate([0,0, -rivet_posn])
 405       rotate([90, 0,0])
 406       translate([0,0, -100])
 407       cylinder(r= jig_hole_dia/2, h = 200);
 408   }
 409 }
 410
 411 module CoverTest2(){ ////toplevel
 412   difference(){
 413     Cover();
 414     SavingHole();
 415   }
 416 }
 417
 418 module CoverTest1(){ ////toplevel
 419   difference(){
 420     CoverTest2();
 421     difference(){
 422       for (r= [ 40, 147 ]){
 423         rotate([0,0, r]){
 424           translate([0,0, -10]) {
 425             cube([ main_dia*3, main_dia * .53, 18], center=true);
 426           }
 427         }
 428       }
 429 //      translate([ 50, 0, 0 ])
 430 //      cube([ 100,
 431 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 432 //             100 ],
 433 //           center=true);
 434     }
 435   }
 436 }
 437
 438 module ImplHeadCupTest(){ ////toplevel
 439   for (r=[0,180])
 440     rotate([0,0,r])
 441       translate([-17,0,0])
 442       ImplHeadCup();
 443 }
 444
 445 module StrapMountBolt(l_delta){ ///toplevel
 446   // positioned relative to smc_pos
 447   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 448              smc_bolt_y,
 449              sm_main_width/2]){
 450     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 451       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 452     }
 453     translate([ -sm_bolt_shaft/2, 0,0 ])
 454       rotate([0,-90,0])
 455       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 456                h=smc_bolt_nut_eff_thick + l_delta);
 457     translate([ sm_bolt_shaft/2, 0,0 ])
 458       rotate([0,90,0])
 459       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 460   }
 461 }
 462
 463 module StrapMountProtrusion(half_x, max_y, cnr){
 464   translate(smc_pos){
 465     linear_extrude(height=sm_main_width, convexity=10){
 466       hull(){
 467         for (m = [0,1]) mirror([m,0,0]) {
 468           translate([-(half_x - cnr), max_y - cnr])
 469             circle(r=cnr);
 470           translate([-half_x, -sm_inner_rad])
 471             square([1,1]);
 472         }
 473       }
 474     }
 475   }
 476 }
 477
 478 module StrapMount(){ ////toplevel
 479   difference(){
 480     union(){
 481       cylinder(r=sm_outer_rad, h=sm_main_width);
 482       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 483                            smc_max_y,
 484                            sm_closure_cnr);
 485       rotate([0,0,180]){
 486         StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
 487                              strap_hoop_thick,
 488                              sm_closure_cnr);
 489         translate(smc_pos +
 490                   [0,0, sm_main_width] +
 491                   strap_hoop_thick * [ 0, 0.5, -1.0 ])
 492           StrapHoop();
 493       }
 494     }
 495     translate([0,0,-1])
 496       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 497     translate(smc_pos)
 498       StrapMountBolt(10);
 499     translate(smc_pos)
 500       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 501   }
 502 }
 503
 504 module CatchCoreProfile(){
 505
 506 }
 507
 508 //ProfilesDemo();
 509 //BayonetCutout();
 510 //MainProfile();
 511 //Cover();
 512 //Jig();
 513 //CoverTest();