3 // Print, for each end:
13 enable_head_cups = false;
15 main_dia = 71.2 + 0.50 - 2.26;
17 top_thick_by_oring = 3.0;
24 rivet_posn = 6.0 + 0.30;
26 rivet_width = 4.15 + 1.0;
27 rivet_tall = 5.51 + 1.49;
29 over_rivet_wall = 1.0;
31 inside_rivet_gap = 1.5;
35 bayo_interf_width = 2.0;
36 bayo_interf_slope = 0.5;
41 oring_upper_embed_angle = 80;
42 oring_compress = 0.1; // proportion
43 oring_compress_more = 0.2;
56 bayo_slice_size = coarse ? 5 : 1;
58 brace_hole_width = 1.0;
59 brace_above_below = 1.2;
60 brace_end_shorter = 0.3;
68 strap_loop_inside = 10;
69 strap_loop_strlen = 10;
70 strap_loop_elevation = 45;
72 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
76 sm_bolt_dia = 3.5 + 0.1;
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;
84 sm_bolt_y_clear = 0.75;
90 wm_screw_dia = 4.5; // XXX
91 wm_screwdriver_dia = 6.0; // XXX
92 wm_screw_around = 4.0; // XXX
94 wm_screw_head = 7.5; // XXX
97 wmb_screw_around_x = 4; // XXX
98 wmb_screw_around_z = 6; // XXX
99 wmb_screw_depth_min = 10;
101 wmb_nut_across = 8; // XXX
102 wmb_nut_around_min = 2; // XXX
103 wmb_nut_behind_min = 5;
104 wmb_nut_th = 4; // XXX
108 catch_stalk_len = 50;
112 catch_pin_slop = 0.25; // each side, and above
113 catch_pin_slop_x_extra = 0.0; // only on one side
114 catch_stalk_above_gap = 1.5;
115 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
117 catch_strap_width = 12;
118 catch_stalk_base_width = 15;
121 catch_knob_above_gap = 5;
122 catch_knob_height = 3.0;
124 catch_stalk_below_gap = 1.0;
125 catch_stalk_beside_gap = 2.0;
131 bayo_entry_x = bayo_entry;
132 bayo_entry_z = bayo_entry;
133 bayo_inramp_x = bayo_inramp;
134 bayo_inramp_z = bayo_inramp;
136 oring_mid_dia = oring_bore + oring_thick;
137 oring_outer_dia = oring_mid_dia + oring_thick;
139 oring_oblate = (1 - oring_compress);
141 oring_y_rad = oring_thick/2 * oring_oblate;
142 oring_x_rad = oring_thick/2 / oring_oblate;
144 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
146 side_height = rivet_posn + bayo_behind + rivet_thick/2;
147 side_thick = rivet_tall + over_rivet_wall;
149 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
151 middle_bot_z = top_z - top_thick_middle;
153 bayo_top_z = bayo_behind + bayo_gap;
155 bayo_nom_rad = main_dia/2 + side_thick;
156 bayo_real_rad = main_dia/2 + rivet_tall;
158 rivet_entry_width = rivet_width + side_rivet_gap;
160 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
162 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
165 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
166 sm_outer_rad = sm_inner_rad + sm_main_thick;
168 wm_main_width = sm_main_width;
169 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
170 pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
171 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
172 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
173 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
174 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
175 wm_y_slot1_max = wm_y_max + wm_screw_slot;
176 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
177 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
178 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
179 wm_z_max = wm_z_slot1_screw + wm_screw_around;
181 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
182 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
183 wmb_x_screw_plus_around_r = max(
184 wmb_screw_around_x + wmb_screw_dia/2,
185 wmb_nut_around_min + wmb_nut_across/2
187 wmb_x_screw = -sm_outer_rad + wmb_x_screw_plus_around_r;
188 wmb_x_outer = -sm_outer_rad + wmb_x_screw_plus_around_r * 2;
189 function wmb_screw_thing_y_min(dia) = sqrt(
190 pow(wmb_mount_cut_rad, 2) -
191 pow(wmb_x_screw + dia/2, 2)
193 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
194 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2);
195 wmb_y_mount_max = max(
196 wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
197 wmb_y_screw_end + wmb_screw_depth_min
200 wmb_screw_around_z + wmb_screw_dia/2,
201 wmb_nut_around_min + wmb_nut_rad
203 wmb_z_max = wmb_z_screw * 2;
205 smc_pos = [ 0, sm_inner_rad, 0 ];
207 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
208 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
210 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
211 smc_max_y = smc_bolt_y + sm_bolt_y_over
212 + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
213 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
214 + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
216 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
217 catch_strap_thick = sm_main_thick;
219 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
221 $fs= coarse ? 2.5 : 0.5;
224 include <poster-tube-lid-parametric.scad>
226 // bayonet definition
228 bayo_a = [ bayo_entry_x, 0 ];
229 bayo_p = [ 0, bayo_entry_z ];
230 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
231 bayo_m = [ bayo_inramp_x, bayo_behind ];
232 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope, 1 ];
233 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
234 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
235 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
236 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
237 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
239 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
240 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
241 bayo_c = bayo_d + [0,-5];
242 bayo_b = bayo_a + [0,-5];
244 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
246 bayo_polygon = [ bayo_a,
266 cppxC = 0.41 * sm_inner_rad * TAU;
270 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
271 // radius scaling due to nom and actual radius difference in
272 // bayo entry construction
274 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
275 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
277 - catch_pin_slop - catch_pin_slop_x_extra,
278 -catch_stalk_above_gap ];
279 cppi = [ cppa[0], cppd[1] ];
280 cppc = [ cppd[0], cppb[1] ];
281 cpph = cppd + [0,-1] * catch_stalk_h;
282 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
283 cppf = [ cppa[0], cppe[1] ];
284 cppg = [ cppa[0], cpph[1] ];
285 cppB = 0.5 * (cppf + cppe);
287 echo("RR", sm_inner_rad / bayo_nom_rad);
289 // catch assembly depression below pin
291 cppy6 = cppB[1] - (catch_knob_dia/2
292 + (cppc[1] - cppd[1])
293 + catch_stalk_below_gap);
294 cpp7 = [ cppB[0], cppy6 + catch_cr ];
295 cpp11 = cpp7 + [1,0] * catch_cr;
296 cppy9 = cppy6 + catch_strap_width * 1/3;
297 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
298 cpp8 = cpp9 + [0,-1] * catch_cr;
299 cpp10 = cpp8 + [-1,0] * catch_cr;
300 cppC = [ cppxC, cpp9[1] ];
301 cppD = cppC + [0,-1] * catch_strap_width;
303 // catch assembly stalk and so on
305 catch_cr3 = catch_cr + catch_stalk_h;
307 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
308 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
309 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
310 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
311 cpp2r = cpp2 + [1,0] * catch_cr;
312 cpp2d = cpp2 + [0,-1] * catch_cr;
313 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
314 cppA = [ -cppxC, cpp9[1] ];
315 cppE = [ cppA[0], cppD[1] ];
317 catch_assembly_dy = -cppy9 + catch_strap_width;
320 module MainProfile(){
321 main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
324 translate(main_cnr_pos){
327 circle(r = main_cnr);
328 circle(r = main_cnr * 0.5);
333 polygon([[ -top_middle_dr, middle_bot_z ],
334 [ -top_middle_dr, top_z ],
335 [ main_cnr_pos[0], top_z ],
336 [ side_thick, main_cnr_pos[1] ],
337 [ side_thick, -side_height ],
338 [ side_taper, -side_height ],
341 [ -oring_x_rad, by_oring_z ],
345 translate([ oring_mid_dia/2 - main_dia/2, 0 ])
347 translate([ 0, oring_y_rad ])
348 scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
349 circle(oring_thick/2);
350 translate([ 0, oring_y_rad*2 - oring_thick/2 ])
351 circle(oring_thick/2);
356 module StrapLoopProfile(){
357 circle(r = strap_loop_thick/2);
360 module StrapLoop(){ ////toplevel
361 bigrad = strap_loop_inside/2 + strap_loop_thick/2;
362 extralen = strap_loop_thick * 5;
365 rotate([strap_loop_elevation, 0,0]){
366 for (x= [ -1, +1 ] * bigrad) {
367 translate([x, -extralen, 0])
369 linear_extrude(height= extralen + strap_loop_strlen + 0.1,
373 translate([0, strap_loop_strlen, 0]){
375 rotate_extrude(convexity=10)
376 translate([bigrad, 0,0])
379 cube([100,100,100], center=true);
383 translate([0, 50, 0])
384 cube(100, center=true);
388 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
389 // nom_rad > real_rad
390 rotate([0,0, atan2(offset, nom_rad) ]){
392 translate([-offset, -10, 0])
394 linear_extrude(height= nom_rad*2, convexity=50)
396 translate([0,0, -25])
397 cylinder(h=50, r= real_rad);
398 translate([0,0, -25])
399 linear_extrude(height= 50, convexity=50)
401 [ -slice_size, -real_rad*2 ],
402 [ +slice_size, -real_rad*2 ] ]);
407 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
408 offs = [ for (i=[ x_min :
410 x_max + slice_size ]) i ];
413 RotateProjectSlice(off, slice_size, nom_rad, real_rad)
417 module BayonetCutout(){
418 RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
421 translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
422 polygon(bayo_polygon, convexity=10);
425 module ProfilesDemo(){ ////toplevel
426 translate([-10,0]) MainProfile();
427 translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
430 module LimitForHandling(){ ////toplevel
431 hull() for (r=[0,180])
435 rotate([0,0, rs * handling_angle/2]) {
436 translate([rs * xd * main_dia/2 * tan(handling_angle/2),
437 main_dia/2 + side_thick - main_cnr,
440 cylinder(r= main_cnr, h=50);
447 hull() rotate_extrude(convexity=10){
448 translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
449 circle(r = main_cnr);
450 mirror([0,1]) square([ main_cnr, 50 ]);
453 //cylinder(r= handling_dia/2, h=20);
456 module Cover(){ ////toplevel
457 render() difference(){
460 rotate_extrude(convexity=10)
461 translate([main_dia/2, 0])
463 translate([0,0, middle_bot_z])
464 cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
470 translate([0,0, -side_height])
472 rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
474 oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
476 rotate([-oring_rm_angle, 0, 0])
478 cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
480 for (r=[0 : 60 : 179]) {
482 height = top_thick_middle - brace_above_below*2;
483 translate([0,0, middle_bot_z + brace_above_below + height/2 ])
484 cube(center=true, [ oring_bore - brace_end_shorter,
485 brace_hole_width, height ]);
489 if (enable_head_cups)
492 translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
493 -implheadcup_large_dia * .0,
497 // translate(strap_loop_thick * [-0.5, 0, +1])
498 // translate([handling_dia/2, 0, -side_height])
499 // rotate([0,180,0]) rotate([0,0,90])
504 translate([0,0, -10])
505 cylinder(r= main_dia/2 - jig_rim, h=20);
508 module Jig(){ ////toplevel
511 translate([0,0, -side_height]){
512 cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
514 translate([-jig_mark_rad, 0, jig_thick - jig_mark])
515 cube([jig_mark_rad*2, jig_mark, jig_mark]);
517 translate([0,0, -side_height-1])
518 cylinder(r= main_dia/2, h= side_height + 1);
520 translate([0,0, -rivet_posn])
522 translate([0,0, -100])
523 cylinder(r= jig_hole_dia/2, h = 200);
527 module CoverPrint(){ ////toplevel
528 rotate([0,180,0]) Cover();
531 module CoverTest2(){ ////toplevel
538 module CoverTest1(){ ////toplevel
542 for (r= [ 40, 147 ]){
544 translate([0,0, -10]) {
545 cube([ main_dia*3, main_dia * .53, 18], center=true);
549 // translate([ 50, 0, 0 ])
551 // strap_loop_inside + strap_loop_thick*2 + 1,
558 module ImplHeadCupTest(){ ////toplevel
565 module SomeStrap(width, cut_width=0){
566 // children(0) is to add, (1) subtract
569 cylinder(r=sm_outer_rad, h=width);
570 StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
577 cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
579 StrapMountBolt(10, width);
581 cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
586 module StrapMountBolt(l_delta, strap_width){ ///toplevel
587 // positioned relative to smc_pos
588 translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
591 translate([ -sm_bolt_shaft/2-1, 0,0 ]){
592 rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
594 translate([ -sm_bolt_shaft/2, 0,0 ])
596 cylinder($fn=6, r=smc_bolt_nut_dia/2,
597 h=smc_bolt_nut_eff_thick + l_delta);
598 translate([ sm_bolt_shaft/2, 0,0 ])
600 cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
604 module StrapMountProtrusion(half_x, max_y, cnr, width){
606 linear_extrude(height=width, convexity=10){
608 for (m = [0,1]) mirror([m,0,0]) {
609 translate([-(half_x - cnr), max_y - cnr])
611 translate([-half_x, -sm_inner_rad])
619 module StrapMount(){ ////toplevel
620 SomeStrap(sm_main_width){
622 StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
627 [0,0, sm_main_width] +
628 strap_loop_thick * [ 0, 0.5, -1.0 ])
635 module WallScrewHoleSlot(){ ////toplevel
636 ds = [-1,+1] * wm_screw_slot/2;
637 linextr_x_yz(-(wm_thick + 1), 1) {
641 circle(r = wm_screw_dia/2);
646 translate([0, d, 0]){
648 circle(r = wm_screw_head/2);
649 linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
650 circle(r = wm_screw_dia/2);
656 module WallMountMounts(){
657 linextr(0, wm_z_max){
658 translate([ -sm_outer_rad, 0 ])
659 rectfromto([ 0, -wm_y_max ],
660 [ wm_thick, wm_y_slot1_max ]);
663 module WallMountScrewHoles(){
664 translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
665 translate([ 0, wm_y_slotc_screw, 0 ])
667 translate([ 0, -wm_y_slotc_screw, 0 ])
673 module WallMount(){ ////toplevel
674 SomeStrap(sm_main_width, wm_z_max + 2){
676 WallMountScrewHoles();
680 module WallMountBaseMounts(){
681 linextr(0, wmb_z_max) {
683 rectfromto([ -sm_outer_rad, -wmb_y_mount_max ],
684 [ wmb_x_outer, +wmb_y_mount_max ]);
685 circle(r = wmb_mount_cut_rad);
690 // screws, nuts, slots for nuts to go down into
691 module WallMountBaseScrewsEtc(){ ////toplevel
694 translate([wmb_x_screw, 0, wmb_z_screw]) {
695 linextr_y_xz(wmb_y_screw_end,
696 wmb_y_screw_end + 100) // XXX change 100
697 circle(r = wmb_screw_dia/2);
698 linextr_y_xz(wmb_y_nut_min,
699 wmb_y_nut_min + wmb_nut_th){
702 circle(r = wmb_nut_rad, $fn = 6);
703 translate([0, 100]) // XXX change 100
704 square(wmb_nut_across, center=true);
714 linextr(wmb_y_screw_end
717 translate([ wmb_x_screw, wmb_y_screw_end ])
718 rectfromto([ -wmb_screw_dia/2, 0 ],
719 [ +wmb_screw_dia/2, wmb_screw_depth ]);
727 module WallMountForBase(){ ////toplevel
728 SomeStrap(sm_main_width, wm_z_max + 2){
731 WallMountBaseMounts();
734 WallMountScrewHoles();
735 WallMountBaseScrewsEtc();
740 module WallMountForBaseDemo(){ ////toplevel
742 %WallMountBaseScrewsEtc();
745 module CatchAssemblyCoreProfile(){
749 translate(cpp3) circle(r= catch_cr3);
768 translate(cpp8) circle(r= catch_cr);
771 translate(cpp4) circle(r= catch_cr);
772 translate(cpp5) circle(r= catch_cr);
773 translate(cpp7) circle(r= catch_cr);
781 translate(cpp2) circle(r= catch_cr);
783 // if cpp11 is above cpp10, the subtracted hull above
784 // can go down too far. Ensure we do not cut off below cppy6.
789 [ cpp7[0] - catch_cr, cppy6 ],
794 module CatchTipProfile(dy){
799 // circle(r = dist2d(cppF, cppd));
800 //circle(r = dist2d(cppF, cppa));
811 module CatchHeadProfile(){
821 module CatchCore(){ /////toplevel
822 linear_extrude(height=catch_strap_thick, convexity=10)
823 CatchAssemblyCoreProfile();
826 linear_extrude(height=catch_head_th, convexity=10)
828 linear_extrude(height=catch_tip_th, convexity=10)
829 CatchTipProfile(catch_tip_th - catch_head_th);
832 linear_extrude(height=catch_head_th, convexity=10)
835 translate(concat(cppB,[0])) hull(){
836 translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
837 sphere(r = catch_knob_dia/2);
838 cylinder(r = catch_knob_dia/2, h = 0.1);
842 module CatchPreDistort(){ /////toplevel
843 scale(100 / sm_inner_rad)
848 module CatchAssembly(){ /////toplevel
849 rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
850 translate([0,0, catch_assembly_dy])
851 scale(sm_inner_rad / 100)
852 import(str("poster-tube-lid,CatchPostDistort-fa",
857 SomeStrap(catch_strap_width){
860 translate([-200, -200, -200])
861 cube([400, 200, 400]);
866 module CatchDemo(){ /////toplevel
867 color("blue") translate([0,0,
871 translate([0,0,+side_height
876 module CatchDemoS(){ /////toplevel
877 color("blue") translate([0,0,
882 translate([0,0,+side_height
885 mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
889 cube([6.15, 2,2], center=true);
892 module CatchPinProfileDemo(){ /////toplevel
893 translate([0, 0 * -bayo_behind,0]) {
895 bayo_n[0] - bayo_e[0]);
896 color("blue") translate([0,0,
899 CatchAssemblyCoreProfile();
906 polygon(bayo_polygon, convexity=10);
908 // adhoc show a position
913 )) difference(){ circle(2.5); circle(2.0); }