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_mount_gap_z = 0.5;
 109 wmb_mount_y_width = 10;
 110 wmb_bottom_gap = 35; // includes allowance for padding, etc.
 111 wmb_bottom_th = 7;
 112 wmb_bottom_th_min = 1;
 113 wmb_ring_gap = 1.0;
 114 wmb_base_extra_rad = 10;
 115 wmb_jig_th = 2;
 116 wmb_jig_around_gap = 1;
 117
 118 catch_stalk_h = 4.5;
 119 catch_stalk_len = 50;
 120 catch_tip_th = 4;
 121 catch_head_th = 3;
 122
 123 catch_pin_slop = 0.25; // each side, and above
 124 catch_pin_slop_x_extra = 0.0; // only on one side
 125 catch_stalk_above_gap = 1.5;
 126 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 127
 128 catch_strap_width = 12;
 129 catch_stalk_base_width = 15;
 130
 131 catch_knob_dia = 6;
 132 catch_knob_above_gap = 5;
 133 catch_knob_height = 3.0;
 134
 135 catch_stalk_below_gap = 1.0;
 136 catch_stalk_beside_gap = 2.0;
 137
 138 // calculated
 139
 140 TAU = PI*2;
 141
 142 bayo_entry_x = bayo_entry;
 143 bayo_entry_z = bayo_entry;
 144 bayo_inramp_x = bayo_inramp;
 145 bayo_inramp_z = bayo_inramp;
 146
 147 oring_mid_dia = oring_bore + oring_thick;
 148 oring_outer_dia = oring_mid_dia + oring_thick;
 149
 150 oring_oblate = (1 - oring_compress);
 151
 152 oring_y_rad = oring_thick/2 * oring_oblate;
 153 oring_x_rad = oring_thick/2 / oring_oblate;
 154
 155 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 156
 157 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 158 side_thick = rivet_tall + over_rivet_wall;
 159
 160 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 161
 162 middle_bot_z = top_z - top_thick_middle;
 163
 164 bayo_top_z = bayo_behind + bayo_gap;
 165
 166 bayo_nom_rad = main_dia/2 + side_thick;
 167 bayo_real_rad = main_dia/2 + rivet_tall;
 168
 169 rivet_entry_width = rivet_width + side_rivet_gap;
 170
 171 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 172
 173 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 174 handling_angle = 45;
 175
 176 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 177 sm_outer_rad = sm_inner_rad + sm_main_thick;
 178
 179 wm_main_width = sm_main_width;
 180 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 181                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 182 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 183 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 184 wm_y_slotc_screw = wm_y_screw + wm_screw_slot/2;
 185 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 186 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 187 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 188 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 189 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot;
 190 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 191
 192 wmb_mount_cut_rad = sm_outer_rad + wmb_ring_gap;
 193 wmb_nut_rad = wmb_nut_across / cos(30) * 0.5;
 194 wmb_x_screw_plus_around_r = max(
 195                                 wmb_screw_around_x + wmb_screw_dia/2,
 196                                 wmb_nut_around_min + wmb_nut_across/2
 197                                 );
 198 wmb_x_screw = -sm_outer_rad + wmb_x_screw_plus_around_r;
 199 wmb_x_outer = -sm_outer_rad + wmb_x_screw_plus_around_r * 2;
 200 function wmb_screw_thing_y_min(dia) = sqrt(
 201                        pow(wmb_mount_cut_rad, 2) -
 202                        pow(wmb_x_screw + dia/2, 2)
 203                        );
 204 wmb_y_screw_end = wmb_screw_thing_y_min(wmb_screw_dia);
 205 wmb_y_nut_min = wmb_screw_thing_y_min(wmb_nut_across + wmb_nut_around_min*2);
 206 wmb_y_mount_max = max(
 207                       wmb_y_nut_min + wmb_nut_th + wmb_nut_behind_min,
 208                       wmb_y_screw_end + wmb_screw_depth_min
 209                       );
 210 wmb_z_screw = max(
 211                   wmb_screw_around_z + wmb_screw_dia/2,
 212                   wmb_nut_around_min + wmb_nut_rad
 213                   );
 214 wmb_z_max = wmb_z_screw * 2;
 215 wmbb_y_max = wmb_y_mount_max + wmb_mount_gap_xy + wmb_mount_wall;
 216 wmbb_x_outer = wmb_x_outer + (wmb_mount_gap_xy + wmb_mount_wall);
 217 wmbb_z_flat_max = -wmb_bottom_gap;
 218 wmbb_z_flat_whole_min = wmbb_z_flat_max - wmb_bottom_th_min;
 219 wmbb_z_min      = wmbb_z_flat_max - wmb_bottom_th;
 220 wmbb_r_top = main_dia/2 + wmb_base_extra_rad;
 221 wmbb_r_bottom = wmbb_r_top - (wmb_bottom_th - wmb_bottom_th_min);
 222
 223 smc_pos = [ 0, sm_inner_rad, 0 ];
 224
 225 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 226 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 227
 228 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 229 smc_max_y = smc_bolt_y + sm_bolt_y_over
 230   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 231 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 232   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 233
 234 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 235 catch_strap_thick = sm_main_thick;
 236
 237 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 238
 239 $fs= coarse ? 2.5 : 0.5;
 240 $fa= coarse ? 5 : 1;
 241
 242 include <poster-tube-lid-parametric.scad>
 243
 244 // bayonet definition
 245
 246 bayo_a = [ bayo_entry_x, 0 ];
 247 bayo_p = [ 0, bayo_entry_z ];
 248 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 249 bayo_m = [ bayo_inramp_x, bayo_behind ];
 250 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 251 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 252 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 253 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 254 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 255 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 256
 257 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 258 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 259 bayo_c = bayo_d + [0,-5];
 260 bayo_b = bayo_a + [0,-5];
 261
 262 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 263
 264 bayo_polygon = [ bayo_a,
 265                  bayo_b,
 266                  bayo_c,
 267                  bayo_d,
 268                  bayo_e,
 269                  bayo_f,
 270                  bayo_g,
 271                  bayo_h,
 272                  bayo_i,
 273                  bayo_j,
 274                  bayo_k,
 275                  bayo_l,
 276                  bayo_m,
 277                  bayo_n,
 278                  bayo_p ];
 279
 280 echo(bayo_polygon);
 281
 282 // CATCH
 283
 284 cppxC = 0.41 * sm_inner_rad * TAU;
 285
 286 // catch pin
 287
 288 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 289 // radius scaling due to nom and actual radius difference in
 290 // bayo entry construction
 291
 292 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 293 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 294 cppd = [ bayo_n[0]
 295          - catch_pin_slop - catch_pin_slop_x_extra,
 296          -catch_stalk_above_gap ];
 297 cppi = [ cppa[0], cppd[1] ];
 298 cppc = [ cppd[0], cppb[1] ];
 299 cpph = cppd + [0,-1] * catch_stalk_h;
 300 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 301 cppf = [ cppa[0], cppe[1] ];
 302 cppg = [ cppa[0], cpph[1] ];
 303 cppB = 0.5 * (cppf + cppe);
 304
 305 echo("RR", sm_inner_rad / bayo_nom_rad);
 306
 307 // catch assembly depression below pin
 308
 309 cppy6 = cppB[1] - (catch_knob_dia/2
 310                    + (cppc[1] - cppd[1])
 311                    + catch_stalk_below_gap);
 312 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 313 cpp11 = cpp7 + [1,0] * catch_cr;
 314 cppy9 = cppy6 + catch_strap_width * 1/3;
 315 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 316 cpp8 = cpp9 + [0,-1] * catch_cr;
 317 cpp10 = cpp8 + [-1,0] * catch_cr;
 318 cppC = [ cppxC, cpp9[1] ];
 319 cppD = cppC + [0,-1] * catch_strap_width;
 320
 321 // catch assembly stalk and so on
 322
 323 catch_cr3 = catch_cr + catch_stalk_h;
 324
 325 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 326 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 327 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 328 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 329 cpp2r = cpp2 + [1,0] * catch_cr;
 330 cpp2d = cpp2 + [0,-1] * catch_cr;
 331 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 332 cppA = [ -cppxC, cpp9[1] ];
 333 cppE = [ cppA[0], cppD[1] ];
 334
 335 catch_assembly_dy = -cppy9 + catch_strap_width;
 336
 337
 338 module MainProfile(){
 339   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 340   difference(){
 341     union(){
 342       translate(main_cnr_pos){
 343         intersection(){
 344           difference(){
 345             circle(r = main_cnr);
 346             circle(r = main_cnr * 0.5);
 347           }
 348           square([10,10]);
 349         }
 350       }
 351       polygon([[ -top_middle_dr,        middle_bot_z      ],
 352                [ -top_middle_dr,        top_z             ],
 353                [ main_cnr_pos[0],       top_z             ],
 354                [ side_thick,            main_cnr_pos[1]   ],
 355                [ side_thick,            -side_height      ],
 356                [ side_taper,            -side_height      ],
 357                [ 0,                     -rivet_posn       ],
 358                [ 0,                     by_oring_z        ],
 359                [ -oring_x_rad,          by_oring_z        ],
 360                ],
 361               convexity=10);
 362     }
 363     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 364       hull(){
 365       translate([ 0, oring_y_rad ])
 366         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 367         circle(oring_thick/2);
 368       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 369         circle(oring_thick/2);
 370     }
 371   }
 372 }
 373
 374 module StrapLoopProfile(){
 375   circle(r = strap_loop_thick/2);
 376 }
 377
 378 module StrapLoop(){ ////toplevel
 379   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 380   extralen = strap_loop_thick * 5;
 381
 382   intersection(){
 383     rotate([strap_loop_elevation, 0,0]){
 384       for (x= [ -1, +1 ] * bigrad) {
 385         translate([x, -extralen, 0])
 386           rotate([-90,0,0])
 387           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 388                          convexity=10)
 389           StrapLoopProfile();
 390       }
 391       translate([0, strap_loop_strlen, 0]){
 392         intersection(){
 393           rotate_extrude(convexity=10)
 394             translate([bigrad, 0,0])
 395             StrapLoopProfile();
 396           translate([0,50,0])
 397             cube([100,100,100], center=true);
 398         }
 399       }
 400     }
 401     translate([0, 50, 0])
 402       cube(100, center=true);
 403   }
 404 }
 405
 406 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 407   // nom_rad > real_rad
 408   rotate([0,0, atan2(offset, nom_rad) ]){
 409     intersection(){
 410       translate([-offset, -10, 0])
 411         rotate([90,0,0])
 412         linear_extrude(height= nom_rad*2, convexity=50)
 413         children(0);
 414       translate([0,0, -25])
 415         cylinder(h=50, r= real_rad);
 416       translate([0,0, -25])
 417         linear_extrude(height= 50, convexity=50)
 418         polygon([ [ 0,0 ],
 419                   [ -slice_size, -real_rad*2 ],
 420                   [ +slice_size, -real_rad*2 ] ]);
 421     }
 422   }
 423 }
 424
 425 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 426   offs = [ for (i=[ x_min :
 427                     slice_size :
 428                     x_max + slice_size ]) i ];
 429   echo (offs);
 430   for (off=offs)
 431     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 432     children(0);
 433 }
 434
 435 module BayonetCutout(){
 436   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 437                 bayo_nom_rad,
 438                 bayo_real_rad)
 439     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 440     polygon(bayo_polygon, convexity=10);
 441 }
 442
 443 module ProfilesDemo(){ ////toplevel
 444   translate([-10,0]) MainProfile();
 445   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 446 }
 447
 448 module LimitForHandling(){ ////toplevel
 449   hull() for (r=[0,180])
 450     rotate([0,0,r]) {
 451       for (rs=[-1,+1]) {
 452         for (xd=[0,1]) {
 453           rotate([0,0, rs * handling_angle/2]) {
 454             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 455                        main_dia/2 + side_thick - main_cnr,
 456                        top_z - main_cnr]) {
 457               mirror([0,0,1])
 458                 cylinder(r= main_cnr, h=50);
 459               sphere(main_cnr);
 460             }
 461           }
 462         }
 463       }
 464     }
 465   hull() rotate_extrude(convexity=10){
 466     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 467       circle(r = main_cnr);
 468       mirror([0,1]) square([ main_cnr, 50 ]);
 469     }
 470   }
 471   //cylinder(r= handling_dia/2, h=20);
 472 }
 473
 474 module Cover(){ ////toplevel
 475   render() difference(){
 476     intersection(){
 477       union(){
 478         rotate_extrude(convexity=10)
 479           translate([main_dia/2, 0])
 480           MainProfile();
 481         translate([0,0, middle_bot_z])
 482           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 483       }
 484       LimitForHandling();
 485     }
 486     for (r=[0,180]){
 487       rotate([0,0, r])
 488         translate([0,0, -side_height])
 489         BayonetCutout();
 490       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 491         translate([0,
 492                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 493                    oring_y_rad * 1.5])
 494         rotate([-oring_rm_angle, 0, 0])
 495         mirror([0,0,1])
 496         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 497     }
 498     for (r=[0 : 60 : 179]) {
 499       rotate([0,0, r]) {
 500         height = top_thick_middle - brace_above_below*2;
 501         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 502         cube(center=true, [ oring_bore - brace_end_shorter,
 503                             brace_hole_width, height ]);
 504       }
 505     }
 506   }
 507   if (enable_head_cups)
 508     for (r=[0,180])
 509       rotate([0,0,r])
 510         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 511                    -implheadcup_large_dia * .0,
 512                    middle_bot_z + 0.1])
 513         ImplHeadCup();
 514
 515 //  translate(strap_loop_thick * [-0.5, 0, +1])
 516 //    translate([handling_dia/2, 0, -side_height])
 517 //    rotate([0,180,0]) rotate([0,0,90])
 518 //    StrapLoop();
 519 }
 520
 521 module SavingHole(){
 522   translate([0,0, -10])
 523     cylinder(r= main_dia/2 - jig_rim, h=20);
 524 }
 525
 526 module Jig(){ ////toplevel
 527   difference(){
 528     union(){
 529       translate([0,0, -side_height]){
 530         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 531       }
 532       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 533         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 534     }
 535     translate([0,0, -side_height-1])
 536       cylinder(r= main_dia/2, h= side_height + 1);
 537     SavingHole();
 538     translate([0,0, -rivet_posn])
 539       rotate([90, 0,0])
 540       translate([0,0, -100])
 541       cylinder(r= jig_hole_dia/2, h = 200);
 542   }
 543 }
 544
 545 module CoverPrint(){ ////toplevel
 546   rotate([0,180,0]) Cover();
 547 }
 548
 549 module CoverTest2(){ ////toplevel
 550   difference(){
 551     Cover();
 552     SavingHole();
 553   }
 554 }
 555
 556 module CoverTest1(){ ////toplevel
 557   difference(){
 558     CoverTest2();
 559     difference(){
 560       for (r= [ 40, 147 ]){
 561         rotate([0,0, r]){
 562           translate([0,0, -10]) {
 563             cube([ main_dia*3, main_dia * .53, 18], center=true);
 564           }
 565         }
 566       }
 567 //      translate([ 50, 0, 0 ])
 568 //      cube([ 100,
 569 //             strap_loop_inside + strap_loop_thick*2 + 1,
 570 //             100 ],
 571 //           center=true);
 572     }
 573   }
 574 }
 575
 576 module ImplHeadCupTest(){ ////toplevel
 577   for (r=[0,180])
 578     rotate([0,0,r])
 579       translate([-17,0,0])
 580       ImplHeadCup();
 581 }
 582
 583 module SomeStrap(width, cut_width=0){
 584   // children(0) is to add, (1) subtract
 585   difference(){
 586     union(){
 587       cylinder(r=sm_outer_rad, h=width);
 588       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 589                            smc_max_y,
 590                            sm_closure_cnr,
 591                            width);
 592       children(0);
 593     }
 594     translate([0,0,-1])
 595       cylinder(r=sm_inner_rad, h=max(width+2, cut_width));
 596     translate(smc_pos)
 597       StrapMountBolt(10, width);
 598     translate(smc_pos)
 599       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 600     children(1);
 601   }
 602 }
 603
 604 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 605   // positioned relative to smc_pos
 606   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 607              smc_bolt_y,
 608              strap_width/2]){
 609     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 610       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 611     }
 612     translate([ -sm_bolt_shaft/2, 0,0 ])
 613       rotate([0,-90,0])
 614       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 615                h=smc_bolt_nut_eff_thick + l_delta);
 616     translate([ sm_bolt_shaft/2, 0,0 ])
 617       rotate([0,90,0])
 618       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 619   }
 620 }
 621
 622 module StrapMountProtrusion(half_x, max_y, cnr, width){
 623   translate(smc_pos){
 624     linear_extrude(height=width, convexity=10){
 625       hull(){
 626         for (m = [0,1]) mirror([m,0,0]) {
 627           translate([-(half_x - cnr), max_y - cnr])
 628             circle(r=cnr);
 629           translate([-half_x, -sm_inner_rad])
 630             square([1,1]);
 631         }
 632       }
 633     }
 634   }
 635 }
 636
 637 module StrapMount(){ ////toplevel
 638   SomeStrap(sm_main_width){
 639     rotate([0,0,180]){
 640       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 641                            strap_loop_thick,
 642                            sm_closure_cnr,
 643                            sm_main_width);
 644       translate(smc_pos +
 645                 [0,0, sm_main_width] +
 646                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 647         StrapLoop();
 648     }
 649     union(){ };
 650   }
 651 }
 652
 653 module WallScrewHoleSlot(){ ////toplevel
 654   ds = [-1,+1] * wm_screw_slot/2;
 655   linextr_x_yz(-(wm_thick + 1), 1) {
 656     hull(){
 657       for (d = ds)
 658         translate([d, 0])
 659           circle(r = wm_screw_dia/2);
 660     }
 661   }
 662   hull(){
 663     for (d = ds){
 664       translate([0, d, 0]){
 665         linextr_x_yz(0, 1)
 666           circle(r = wm_screw_head/2);
 667         linextr_x_yz(-(wm_screw_head - wm_screw_dia)/2, 0)
 668           circle(r = wm_screw_dia/2);
 669       }
 670     }
 671   }
 672 }
 673
 674 module WallMountMounts(){
 675   linextr(0, wm_z_max){
 676     translate([ -sm_outer_rad, 0 ])
 677       rectfromto([ 0, -wm_y_max ],
 678                  [ wm_thick, wm_y_slot1_max ]);
 679   }
 680 }
 681 module WallMountScrewHoles(){
 682   translate([ -sm_outer_rad + wm_thick, 0, wm_z_slotc_screw]) {
 683     translate([ 0, wm_y_slotc_screw, 0 ])
 684       WallScrewHoleSlot();
 685     translate([ 0, -wm_y_slotc_screw, 0 ])
 686       rotate([90,0,0])
 687       WallScrewHoleSlot();
 688   }
 689 }
 690
 691 module WallMount(){ ////toplevel
 692   SomeStrap(sm_main_width, wm_z_max + 2){
 693     WallMountMounts();
 694     WallMountScrewHoles();
 695   }
 696 }
 697
 698 module WallMountBaseRingCut(){
 699   circle(r = wmb_mount_cut_rad);
 700 }
 701
 702 module WallMountBaseMounts(){
 703   linextr(0, wmb_z_max) {
 704     difference(){
 705       rectfromto([ -sm_outer_rad, -wmb_y_mount_max ],
 706                  [ wmb_x_outer,   +wmb_y_mount_max ]);
 707       WallMountBaseRingCut();
 708     }
 709   }
 710 }
 711
 712 // screws, nuts, slots for nuts to go down into
 713 module WallMountBaseScrewsEtc(){ ////toplevel
 714   for (my=[0,1]) {
 715     mirror([0, my, 0]) {
 716       translate([wmb_x_screw, 0, wmb_z_screw]) {
 717         linextr_y_xz(wmb_y_screw_end,
 718                      wmb_y_screw_end + 100) // XXX change 100
 719           circle(r = wmb_screw_dia/2);
 720         linextr_y_xz(wmb_y_screw_end + web_screw_len,
 721                      wmb_y_screw_end + 100) // XXX change 100
 722           circle(r = wmb_screw_head_dia/2);
 723         linextr_y_xz(wmb_y_nut_min,
 724                      wmb_y_nut_min + wmb_nut_th) {
 725           hull(){
 726             rotate(30)
 727               circle(r = wmb_nut_rad, $fn = 6);
 728             translate([0, 100]) // XXX change 100
 729               square(wmb_nut_across, center=true);
 730           }
 731         }
 732       }
 733     }
 734   }
 735 }
 736
 737 module WallMountForBase(){ ////toplevel
 738   SomeStrap(sm_main_width, wm_z_max + 2){
 739     union(){
 740       WallMountMounts();
 741       WallMountBaseMounts();
 742     }
 743     union(){
 744       WallMountScrewHoles();
 745       WallMountBaseScrewsEtc();
 746     }
 747   }
 748 }
 749
 750 module WallMountBasePillarsPlan(){
 751   for (my = [0,1]) {
 752     mirror([0, my]) {
 753       rectfromto([ -sm_outer_rad, wmbb_y_max - wmb_mount_y_width ],
 754                  [ wmbb_x_outer, wmbb_y_max ]);
 755     }
 756   }
 757 }
 758
 759 // trim parts that are would foul the wall
 760 module WallMountTrimWallFoulPlan(){
 761     translate([ -sm_outer_rad, 0])
 762     rectfromto([ -wmbb_r_top, -(wmbb_r_top + 1) ],
 763                [ 0,           +(wmbb_r_top + 1) ]);
 764 }
 765
 766 module WallMountBase(){ ////toplevel
 767   difference(){
 768     union(){
 769       // vertical blocks rising to join to wall mount
 770       linextr(wmbb_z_min, wmb_z_max) {
 771         difference(){
 772           WallMountBasePillarsPlan();
 773           WallMountBaseRingCut();
 774         }
 775       }
 776
 777       hull(){
 778         linextr(wmbb_z_flat_whole_min, wmbb_z_flat_max)
 779           circle(r = wmbb_r_top);
 780         linextr(wmbb_z_min, wmbb_z_flat_max)
 781           circle(r = wmbb_r_bottom);
 782       }
 783       linextr(wmbb_z_min, wmbb_z_flat_max) {
 784         hull(){
 785           WallMountBasePillarsPlan();
 786           circle(r = wmbb_r_bottom);
 787         }
 788       }
 789     }
 790
 791     // cutaway for mount part
 792     linextr(-wmb_mount_gap_z, wmb_z_max+1) {
 793       for (my = [0,1]) {
 794         mirror([0, my])
 795           rectfromto([ -sm_outer_rad-1, wmb_y_mount_max + wmb_mount_gap_xy ],
 796                      [ wmb_x_outer + wmb_mount_gap_xy, 1 ]);
 797       }
 798     }
 799
 800     linextr(wmbb_z_min - 1, wmb_z_max + 1)
 801       WallMountTrimWallFoulPlan();
 802     WallMountBaseScrewsEtc();
 803   }
 804 }
 805
 806 module WallMountBaseCutJigPlan(){ ////toplevel
 807   difference(){
 808     union(){
 809       circle(r = wmbb_r_top);
 810     }
 811
 812     translate([ wmb_jig_around_gap, 0 ])
 813       WallMountTrimWallFoulPlan();
 814
 815     offset(delta = wmb_jig_around_gap)
 816       WallMountBasePillarsPlan();
 817   }
 818 }
 819
 820 module WallMountBaseCutJig(){ ////toplevel
 821   translate([ 0,0, wmbb_z_flat_max + 0.5 ])
 822     linextr(0, wmb_jig_th)
 823     WallMountBaseCutJigPlan();
 824 }
 825
 826 module WallMountForBaseDemo(){ ////toplevel
 827   render() WallMountForBase();
 828   color("blue") render() WallMountBase();
 829   %WallMountBaseScrewsEtc();
 830   %WallMountBaseCutJig();
 831 }
 832
 833 module CatchAssemblyCoreProfile(){
 834   difference(){
 835     union(){
 836       hull(){
 837         translate(cpp3) circle(r= catch_cr3);
 838         polygon([ cpp3,
 839                   cpp2r,
 840                   cpp5,
 841                   cpph,
 842                   cppd
 843                   ]);
 844       }
 845       polygon([cppD,
 846                cppC,
 847                cpp9,
 848                cpp10,
 849                cpp11,
 850                cpp4,
 851                cpp2r,
 852                cpp2d,
 853                cppA,
 854                cppE
 855                ]);
 856       translate(cpp8) circle(r= catch_cr);
 857     }
 858     hull(){
 859       translate(cpp4) circle(r= catch_cr);
 860       translate(cpp5) circle(r= catch_cr);
 861       translate(cpp7) circle(r= catch_cr);
 862       polygon([cpp4,
 863                cppg,
 864                cpph,
 865                cpp10,
 866                cpp11,
 867                ]);
 868     }
 869     translate(cpp2) circle(r= catch_cr);
 870   }
 871   // if cpp11 is above cpp10, the subtracted hull above
 872   // can go down too far.  Ensure we do not cut off below cppy6.
 873   polygon([ cppE,
 874             cppD,
 875             cpp9,
 876             [ cpp9[0],            cppy6 ],
 877             [ cpp7[0] - catch_cr, cppy6 ],
 878             cpp2d
 879             ]);
 880 }
 881
 882 module CatchTipProfile(dy){
 883   ddy = [0,dy];
 884   intersection(){
 885     translate(cppF){
 886       difference(){
 887 //      circle(r = dist2d(cppF, cppd));
 888         //circle(r = dist2d(cppF, cppa));
 889       }
 890     }
 891     polygon([ cppa,
 892               cppi + ddy,
 893               cppd + ddy,
 894               cppc,
 895               cppb ]);
 896   }
 897 }
 898
 899 module CatchHeadProfile(){
 900   polygon([ cppd,
 901             cppd,
 902             cppi,
 903             cppf,
 904             cppe,
 905             cpph ]);
 906 }
 907
 908
 909 module CatchCore(){ /////toplevel
 910   linear_extrude(height=catch_strap_thick, convexity=10)
 911     CatchAssemblyCoreProfile();
 912
 913   hull(){
 914     linear_extrude(height=catch_head_th, convexity=10)
 915       CatchTipProfile(0);
 916     linear_extrude(height=catch_tip_th, convexity=10)
 917       CatchTipProfile(catch_tip_th - catch_head_th);
 918   }
 919
 920   linear_extrude(height=catch_head_th, convexity=10)
 921     CatchHeadProfile();
 922
 923   translate(concat(cppB,[0])) hull(){
 924     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 925       sphere(r = catch_knob_dia/2);
 926     cylinder(r = catch_knob_dia/2, h = 0.1);
 927   }
 928 }
 929
 930 module CatchPreDistort(){ /////toplevel
 931   scale(100 / sm_inner_rad)
 932     rotate([90,0,0])
 933     CatchCore();
 934 }
 935
 936 module CatchAssembly(){ /////toplevel
 937   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 938     translate([0,0, catch_assembly_dy])
 939     scale(sm_inner_rad / 100)
 940     import(str("poster-tube-lid,CatchPostDistort-fa",
 941                (coarse ? 20 : 3),
 942                ".stl"),
 943            convexity=20);
 944
 945   SomeStrap(catch_strap_width){
 946     union(){ }
 947     union(){
 948       translate([-200, -200, -200])
 949         cube([400, 200, 400]);
 950     }
 951   }
 952 }
 953
 954 module CatchDemo(){ /////toplevel
 955   color("blue") translate([0,0,
 956                            -catch_assembly_dy
 957              ])
 958     CatchAssembly();
 959   translate([0,0,+side_height
 960              ])
 961     Cover();
 962 }
 963
 964 module CatchDemoS(){ /////toplevel
 965   color("blue") translate([0,0,
 966              -catch_assembly_dy
 967              ])
 968     CatchAssembly();
 969   intersection(){
 970     translate([0,0,+side_height
 971                ])
 972       Cover();
 973     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 974   }
 975   color("black")
 976     translate([0,-33,0])
 977     cube([6.15, 2,2], center=true);
 978 }
 979
 980 module CatchPinProfileDemo(){ /////toplevel
 981   translate([0, 0 * -bayo_behind,0]) {
 982     echo("G ",
 983          bayo_n[0] - bayo_e[0]);
 984     color("blue") translate([0,0,
 985                              +1,
 986                ]) {
 987       CatchAssemblyCoreProfile();
 988       CatchHeadProfile();
 989     }
 990     translate([0,0,10])
 991       color("red")
 992       CatchTipProfile(0);
 993
 994     polygon(bayo_polygon, convexity=10);
 995
 996     // adhoc show a position
 997     color("purple")
 998     translate(concat(
 999                      cppa,
1000                      10
1001                      )) difference(){ circle(2.5); circle(2.0); }
1002
1003  }
1004 }
1005
1006 //ProfilesDemo();
1007 //BayonetCutout();
1008 //MainProfile();
1009 //Cover();
1010 //Jig();
1011 //CoverTest();