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