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 = 3.5; // XXX
  93 wm_screw_slot = 4.0;
  94 wm_csink = 2.5; // XXX
  95
  96 catch_stalk_h = 4.5;
  97 catch_stalk_len = 50;
  98 catch_tip_th = 4;
  99 catch_head_th = 3;
 100
 101 catch_pin_slop = 0.25; // each side, and above
 102 catch_pin_slop_x_extra = 0.0; // only on one side
 103 catch_stalk_above_gap = 1.5;
 104 catch_stalk_eff_bend_rad = catch_stalk_len * 0.75;
 105
 106 catch_strap_width = 12;
 107 catch_stalk_base_width = 15;
 108
 109 catch_knob_dia = 6;
 110 catch_knob_above_gap = 5;
 111 catch_knob_height = 3.0;
 112
 113 catch_stalk_below_gap = 1.0;
 114 catch_stalk_beside_gap = 2.0;
 115
 116 // calculated
 117
 118 TAU = PI*2;
 119
 120 bayo_entry_x = bayo_entry;
 121 bayo_entry_z = bayo_entry;
 122 bayo_inramp_x = bayo_inramp;
 123 bayo_inramp_z = bayo_inramp;
 124
 125 oring_mid_dia = oring_bore + oring_thick;
 126 oring_outer_dia = oring_mid_dia + oring_thick;
 127
 128 oring_oblate = (1 - oring_compress);
 129
 130 oring_y_rad = oring_thick/2 * oring_oblate;
 131 oring_x_rad = oring_thick/2 / oring_oblate;
 132
 133 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 134
 135 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 136 side_thick = rivet_tall + over_rivet_wall;
 137
 138 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 139
 140 middle_bot_z = top_z - top_thick_middle;
 141
 142 bayo_top_z = bayo_behind + bayo_gap;
 143
 144 bayo_nom_rad = main_dia/2 + side_thick;
 145 bayo_real_rad = main_dia/2 + rivet_tall;
 146
 147 rivet_entry_width = rivet_width + side_rivet_gap;
 148
 149 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 150
 151 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 152 handling_angle = 45;
 153
 154 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 155 sm_outer_rad = sm_inner_rad + sm_main_thick;
 156
 157 wm_main_width = sm_main_width;
 158 wm_y_min = sqrt( pow(sm_inner_rad, 2) -
 159                  pow(sm_inner_rad - (wm_thick - sm_main_thick), 2) );
 160 wm_y_screw = wm_y_min + wm_screw_around + wm_screw_dia/2;
 161 wm_y_max = wm_y_screw + wm_screw_dia/2 + wm_screw_around;
 162 wm_y_slot1_screw = wm_y_screw + wm_screw_slot;
 163 wm_y_slot1_max = wm_y_max + wm_screw_slot;
 164 wm_z_slot0_screw = wm_main_width + wm_screwdriver_dia/2;
 165 wm_z_slotc_screw = wm_z_slot0_screw + wm_screw_slot/2;
 166 wm_z_slot1_screw = wm_z_slot0_screw + wm_screw_slot/2;
 167 wm_z_max = wm_z_slot1_screw + wm_screw_around;
 168
 169 smc_pos = [ 0, sm_inner_rad, 0 ];
 170
 171 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 172 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 173
 174 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 175 smc_max_y = smc_bolt_y + sm_bolt_y_over
 176   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 177 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 178   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 179
 180 catch_cr = catch_knob_dia/2 + catch_stalk_beside_gap;
 181 catch_strap_thick = sm_main_thick;
 182
 183 echo("R ", sm_inner_rad, bayo_real_rad, bayo_nom_rad);
 184
 185 $fs= coarse ? 2.5 : 0.5;
 186 $fa= coarse ? 5 : 1;
 187
 188 include <poster-tube-lid-parametric.scad>
 189
 190 // bayonet definition
 191
 192 bayo_a = [ bayo_entry_x, 0 ];
 193 bayo_p = [ 0, bayo_entry_z ];
 194 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 195 bayo_m = [ bayo_inramp_x, bayo_behind ];
 196 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 197 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 198 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 199 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 200 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 201 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 202
 203 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 204 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 205 bayo_c = bayo_d + [0,-5];
 206 bayo_b = bayo_a + [0,-5];
 207
 208 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 209
 210 bayo_polygon = [ bayo_a,
 211                  bayo_b,
 212                  bayo_c,
 213                  bayo_d,
 214                  bayo_e,
 215                  bayo_f,
 216                  bayo_g,
 217                  bayo_h,
 218                  bayo_i,
 219                  bayo_j,
 220                  bayo_k,
 221                  bayo_l,
 222                  bayo_m,
 223                  bayo_n,
 224                  bayo_p ];
 225
 226 echo(bayo_polygon);
 227
 228 // CATCH
 229
 230 cppxC = 0.41 * sm_inner_rad * TAU;
 231
 232 // catch pin
 233
 234 cpp_adj = (bayo_n[0] - bayo_f[0]) * (1 - sm_inner_rad / bayo_nom_rad);
 235 // radius scaling due to nom and actual radius difference in
 236 // bayo entry construction
 237
 238 cppa = bayo_f + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 239 cppb = bayo_g + [1,-1] * catch_pin_slop + [1,0] * cpp_adj;
 240 cppd = [ bayo_n[0]
 241          - catch_pin_slop - catch_pin_slop_x_extra,
 242          -catch_stalk_above_gap ];
 243 cppi = [ cppa[0], cppd[1] ];
 244 cppc = [ cppd[0], cppb[1] ];
 245 cpph = cppd + [0,-1] * catch_stalk_h;
 246 cppe = cppd + [0,-1] * (catch_knob_above_gap + catch_knob_dia/2);
 247 cppf = [ cppa[0], cppe[1] ];
 248 cppg = [ cppa[0], cpph[1] ];
 249 cppB = 0.5 * (cppf + cppe);
 250
 251 echo("RR", sm_inner_rad / bayo_nom_rad);
 252
 253 // catch assembly depression below pin
 254
 255 cppy6 = cppB[1] - (catch_knob_dia/2
 256                    + (cppc[1] - cppd[1])
 257                    + catch_stalk_below_gap);
 258 cpp7 = [ cppB[0], cppy6 + catch_cr ];
 259 cpp11 = cpp7 + [1,0] * catch_cr;
 260 cppy9 = cppy6 + catch_strap_width * 1/3;
 261 cpp9 = [ cpp7[0] + catch_cr * 2, cppy9 ];
 262 cpp8 = cpp9 + [0,-1] * catch_cr;
 263 cpp10 = cpp8 + [-1,0] * catch_cr;
 264 cppC = [ cppxC, cpp9[1] ];
 265 cppD = cppC + [0,-1] * catch_strap_width;
 266
 267 // catch assembly stalk and so on
 268
 269 catch_cr3 = catch_cr + catch_stalk_h;
 270
 271 cppF = [ cppg[0] - catch_stalk_eff_bend_rad, cppd[1] ];
 272 cpp4 = [ cppg[0] - catch_stalk_len, cpph[1] ] + [1,-1] * catch_cr;
 273 cpp5 = [ cpp4[0], cppC[1] + catch_cr ];
 274 cpp2 = cpp5 + [-1,0] * (catch_cr * 2 + catch_stalk_base_width);
 275 cpp2r = cpp2 + [1,0] * catch_cr;
 276 cpp2d = cpp2 + [0,-1] * catch_cr;
 277 cpp3 = [ cpp2[0] + catch_cr + catch_cr3, cppd[1] - catch_cr3 ];
 278 cppA = [ -cppxC, cpp9[1] ];
 279 cppE = [ cppA[0], cppD[1] ];
 280
 281 catch_assembly_dy = -cppy9 + catch_strap_width;
 282
 283
 284 module MainProfile(){
 285   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 286   difference(){
 287     union(){
 288       translate(main_cnr_pos){
 289         intersection(){
 290           difference(){
 291             circle(r = main_cnr);
 292             circle(r = main_cnr * 0.5);
 293           }
 294           square([10,10]);
 295         }
 296       }
 297       polygon([[ -top_middle_dr,        middle_bot_z      ],
 298                [ -top_middle_dr,        top_z             ],
 299                [ main_cnr_pos[0],       top_z             ],
 300                [ side_thick,            main_cnr_pos[1]   ],
 301                [ side_thick,            -side_height      ],
 302                [ side_taper,            -side_height      ],
 303                [ 0,                     -rivet_posn       ],
 304                [ 0,                     by_oring_z        ],
 305                [ -oring_x_rad,          by_oring_z        ],
 306                ],
 307               convexity=10);
 308     }
 309     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 310       hull(){
 311       translate([ 0, oring_y_rad ])
 312         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 313         circle(oring_thick/2);
 314       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 315         circle(oring_thick/2);
 316     }
 317   }
 318 }
 319
 320 module StrapLoopProfile(){
 321   circle(r = strap_loop_thick/2);
 322 }
 323
 324 module StrapLoop(){ ////toplevel
 325   bigrad = strap_loop_inside/2 + strap_loop_thick/2;
 326   extralen = strap_loop_thick * 5;
 327
 328   intersection(){
 329     rotate([strap_loop_elevation, 0,0]){
 330       for (x= [ -1, +1 ] * bigrad) {
 331         translate([x, -extralen, 0])
 332           rotate([-90,0,0])
 333           linear_extrude(height= extralen + strap_loop_strlen + 0.1,
 334                          convexity=10)
 335           StrapLoopProfile();
 336       }
 337       translate([0, strap_loop_strlen, 0]){
 338         intersection(){
 339           rotate_extrude(convexity=10)
 340             translate([bigrad, 0,0])
 341             StrapLoopProfile();
 342           translate([0,50,0])
 343             cube([100,100,100], center=true);
 344         }
 345       }
 346     }
 347     translate([0, 50, 0])
 348       cube(100, center=true);
 349   }
 350 }
 351
 352 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 353   // nom_rad > real_rad
 354   rotate([0,0, atan2(offset, nom_rad) ]){
 355     intersection(){
 356       translate([-offset, -10, 0])
 357         rotate([90,0,0])
 358         linear_extrude(height= nom_rad*2, convexity=50)
 359         children(0);
 360       translate([0,0, -25])
 361         cylinder(h=50, r= real_rad);
 362       translate([0,0, -25])
 363         linear_extrude(height= 50, convexity=50)
 364         polygon([ [ 0,0 ],
 365                   [ -slice_size, -real_rad*2 ],
 366                   [ +slice_size, -real_rad*2 ] ]);
 367     }
 368   }
 369 }
 370
 371 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 372   offs = [ for (i=[ x_min :
 373                     slice_size :
 374                     x_max + slice_size ]) i ];
 375   echo (offs);
 376   for (off=offs)
 377     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 378     children(0);
 379 }
 380
 381 module BayonetCutout(){
 382   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 383                 bayo_nom_rad,
 384                 bayo_real_rad)
 385     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 386     polygon(bayo_polygon, convexity=10);
 387 }
 388
 389 module ProfilesDemo(){ ////toplevel
 390   translate([-10,0]) MainProfile();
 391   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 392 }
 393
 394 module LimitForHandling(){ ////toplevel
 395   hull() for (r=[0,180])
 396     rotate([0,0,r]) {
 397       for (rs=[-1,+1]) {
 398         for (xd=[0,1]) {
 399           rotate([0,0, rs * handling_angle/2]) {
 400             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 401                        main_dia/2 + side_thick - main_cnr,
 402                        top_z - main_cnr]) {
 403               mirror([0,0,1])
 404                 cylinder(r= main_cnr, h=50);
 405               sphere(main_cnr);
 406             }
 407           }
 408         }
 409       }
 410     }
 411   hull() rotate_extrude(convexity=10){
 412     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 413       circle(r = main_cnr);
 414       mirror([0,1]) square([ main_cnr, 50 ]);
 415     }
 416   }
 417   //cylinder(r= handling_dia/2, h=20);
 418 }
 419
 420 module Cover(){ ////toplevel
 421   render() difference(){
 422     intersection(){
 423       union(){
 424         rotate_extrude(convexity=10)
 425           translate([main_dia/2, 0])
 426           MainProfile();
 427         translate([0,0, middle_bot_z])
 428           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 429       }
 430       LimitForHandling();
 431     }
 432     for (r=[0,180]){
 433       rotate([0,0, r])
 434         translate([0,0, -side_height])
 435         BayonetCutout();
 436       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 437         translate([0,
 438                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 439                    oring_y_rad * 1.5])
 440         rotate([-oring_rm_angle, 0, 0])
 441         mirror([0,0,1])
 442         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 443     }
 444     for (r=[0 : 60 : 179]) {
 445       rotate([0,0, r]) {
 446         height = top_thick_middle - brace_above_below*2;
 447         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 448         cube(center=true, [ oring_bore - brace_end_shorter,
 449                             brace_hole_width, height ]);
 450       }
 451     }
 452   }
 453   if (enable_head_cups)
 454     for (r=[0,180])
 455       rotate([0,0,r])
 456         translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 457                    -implheadcup_large_dia * .0,
 458                    middle_bot_z + 0.1])
 459         ImplHeadCup();
 460
 461 //  translate(strap_loop_thick * [-0.5, 0, +1])
 462 //    translate([handling_dia/2, 0, -side_height])
 463 //    rotate([0,180,0]) rotate([0,0,90])
 464 //    StrapLoop();
 465 }
 466
 467 module SavingHole(){
 468   translate([0,0, -10])
 469     cylinder(r= main_dia/2 - jig_rim, h=20);
 470 }
 471
 472 module Jig(){ ////toplevel
 473   difference(){
 474     union(){
 475       translate([0,0, -side_height]){
 476         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 477       }
 478       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 479         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 480     }
 481     translate([0,0, -side_height-1])
 482       cylinder(r= main_dia/2, h= side_height + 1);
 483     SavingHole();
 484     translate([0,0, -rivet_posn])
 485       rotate([90, 0,0])
 486       translate([0,0, -100])
 487       cylinder(r= jig_hole_dia/2, h = 200);
 488   }
 489 }
 490
 491 module CoverPrint(){ ////toplevel
 492   rotate([0,180,0]) Cover();
 493 }
 494
 495 module CoverTest2(){ ////toplevel
 496   difference(){
 497     Cover();
 498     SavingHole();
 499   }
 500 }
 501
 502 module CoverTest1(){ ////toplevel
 503   difference(){
 504     CoverTest2();
 505     difference(){
 506       for (r= [ 40, 147 ]){
 507         rotate([0,0, r]){
 508           translate([0,0, -10]) {
 509             cube([ main_dia*3, main_dia * .53, 18], center=true);
 510           }
 511         }
 512       }
 513 //      translate([ 50, 0, 0 ])
 514 //      cube([ 100,
 515 //             strap_loop_inside + strap_loop_thick*2 + 1,
 516 //             100 ],
 517 //           center=true);
 518     }
 519   }
 520 }
 521
 522 module ImplHeadCupTest(){ ////toplevel
 523   for (r=[0,180])
 524     rotate([0,0,r])
 525       translate([-17,0,0])
 526       ImplHeadCup();
 527 }
 528
 529 module SomeStrap(width){
 530   // children(0) is to add, (1) subtract
 531   difference(){
 532     union(){
 533       cylinder(r=sm_outer_rad, h=width);
 534       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 535                            smc_max_y,
 536                            sm_closure_cnr,
 537                            width);
 538       children(0);
 539     }
 540     translate([0,0,-1])
 541       cylinder(r=sm_inner_rad, h=width+2);
 542     translate(smc_pos)
 543       StrapMountBolt(10, width);
 544     translate(smc_pos)
 545       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 546     children(1);
 547   }
 548 }
 549
 550 module StrapMountBolt(l_delta, strap_width){ ///toplevel
 551   // positioned relative to smc_pos
 552   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 553              smc_bolt_y,
 554              strap_width/2]){
 555     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 556       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 557     }
 558     translate([ -sm_bolt_shaft/2, 0,0 ])
 559       rotate([0,-90,0])
 560       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 561                h=smc_bolt_nut_eff_thick + l_delta);
 562     translate([ sm_bolt_shaft/2, 0,0 ])
 563       rotate([0,90,0])
 564       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 565   }
 566 }
 567
 568 module StrapMountProtrusion(half_x, max_y, cnr, width){
 569   translate(smc_pos){
 570     linear_extrude(height=width, convexity=10){
 571       hull(){
 572         for (m = [0,1]) mirror([m,0,0]) {
 573           translate([-(half_x - cnr), max_y - cnr])
 574             circle(r=cnr);
 575           translate([-half_x, -sm_inner_rad])
 576             square([1,1]);
 577         }
 578       }
 579     }
 580   }
 581 }
 582
 583 module StrapMount(){ ////toplevel
 584   SomeStrap(sm_main_width){
 585     rotate([0,0,180]){
 586       StrapMountProtrusion(strap_loop_inside/2 + strap_loop_thick,
 587                            strap_loop_thick,
 588                            sm_closure_cnr,
 589                            sm_main_width);
 590       translate(smc_pos +
 591                 [0,0, sm_main_width] +
 592                 strap_loop_thick * [ 0, 0.5, -1.0 ])
 593         StrapLoop();
 594     }
 595     union(){ };
 596   }
 597 }
 598
 599 module WallMount(){ ////toplevel
 600   SomeStrap(sm_main_width){
 601     union(){
 602       linextr(0, wm_z_max){
 603         translate([ -sm_outer_rad, 0 ])
 604           rectfromto([ 0, -wm_y_max ],
 605                      [ wm_thick, wm_y_slot1_max ]);
 606       }
 607     }
 608     union(){ }
 609   }
 610 }
 611
 612 module CatchAssemblyCoreProfile(){
 613   difference(){
 614     union(){
 615       hull(){
 616         translate(cpp3) circle(r= catch_cr3);
 617         polygon([ cpp3,
 618                   cpp2r,
 619                   cpp5,
 620                   cpph,
 621                   cppd
 622                   ]);
 623       }
 624       polygon([cppD,
 625                cppC,
 626                cpp9,
 627                cpp10,
 628                cpp11,
 629                cpp4,
 630                cpp2r,
 631                cpp2d,
 632                cppA,
 633                cppE
 634                ]);
 635       translate(cpp8) circle(r= catch_cr);
 636     }
 637     hull(){
 638       translate(cpp4) circle(r= catch_cr);
 639       translate(cpp5) circle(r= catch_cr);
 640       translate(cpp7) circle(r= catch_cr);
 641       polygon([cpp4,
 642                cppg,
 643                cpph,
 644                cpp10,
 645                cpp11,
 646                ]);
 647     }
 648     translate(cpp2) circle(r= catch_cr);
 649   }
 650   // if cpp11 is above cpp10, the subtracted hull above
 651   // can go down too far.  Ensure we do not cut off below cppy6.
 652   polygon([ cppE,
 653             cppD,
 654             cpp9,
 655             [ cpp9[0],            cppy6 ],
 656             [ cpp7[0] - catch_cr, cppy6 ],
 657             cpp2d
 658             ]);
 659 }
 660
 661 module CatchTipProfile(dy){
 662   ddy = [0,dy];
 663   intersection(){
 664     translate(cppF){
 665       difference(){
 666 //      circle(r = dist2d(cppF, cppd));
 667         //circle(r = dist2d(cppF, cppa));
 668       }
 669     }
 670     polygon([ cppa,
 671               cppi + ddy,
 672               cppd + ddy,
 673               cppc,
 674               cppb ]);
 675   }
 676 }
 677
 678 module CatchHeadProfile(){
 679   polygon([ cppd,
 680             cppd,
 681             cppi,
 682             cppf,
 683             cppe,
 684             cpph ]);
 685 }
 686
 687
 688 module CatchCore(){ /////toplevel
 689   linear_extrude(height=catch_strap_thick, convexity=10)
 690     CatchAssemblyCoreProfile();
 691
 692   hull(){
 693     linear_extrude(height=catch_head_th, convexity=10)
 694       CatchTipProfile(0);
 695     linear_extrude(height=catch_tip_th, convexity=10)
 696       CatchTipProfile(catch_tip_th - catch_head_th);
 697   }
 698
 699   linear_extrude(height=catch_head_th, convexity=10)
 700     CatchHeadProfile();
 701
 702   translate(concat(cppB,[0])) hull(){
 703     translate([0,0, catch_knob_height + catch_head_th - catch_knob_dia/2])
 704       sphere(r = catch_knob_dia/2);
 705     cylinder(r = catch_knob_dia/2, h = 0.1);
 706   }
 707 }
 708
 709 module CatchPreDistort(){ /////toplevel
 710   scale(100 / sm_inner_rad)
 711     rotate([90,0,0])
 712     CatchCore();
 713 }
 714
 715 module CatchAssembly(){ /////toplevel
 716   rotate([0,0, -(cppe[0] + cppB[0] + catch_pin_slop) / sm_inner_rad * 360/TAU])
 717     translate([0,0, catch_assembly_dy])
 718     scale(sm_inner_rad / 100)
 719     import(str("poster-tube-lid,CatchPostDistort-fa",
 720                (coarse ? 20 : 3),
 721                ".stl"),
 722            convexity=20);
 723
 724   SomeStrap(catch_strap_width){
 725     union(){ }
 726     union(){
 727       translate([-200, -200, -200])
 728         cube([400, 200, 400]);
 729     }
 730   }
 731 }
 732
 733 module CatchDemo(){ /////toplevel
 734   color("blue") translate([0,0,
 735                            -catch_assembly_dy
 736              ])
 737     CatchAssembly();
 738   translate([0,0,+side_height
 739              ])
 740     Cover();
 741 }
 742
 743 module CatchDemoS(){ /////toplevel
 744   color("blue") translate([0,0,
 745              -catch_assembly_dy
 746              ])
 747     CatchAssembly();
 748   intersection(){
 749     translate([0,0,+side_height
 750                ])
 751       Cover();
 752     mirror([0,1,0]) translate([-250,33,0]) cube([500,500,500]);
 753   }
 754   color("black")
 755     translate([0,-33,0])
 756     cube([6.15, 2,2], center=true);
 757 }
 758
 759 module CatchPinProfileDemo(){ /////toplevel
 760   translate([0, 0 * -bayo_behind,0]) {
 761     echo("G ",
 762          bayo_n[0] - bayo_e[0]);
 763     color("blue") translate([0,0,
 764                              +1,
 765                ]) {
 766       CatchAssemblyCoreProfile();
 767       CatchHeadProfile();
 768     }
 769     translate([0,0,10])
 770       color("red")
 771       CatchTipProfile(0);
 772
 773     polygon(bayo_polygon, convexity=10);
 774
 775     // adhoc show a position
 776     color("purple")
 777     translate(concat(
 778                      cppa,
 779                      10
 780                      )) difference(){ circle(2.5); circle(2.0); }
 781
 782  }
 783 }
 784
 785 //ProfilesDemo();
 786 //BayonetCutout();
 787 //MainProfile();
 788 //Cover();
 789 //Jig();
 790 //CoverTest();