poster-tube-lid.scad

   1 // -*- C -*-
   2
   3 coarse = false;
   4
   5 main_dia = 71.2 + 0.50 - 2.26;
   6 top_thick_middle = 4;
   7 top_thick_by_oring = 3.0;
   8 top_middle_dr = 11;
   9
  10 main_cnr = 6.0;
  11
  12 min_wall = 3;
  13
  14 rivet_posn = 6.0 + 0.30;
  15 rivet_thick = 1.67;
  16 rivet_width = 4.15 + 1.0;
  17 rivet_tall = 5.51 + 1.49;
  18
  19 over_rivet_wall = 1.0;
  20 side_rivet_gap = 1.5;
  21 inside_rivet_gap = 1.5;
  22
  23 bayo_interf = 0.30;
  24 bayo_behind = 3.5;
  25 bayo_interf_width = 2.0;
  26 bayo_interf_slope = 0.5;
  27
  28 oring_thick = 5.0;
  29 oring_bore = 62.0;
  30
  31 oring_upper_embed_angle = 80;
  32 oring_compress = 0.1; // proportion
  33 oring_compress_more = 0.2;
  34
  35 oring_rm_beside = 8;
  36 oring_rm_scale = 2.0;
  37 oring_rm_angle = 20;
  38
  39 side_taper = 1.0;
  40
  41 bayo_gap = 6.0;
  42
  43 bayo_entry = bayo_behind/3;
  44
  45 bayo_slice_size = coarse ? 5 : 1;
  46
  47 brace_hole_width = 1.0;
  48 brace_above_below = 1.2;
  49 brace_end_shorter = 0.3;
  50
  51 jig_thick = 1.4;
  52 jig_hole_dia = 3.0;
  53 jig_rim = 5;
  54 jig_mark = 5;
  55
  56 strap_hoop_thick = 6;
  57 strap_hoop_inside = 10;
  58 strap_hoop_strlen = 10;
  59 strap_hoop_elevation = 45;
  60
  61 sm_inner_circum = 218 - 1.90 - 1.00 - 0.50;
  62 sm_main_thick = 2.0;
  63 sm_main_width = 20;
  64
  65 sm_bolt_dia = 3.5 + 0.1;
  66 sm_bolt_shaft = 21.9;
  67 sm_bolt_head_dia = 6.94 + 1.0;
  68 sm_bolt_head_thick = 2.14;
  69 sm_bolt_nut_width = 5.89 + 0.25;
  70 sm_bolt_nut_thick = 3.68;
  71 sm_bolt_tighten_allow = 2.0;
  72
  73 sm_bolt_y_clear = 0.75;
  74 sm_bolt_y_over = 0.5;
  75
  76 sm_closure_cnr = 3.0;
  77
  78 catch_stem_h = 3;
  79 catch_stem_len = 50;
  80 catch_stem_th = 3;
  81
  82 catch_knob_dia = 6;
  83 catch_knob_above_gap = 8;
  84 catch_pin_height = 7;
  85
  86 catch_stem_below_gap = 1.0;
  87 catch_stem_beside_gap = 2.0;
  88 catch_pin_gap = 0.5;
  89 catch_hook_slope = 0.15;
  90
  91 // calculated
  92
  93 TAU = PI*2;
  94
  95 bayo_entry_x = bayo_entry;
  96 bayo_entry_z = bayo_entry;
  97 bayo_inramp_x = bayo_entry;
  98 bayo_inramp_z = bayo_entry;
  99
 100 oring_mid_dia = oring_bore + oring_thick;
 101 oring_outer_dia = oring_mid_dia + oring_thick;
 102
 103 oring_oblate = (1 - oring_compress);
 104
 105 oring_y_rad = oring_thick/2 * oring_oblate;
 106 oring_x_rad = oring_thick/2 / oring_oblate;
 107
 108 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
 109
 110 side_height = rivet_posn + bayo_behind + rivet_thick/2;
 111 side_thick = rivet_tall + over_rivet_wall;
 112
 113 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 114
 115 middle_bot_z = top_z - top_thick_middle;
 116
 117 bayo_entry = bayo_behind / 3.0;
 118 bayo_top_z = bayo_behind + bayo_gap;
 119
 120 rivet_entry_width = rivet_width + side_rivet_gap;
 121
 122 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 123
 124 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 125 handling_angle = 45;
 126
 127 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 128 sm_outer_rad = sm_inner_rad + sm_main_thick;
 129
 130 smc_pos = [ 0, sm_inner_rad, 0 ];
 131
 132 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 133 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 134
 135 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 136 smc_max_y = smc_bolt_y + sm_bolt_y_over
 137   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 138 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 139   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 140
 141 catch_cr = catch_knob_dia/2 + catch_stem_beside_gap;
 142 catch_strap_width = sm_main_width;
 143 catch_stem_end_h = catch_stem_h;
 144 catch_pin_width = rivet_entry_width - catch_pin_gap;
 145
 146 cppy6 = -catch_strap_width/2;
 147 cppB = [ catch_pin_width/2,
 148          cppy6
 149          + catch_stem_below_gap
 150          + catch_pin_height
 151          + catch_knob_dia/2 ];
 152 cpp0 = [ 0,
 153          cppB[1]
 154          + catch_knob_dia
 155          + catch_knob_above_gap ];
 156 cpp12 = cpp0 + [1,0] * (catch_pin_height * catch_hook_slope);
 157 cpp1 = cpp0 + [0,1] * catch_pin_height;
 158 cpp2 = cpp1 + [1,0] * catch_pin_width;
 159 cpp4 = cpp0 + [0,-1] * catch_stem_end_h;
 160 cpp3 = [ cpp2[0], cpp4[1] ];
 161 cpp5 = [ cpp0[0] - catch_stem_len,
 162          -catch_stem_h ];
 163 cpp6 = [ cpp5[0], catch_cr ];
 164 cpp7 = cppB + [1,-1] * catch_knob_dia/2
 165             + [ catch_stem_beside_gap, -catch_stem_below_gap ]
 166             + [ 0, -catch_pin_height ]
 167             + [-1,1] * catch_cr;
 168 cpp11 = cpp7 + [1,0] * catch_cr;
 169 cpp10 = [ cpp11[0], 0 - catch_cr ];
 170 cpp8 = cpp10 + [1,0] * catch_cr;
 171 cpp9 = cpp8 + [0,1] * catch_cr;
 172 cppC = cpp8 + [1,1] * catch_cr;
 173 cppA = [ cpp5[0] - catch_cr, 0 ];
 174 cppD = cppC + [0,-1] * catch_strap_width;
 175 cppE = [ cppA[0], cppD[1] ];
 176
 177 $fs= coarse ? 2.5 : 0.5;
 178 $fa= coarse ? 5 : 1;
 179
 180 include <poster-tube-lid-parametric.scad>
 181
 182 // bayonet definition
 183
 184 bayo_a = [ bayo_entry_x, 0 ];
 185 bayo_p = [ 0, bayo_entry_z ];
 186 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 187 bayo_m = [ bayo_inramp_x, bayo_behind ];
 188 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 189 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 190 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 191 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 192 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 193 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 194
 195 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 196 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 197 bayo_c = bayo_d + [0,-5];
 198 bayo_b = bayo_a + [0,-5];
 199
 200 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 201
 202 bayo_polygon = [ bayo_a,
 203                  bayo_b,
 204                  bayo_c,
 205                  bayo_d,
 206                  bayo_e,
 207                  bayo_f,
 208                  bayo_g,
 209                  bayo_h,
 210                  bayo_i,
 211                  bayo_j,
 212                  bayo_k,
 213                  bayo_l,
 214                  bayo_m,
 215                  bayo_n,
 216                  bayo_p ];
 217
 218 echo(bayo_polygon);
 219
 220 module MainProfile(){
 221   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 222   difference(){
 223     union(){
 224       translate(main_cnr_pos){
 225         intersection(){
 226           difference(){
 227             circle(r = main_cnr);
 228             circle(r = main_cnr * 0.5);
 229           }
 230           square([10,10]);
 231         }
 232       }
 233       polygon([[ -top_middle_dr,        middle_bot_z      ],
 234                [ -top_middle_dr,        top_z             ],
 235                [ main_cnr_pos[0],       top_z             ],
 236                [ side_thick,            main_cnr_pos[1]   ],
 237                [ side_thick,            -side_height      ],
 238                [ side_taper,            -side_height      ],
 239                [ 0,                     -rivet_posn       ],
 240                [ 0,                     by_oring_z        ],
 241                [ -oring_x_rad,          by_oring_z        ],
 242                ],
 243               convexity=10);
 244     }
 245     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 246       hull(){
 247       translate([ 0, oring_y_rad ])
 248         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 249         circle(oring_thick/2);
 250       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 251         circle(oring_thick/2);
 252     }
 253   }
 254 }
 255
 256 module StrapHoopProfile(){
 257   circle(r = strap_hoop_thick/2);
 258 }
 259
 260 module StrapHoop(){ ////toplevel
 261   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 262   extralen = strap_hoop_thick * 5;
 263
 264   intersection(){
 265     rotate([strap_hoop_elevation, 0,0]){
 266       for (x= [ -1, +1 ] * bigrad) {
 267         translate([x, -extralen, 0])
 268           rotate([-90,0,0])
 269           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 270                          convexity=10)
 271           StrapHoopProfile();
 272       }
 273       translate([0, strap_hoop_strlen, 0]){
 274         intersection(){
 275           rotate_extrude(convexity=10)
 276             translate([bigrad, 0,0])
 277             StrapHoopProfile();
 278           translate([0,50,0])
 279             cube([100,100,100], center=true);
 280         }
 281       }
 282     }
 283     translate([0, 50, 0])
 284       cube(100, center=true);
 285   }
 286 }
 287
 288 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 289   // nom_rad > real_rad
 290   rotate([0,0, atan2(offset, nom_rad) ]){
 291     intersection(){
 292       translate([-offset, -10, 0])
 293         rotate([90,0,0])
 294         linear_extrude(height= nom_rad*2)
 295         children(0);
 296       translate([0,0, -25])
 297         cylinder(h=50, r= real_rad);
 298       translate([0,0, -25])
 299         linear_extrude(height= 50)
 300         polygon([ [ 0,0 ],
 301                   [ -slice_size, -real_rad*2 ],
 302                   [ +slice_size, -real_rad*2 ] ]);
 303     }
 304   }
 305 }
 306
 307 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 308   offs = [ for (i=[ x_min :
 309                     slice_size :
 310                     x_max + slice_size ]) i ];
 311   echo (offs);
 312   for (off=offs)
 313     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 314     children(0);
 315 }
 316
 317 module BayonetCutout(){
 318   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 319                 main_dia/2 + side_thick,
 320                 main_dia/2 + rivet_tall)
 321     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 322     polygon(bayo_polygon, convexity=10);
 323 }
 324
 325 module ProfilesDemo(){ ////toplevel
 326   translate([-10,0]) MainProfile();
 327   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 328 }
 329
 330 module LimitForHandling(){ ////toplevel
 331   hull() for (r=[0,180])
 332     rotate([0,0,r]) {
 333       for (rs=[-1,+1]) {
 334         for (xd=[0,1]) {
 335           rotate([0,0, rs * handling_angle/2]) {
 336             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 337                        main_dia/2 + side_thick - main_cnr,
 338                        top_z - main_cnr]) {
 339               mirror([0,0,1])
 340                 cylinder(r= main_cnr, h=50);
 341               sphere(main_cnr);
 342             }
 343           }
 344         }
 345       }
 346     }
 347   hull() rotate_extrude(){
 348     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 349       circle(r = main_cnr);
 350       mirror([0,1]) square([ main_cnr, 50 ]);
 351     }
 352   }
 353   //cylinder(r= handling_dia/2, h=20);
 354 }
 355
 356 module Cover(){ ////toplevel
 357   render() difference(){
 358     intersection(){
 359       union(){
 360         rotate_extrude(convexity=10)
 361           translate([main_dia/2, 0])
 362           MainProfile();
 363         translate([0,0, middle_bot_z])
 364           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 365       }
 366       LimitForHandling();
 367     }
 368     for (r=[0,180]){
 369       rotate([0,0, r])
 370         translate([0,0, -side_height])
 371         BayonetCutout();
 372       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 373         translate([0,
 374                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 375                    oring_y_rad * 1.5])
 376         rotate([-oring_rm_angle, 0, 0])
 377         mirror([0,0,1])
 378         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 379     }
 380     for (r=[0 : 60 : 179]) {
 381       rotate([0,0, r]) {
 382         height = top_thick_middle - brace_above_below*2;
 383         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 384         cube(center=true, [ oring_bore - brace_end_shorter,
 385                             brace_hole_width, height ]);
 386       }
 387     }
 388   }
 389   for (r=[0,180])
 390     rotate([0,0,r])
 391       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 392                  -implheadcup_large_dia * .0,
 393                  middle_bot_z + 0.1])
 394       ImplHeadCup();
 395 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 396 //    translate([handling_dia/2, 0, -side_height])
 397 //    rotate([0,180,0]) rotate([0,0,90])
 398 //    StrapHoop();
 399 }
 400
 401 module SavingHole(){
 402   translate([0,0, -10])
 403     cylinder(r= main_dia/2 - jig_rim, h=20);
 404 }
 405
 406 module Jig(){ ////toplevel
 407   difference(){
 408     union(){
 409       translate([0,0, -side_height]){
 410         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 411       }
 412       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 413         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 414     }
 415     translate([0,0, -side_height-1])
 416       cylinder(r= main_dia/2, h= side_height + 1);
 417     SavingHole();
 418     translate([0,0, -rivet_posn])
 419       rotate([90, 0,0])
 420       translate([0,0, -100])
 421       cylinder(r= jig_hole_dia/2, h = 200);
 422   }
 423 }
 424
 425 module CoverTest2(){ ////toplevel
 426   difference(){
 427     Cover();
 428     SavingHole();
 429   }
 430 }
 431
 432 module CoverTest1(){ ////toplevel
 433   difference(){
 434     CoverTest2();
 435     difference(){
 436       for (r= [ 40, 147 ]){
 437         rotate([0,0, r]){
 438           translate([0,0, -10]) {
 439             cube([ main_dia*3, main_dia * .53, 18], center=true);
 440           }
 441         }
 442       }
 443 //      translate([ 50, 0, 0 ])
 444 //      cube([ 100,
 445 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 446 //             100 ],
 447 //           center=true);
 448     }
 449   }
 450 }
 451
 452 module ImplHeadCupTest(){ ////toplevel
 453   for (r=[0,180])
 454     rotate([0,0,r])
 455       translate([-17,0,0])
 456       ImplHeadCup();
 457 }
 458
 459 module StrapMountBolt(l_delta){ ///toplevel
 460   // positioned relative to smc_pos
 461   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 462              smc_bolt_y,
 463              sm_main_width/2]){
 464     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 465       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 466     }
 467     translate([ -sm_bolt_shaft/2, 0,0 ])
 468       rotate([0,-90,0])
 469       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 470                h=smc_bolt_nut_eff_thick + l_delta);
 471     translate([ sm_bolt_shaft/2, 0,0 ])
 472       rotate([0,90,0])
 473       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 474   }
 475 }
 476
 477 module StrapMountProtrusion(half_x, max_y, cnr){
 478   translate(smc_pos){
 479     linear_extrude(height=sm_main_width, convexity=10){
 480       hull(){
 481         for (m = [0,1]) mirror([m,0,0]) {
 482           translate([-(half_x - cnr), max_y - cnr])
 483             circle(r=cnr);
 484           translate([-half_x, -sm_inner_rad])
 485             square([1,1]);
 486         }
 487       }
 488     }
 489   }
 490 }
 491
 492 module StrapMount(){ ////toplevel
 493   difference(){
 494     union(){
 495       cylinder(r=sm_outer_rad, h=sm_main_width);
 496       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 497                            smc_max_y,
 498                            sm_closure_cnr);
 499       rotate([0,0,180]){
 500         StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
 501                              strap_hoop_thick,
 502                              sm_closure_cnr);
 503         translate(smc_pos +
 504                   [0,0, sm_main_width] +
 505                   strap_hoop_thick * [ 0, 0.5, -1.0 ])
 506           StrapHoop();
 507       }
 508     }
 509     translate([0,0,-1])
 510       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 511     translate(smc_pos)
 512       StrapMountBolt(10);
 513     translate(smc_pos)
 514       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 515   }
 516 }
 517
 518 module CatchCoreProfile(){ ////toplevel
 519   hull(){
 520     translate(cppB) circle(r= catch_knob_dia/2);
 521     polygon([cpp4,
 522              cppB,
 523              cpp3]);
 524   }
 525   translate(cpp8)
 526     circle(catch_cr);
 527   polygon([
 528            cpp4,
 529            cppB,
 530            cpp3,
 531            cpp2,
 532            cpp1,
 533            cpp12,
 534            ]);
 535   difference(){
 536     polygon([ cpp4,
 537               cpp3,
 538               cpp12,
 539               cppA,
 540               cppE,
 541               cppD,
 542               cppC,
 543               cpp9,
 544               cpp10,
 545               cpp11,
 546               cpp7,
 547               cpp5,
 548               ], convexity=10);
 549     hull(){
 550       translate(cpp7) circle(r= catch_cr);
 551       polygon([ cpp7,
 552                 cpp5,
 553                 cpp11 ]);
 554     }
 555     hull(){
 556       translate(cpp6) circle(catch_cr);
 557       polygon([ cppA,
 558                 cpp0,
 559                 cpp1 ]);
 560     }
 561   }
 562 }
 563
 564 //ProfilesDemo();
 565 //BayonetCutout();
 566 //MainProfile();
 567 //Cover();
 568 //Jig();
 569 //CoverTest();