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 // calculated
  79
  80 TAU = PI*2;
  81
  82 bayo_entry_x = bayo_entry;
  83 bayo_entry_z = bayo_entry;
  84 bayo_inramp_x = bayo_entry;
  85 bayo_inramp_z = bayo_entry;
  86
  87 oring_mid_dia = oring_bore + oring_thick;
  88 oring_outer_dia = oring_mid_dia + oring_thick;
  89
  90 oring_oblate = (1 - oring_compress);
  91
  92 oring_y_rad = oring_thick/2 * oring_oblate;
  93 oring_x_rad = oring_thick/2 / oring_oblate;
  94
  95 by_oring_z = oring_y_rad * (1 + cos(oring_upper_embed_angle));
  96
  97 side_height = rivet_posn + bayo_behind + rivet_thick/2;
  98 side_thick = rivet_tall + over_rivet_wall;
  99
 100 top_z = top_thick_by_oring + oring_y_rad + by_oring_z;
 101
 102 middle_bot_z = top_z - top_thick_middle;
 103
 104 bayo_entry = bayo_behind / 3.0;
 105 bayo_top_z = bayo_behind + bayo_gap;
 106
 107 rivet_entry_width = rivet_width + side_rivet_gap;
 108
 109 jig_mark_rad = jig_mark + main_dia/2 + jig_thick;
 110
 111 handling_dia = oring_bore + oring_thick*2 + min_wall*2;
 112 handling_angle = 45;
 113
 114 sm_inner_rad = (sm_inner_circum + sm_bolt_tighten_allow/2) / TAU;
 115 sm_outer_rad = sm_inner_rad + sm_main_thick;
 116
 117 smc_pos = [ 0, sm_inner_rad, 0 ];
 118
 119 smc_bolt_nut_dia = sm_bolt_nut_width / cos(30);
 120 smc_bolt_nut_eff_thick = sm_bolt_nut_thick + sm_bolt_tighten_allow;
 121
 122 smc_bolt_y = sm_bolt_dia/2 + sm_bolt_y_clear;
 123 smc_max_y = smc_bolt_y + sm_bolt_y_over
 124   + max(sm_bolt_head_dia/2, smc_bolt_nut_dia/2);
 125 smc_cnr_c_x = sm_bolt_shaft/2 - sm_closure_cnr
 126   + sm_bolt_head_thick/2 + smc_bolt_nut_eff_thick/2;
 127
 128 $fs= coarse ? 2.5 : 0.5;
 129 $fa= coarse ? 5 : 1;
 130
 131 include <poster-tube-lid-parametric.scad>
 132
 133 // bayonet definition
 134
 135 bayo_a = [ bayo_entry_x, 0 ];
 136 bayo_p = [ 0, bayo_entry_z ];
 137 bayo_n = [ 0, bayo_behind-bayo_inramp_z ];
 138 bayo_m = [ bayo_inramp_x, bayo_behind ];
 139 bayo_l = bayo_m + bayo_interf * [ 1/bayo_interf_slope,  1 ];
 140 bayo_k = bayo_l + [ bayo_interf_width, 0 ];
 141 bayo_j = bayo_k + bayo_interf * [ 1/bayo_interf_slope, -1 ];
 142 bayo_i = bayo_j + [ rivet_width + inside_rivet_gap, 0 ];
 143 bayo_h = [ bayo_i[0], bayo_behind + bayo_gap + bayo_interf ];
 144 bayo_g = [ bayo_m[0] - rivet_width, bayo_h[1] ];
 145
 146 bayo_e = [-bayo_p[0], bayo_p[1]] - [rivet_entry_width,0];
 147 bayo_d = [-bayo_a[0], bayo_a[1]] - [rivet_entry_width,0];
 148 bayo_c = bayo_d + [0,-5];
 149 bayo_b = bayo_a + [0,-5];
 150
 151 bayo_f = [ bayo_e[0], bayo_g[1] + (bayo_e[0] - bayo_g[0]) ];
 152
 153 bayo_polygon = [ bayo_a,
 154                  bayo_b,
 155                  bayo_c,
 156                  bayo_d,
 157                  bayo_e,
 158                  bayo_f,
 159                  bayo_g,
 160                  bayo_h,
 161                  bayo_i,
 162                  bayo_j,
 163                  bayo_k,
 164                  bayo_l,
 165                  bayo_m,
 166                  bayo_n,
 167                  bayo_p ];
 168
 169 echo(bayo_polygon);
 170
 171 module MainProfile(){
 172   main_cnr_pos = [ side_thick, top_z ] - [1,1]*main_cnr;
 173   difference(){
 174     union(){
 175       translate(main_cnr_pos){
 176         intersection(){
 177           difference(){
 178             circle(r = main_cnr);
 179             circle(r = main_cnr * 0.5);
 180           }
 181           square([10,10]);
 182         }
 183       }
 184       polygon([[ -top_middle_dr,        middle_bot_z      ],
 185                [ -top_middle_dr,        top_z             ],
 186                [ main_cnr_pos[0],       top_z             ],
 187                [ side_thick,            main_cnr_pos[1]   ],
 188                [ side_thick,            -side_height      ],
 189                [ side_taper,            -side_height      ],
 190                [ 0,                     -rivet_posn       ],
 191                [ 0,                     by_oring_z        ],
 192                [ -oring_x_rad,          by_oring_z        ],
 193                ],
 194               convexity=10);
 195     }
 196     translate([ oring_mid_dia/2 - main_dia/2, 0 ])
 197       hull(){
 198       translate([ 0, oring_y_rad ])
 199         scale([ 1/oring_oblate * (oring_compress_more+1) , oring_oblate ])
 200         circle(oring_thick/2);
 201       translate([ 0, oring_y_rad*2 - oring_thick/2 ])
 202         circle(oring_thick/2);
 203     }
 204   }
 205 }
 206
 207 module StrapHoopProfile(){
 208   circle(r = strap_hoop_thick/2);
 209 }
 210
 211 module StrapHoop(){ ////toplevel
 212   bigrad = strap_hoop_inside/2 + strap_hoop_thick/2;
 213   extralen = strap_hoop_thick * 5;
 214
 215   intersection(){
 216     rotate([strap_hoop_elevation, 0,0]){
 217       for (x= [ -1, +1 ] * bigrad) {
 218         translate([x, -extralen, 0])
 219           rotate([-90,0,0])
 220           linear_extrude(height= extralen + strap_hoop_strlen + 0.1,
 221                          convexity=10)
 222           StrapHoopProfile();
 223       }
 224       translate([0, strap_hoop_strlen, 0]){
 225         intersection(){
 226           rotate_extrude(convexity=10)
 227             translate([bigrad, 0,0])
 228             StrapHoopProfile();
 229           translate([0,50,0])
 230             cube([100,100,100], center=true);
 231         }
 232       }
 233     }
 234     translate([0, 50, 0])
 235       cube(100, center=true);
 236   }
 237 }
 238
 239 module RotateProjectSlice(offset, slice_size, nom_rad, real_rad){
 240   // nom_rad > real_rad
 241   rotate([0,0, atan2(offset, nom_rad) ]){
 242     intersection(){
 243       translate([-offset, -10, 0])
 244         rotate([90,0,0])
 245         linear_extrude(height= nom_rad*2)
 246         children(0);
 247       translate([0,0, -25])
 248         cylinder(h=50, r= real_rad);
 249       translate([0,0, -25])
 250         linear_extrude(height= 50)
 251         polygon([ [ 0,0 ],
 252                   [ -slice_size, -real_rad*2 ],
 253                   [ +slice_size, -real_rad*2 ] ]);
 254     }
 255   }
 256 }
 257
 258 module RotateProject(x_min, x_max, slice_size, nom_rad, real_rad){
 259   offs = [ for (i=[ x_min :
 260                     slice_size :
 261                     x_max + slice_size ]) i ];
 262   echo (offs);
 263   for (off=offs)
 264     RotateProjectSlice(off, slice_size, nom_rad, real_rad)
 265     children(0);
 266 }
 267
 268 module BayonetCutout(){
 269   RotateProject(bayo_c[0], bayo_i[0], bayo_slice_size,
 270                 main_dia/2 + side_thick,
 271                 main_dia/2 + rivet_tall)
 272     translate([-0.5 * (bayo_a[0] + bayo_d[0]), 0])
 273     polygon(bayo_polygon, convexity=10);
 274 }
 275
 276 module ProfilesDemo(){ ////toplevel
 277   translate([-10,0]) MainProfile();
 278   translate([+10, -side_height]) polygon(bayo_polygon, convexity=10);
 279 }
 280
 281 module LimitForHandling(){ ////toplevel
 282   hull() for (r=[0,180])
 283     rotate([0,0,r]) {
 284       for (rs=[-1,+1]) {
 285         for (xd=[0,1]) {
 286           rotate([0,0, rs * handling_angle/2]) {
 287             translate([rs * xd * main_dia/2 * tan(handling_angle/2),
 288                        main_dia/2 + side_thick - main_cnr,
 289                        top_z - main_cnr]) {
 290               mirror([0,0,1])
 291                 cylinder(r= main_cnr, h=50);
 292               sphere(main_cnr);
 293             }
 294           }
 295         }
 296       }
 297     }
 298   hull() rotate_extrude(){
 299     translate([ handling_dia/2 - main_cnr, top_z - main_cnr ]) {
 300       circle(r = main_cnr);
 301       mirror([0,1]) square([ main_cnr, 50 ]);
 302     }
 303   }
 304   //cylinder(r= handling_dia/2, h=20);
 305 }
 306
 307 module Cover(){ ////toplevel
 308   render() difference(){
 309     intersection(){
 310       union(){
 311         rotate_extrude(convexity=10)
 312           translate([main_dia/2, 0])
 313           MainProfile();
 314         translate([0,0, middle_bot_z])
 315           cylinder(h= top_thick_middle, r = main_dia/2 - top_middle_dr + 1);
 316       }
 317       LimitForHandling();
 318     }
 319     for (r=[0,180]){
 320       rotate([0,0, r])
 321         translate([0,0, -side_height])
 322         BayonetCutout();
 323       rotate([0,0, r + asin((-oring_rm_beside) / (main_dia/2))])
 324         translate([0,
 325                    oring_mid_dia/2 + oring_thick/4 * oring_rm_scale,
 326                    oring_y_rad * 1.5])
 327         rotate([-oring_rm_angle, 0, 0])
 328         mirror([0,0,1])
 329         cylinder(r = oring_thick/4 * oring_rm_scale, h=20);
 330     }
 331     for (r=[0 : 60 : 179]) {
 332       rotate([0,0, r]) {
 333         height = top_thick_middle - brace_above_below*2;
 334         translate([0,0, middle_bot_z + brace_above_below + height/2 ])
 335         cube(center=true, [ oring_bore - brace_end_shorter,
 336                             brace_hole_width, height ]);
 337       }
 338     }
 339   }
 340   for (r=[0,180])
 341     rotate([0,0,r])
 342       translate([-implheadcup_large_dia * .5 - implheadcup_thick/2,
 343                  -implheadcup_large_dia * .0,
 344                  middle_bot_z + 0.1])
 345       ImplHeadCup();
 346 //  translate(strap_hoop_thick * [-0.5, 0, +1])
 347 //    translate([handling_dia/2, 0, -side_height])
 348 //    rotate([0,180,0]) rotate([0,0,90])
 349 //    StrapHoop();
 350 }
 351
 352 module SavingHole(){
 353   translate([0,0, -10])
 354     cylinder(r= main_dia/2 - jig_rim, h=20);
 355 }
 356
 357 module Jig(){ ////toplevel
 358   difference(){
 359     union(){
 360       translate([0,0, -side_height]){
 361         cylinder(r= main_dia/2 + jig_thick, h= side_height + jig_thick);
 362       }
 363       translate([-jig_mark_rad, 0, jig_thick - jig_mark])
 364         cube([jig_mark_rad*2, jig_mark, jig_mark]);
 365     }
 366     translate([0,0, -side_height-1])
 367       cylinder(r= main_dia/2, h= side_height + 1);
 368     SavingHole();
 369     translate([0,0, -rivet_posn])
 370       rotate([90, 0,0])
 371       translate([0,0, -100])
 372       cylinder(r= jig_hole_dia/2, h = 200);
 373   }
 374 }
 375
 376 module CoverTest2(){ ////toplevel
 377   difference(){
 378     Cover();
 379     SavingHole();
 380   }
 381 }
 382
 383 module CoverTest1(){ ////toplevel
 384   difference(){
 385     CoverTest2();
 386     difference(){
 387       for (r= [ 40, 147 ]){
 388         rotate([0,0, r]){
 389           translate([0,0, -10]) {
 390             cube([ main_dia*3, main_dia * .53, 18], center=true);
 391           }
 392         }
 393       }
 394 //      translate([ 50, 0, 0 ])
 395 //      cube([ 100,
 396 //             strap_hoop_inside + strap_hoop_thick*2 + 1,
 397 //             100 ],
 398 //           center=true);
 399     }
 400   }
 401 }
 402
 403 module ImplHeadCupTest(){ ////toplevel
 404   for (r=[0,180])
 405     rotate([0,0,r])
 406       translate([-17,0,0])
 407       ImplHeadCup();
 408 }
 409
 410 module StrapMountBolt(l_delta){ ///toplevel
 411   // positioned relative to smc_pos
 412   translate([(smc_bolt_nut_eff_thick - sm_bolt_head_thick)/2,
 413              smc_bolt_y,
 414              sm_main_width/2]){
 415     translate([ -sm_bolt_shaft/2-1, 0,0 ]){
 416       rotate([0,90,0]) cylinder(r= sm_bolt_dia/2, h= sm_bolt_shaft+2);
 417     }
 418     translate([ -sm_bolt_shaft/2, 0,0 ])
 419       rotate([0,-90,0])
 420       cylinder($fn=6, r=smc_bolt_nut_dia/2,
 421                h=smc_bolt_nut_eff_thick + l_delta);
 422     translate([ sm_bolt_shaft/2, 0,0 ])
 423       rotate([0,90,0])
 424       cylinder(r=sm_bolt_head_dia/2, h=sm_bolt_head_thick + l_delta);
 425   }
 426 }
 427
 428 module StrapMountProtrusion(half_x, max_y, cnr){
 429   translate(smc_pos){
 430     linear_extrude(height=sm_main_width, convexity=10){
 431       hull(){
 432         for (m = [0,1]) mirror([m,0,0]) {
 433           translate([-(half_x - cnr), max_y - cnr])
 434             circle(r=cnr);
 435           translate([-half_x, -sm_inner_rad])
 436             square([1,1]);
 437         }
 438       }
 439     }
 440   }
 441 }
 442
 443 module StrapMount(){ ////toplevel
 444   difference(){
 445     union(){
 446       cylinder(r=sm_outer_rad, h=sm_main_width);
 447       StrapMountProtrusion(smc_cnr_c_x + sm_closure_cnr,
 448                            smc_max_y,
 449                            sm_closure_cnr);
 450       rotate([0,0,180]){
 451         StrapMountProtrusion(strap_hoop_inside/2 + strap_hoop_thick,
 452                              strap_hoop_thick,
 453                              sm_closure_cnr);
 454         translate(smc_pos +
 455                   [0,0, sm_main_width] +
 456                   strap_hoop_thick * [ 0, 0.5, -1.0 ])
 457           StrapHoop();
 458       }
 459     }
 460     translate([0,0,-1])
 461       cylinder(r=sm_inner_rad, h=sm_main_width+2);
 462     translate(smc_pos)
 463       StrapMountBolt(10);
 464     translate(smc_pos)
 465       cube([ sm_bolt_tighten_allow, 40,100 ], center=true);
 466   }
 467 }
 468
 469 //ProfilesDemo();
 470 //BayonetCutout();
 471 //MainProfile();
 472 //Cover();
 473 //Jig();
 474 //CoverTest();