scaffold-clamp-cleat: sort out toplevels

[reprap-play.git] / scaffold-clamp-common.scad

diff --git a/scaffold-clamp-common.scad b/scaffold-clamp-common.scad
index 60d603aba749ff93e7ece5124b6c9ea8527febc6..c16fbd8bce6dcb593b5101b543908aeb3d8af8f1 100644 (file)
--- a/scaffold-clamp-common.scad
+++ b/scaffold-clamp-common.scad
@@ -10,7 +10,7 @@ pin_gap = 1.5; // around
 
 smooth_r = 15;
 
-bolt_dia = 5 + 0.75;
+bolt_dia = 5;
 bolt_flat = 10 + 1;
 
 nbolts = 2;
@@ -22,10 +22,22 @@ hinge_z_gap = 1;
 
 hinge_units = 4;
 
+bolt_gap = 1.0; // total, on both sides
+
 // ---------- vhook ----------
 
 vhook_th = 14;
 
+// ---------- cleat ----------
+
+cleat_frames = 10;
+cleat_curve_r = 200;
+cleat_horn_l = 40;
+cleat_horn_d_min = [10, 12];
+cleat_horn_d_max = [12, 14];
+cleat_height = 25;
+cleat_stem_l = 20;
+
 // ---------- hhook ----------
 
 hhook_inside = 40;
@@ -37,12 +49,16 @@ hhook_l = 40;
 pin_head_th = th/2;
 pin_dia = th;
 pin_hole_dia = pin_dia/2;
-pin_tail = pin_hole_dia + pin_head_th*3;
+pin_tail = pin_hole_dia + pin_head_th + hinge_z_gap*3;
 
 // ========== calculated ==========
 
+TAU = PI*2;
+
 hole_dia = th + pin_gap;
 
+bolt_hole_r = (bolt_dia + bolt_gap)/2;
+
 main_r = tube_dia/2 + th;
 
 hinge_gap = pin_gap;
@@ -51,7 +67,7 @@ hinge_o_r = 0.5 * hole_dia + th;
 
 hinge_x = -0.5 * tube_dia - hinge_o_r;
 bolt_x = 0.5 * tube_dia + th + bolt_flat * 0.5;
-max_x = bolt_x + max(0.5 + bolt_dia + th, 0.5 * bolt_flat/2);
+max_x = bolt_x + max(bolt_hole_r + th, 0.5 * bolt_flat/2);
 
 flats_y = open_gap/2 + th;
 
@@ -75,6 +91,14 @@ vhook_y0 = -max(main_r, (tube_dia/2 + vhook_th));
 vhook_ctr = vhook_y0 - vhook_inside/2;
 vhook_outer_dia = vhook_inside + vhook_th*2;
 
+// calculated - cleat
+
+cleat_horn_tl = cleat_horn_l + cleat_stem_l/2;
+
+vcleat_dz = max(0,
+               cleat_horn_tl + cleat_horn_d_min[0]/2 - total_z/2
+               );
+
 // calculated - hhook
 
 hhook_outer_dia = hhook_inside + hhook_th*2;
@@ -163,7 +187,7 @@ module HalfClampX(flatten=false){
       translate([ bolt_x, 0, min_z + (j + 0.5) * bolt_stride ]) {
        translate([0, -tube_dia/2, 0])
          rotate([-90,0,0])
-         cylinder(r= bolt_dia/2, h= tube_dia);
+         cylinder(r= bolt_hole_r, h= tube_dia);
        translate([0, -flats_y, 0])
          rotate([90,0,0])
          cylinder(r= bolt_flat/2, h= tube_dia/2);
@@ -191,7 +215,7 @@ module VHookHookMain(outer=false){ ////toplevel
     }
 }
 
-module VHookPartA(){ ////toplevel
+module VHookA(){ ////toplevel
   DummyA();
 
   translate([0, vhook_ctr, 0]){
@@ -232,6 +256,80 @@ module VHookPlanDemo(){
     }
 }
 
+// ---------- cleat ----------
+
+function cleat_frame_theta(s) = s * cleat_horn_tl / cleat_curve_r * 360/TAU;
+function cleat_frame_z(s) = cleat_curve_r * (1 - cos(cleat_frame_theta(s)));
+function cleat_frame_x(s) = cleat_curve_r * sin(cleat_frame_theta(s));
+function cleat_frame_r(s) = ( cleat_horn_d_min * s +
+                             cleat_horn_d_max * (1-s) ) * 0.5;
+
+module CleatFrameSphere(r) {
+  scale([1, r[1]/r[0], 1])
+    sphere(r= r[0]);
+}
+
+module CleatFrame(s) {
+  r = cleat_frame_r(s);
+  translate([cleat_frame_x(s), 0, cleat_frame_z(s)])
+    rotate([0, 90, 0])
+    CleatFrameSphere(r);
+}
+
+
+module CleatHorn(){
+  for (si=[0 : cleat_frames-2]) {
+    s0 = si / (cleat_frames-1);
+    s1 = (si+1) / (cleat_frames-1);
+    hull(){
+      CleatFrame(s0);
+      CleatFrame(s1);
+    }
+  }
+}
+
+module CleatBase(){
+  frames = cleat_frames/2;
+  se = cleat_stem_l/2 / cleat_horn_tl;
+  r = cleat_frame_r(se);
+
+  hull(){
+    for (s = [-se, se]) {
+      for (z= [-(cleat_height + tube_dia/2),
+              cleat_frame_z(s)]) {
+       translate([cleat_frame_x(s), 0, z])
+         linear_extrude(height=0.1)
+         scale([1, r[1]/r[0]])
+         circle(r=r[0]);
+      }
+    }
+  }
+}
+
+module VCleat(){
+  translate([0,0, vcleat_dz]){
+    difference(){
+      translate([0, -(main_r + cleat_height), 0]) {
+       rotate([0, -90, 90]) {
+         CleatBase();
+         for (m=[0,1]) {
+           mirror([m,0,0]) {
+             CleatHorn();
+           }
+         }
+       }
+      }
+      linextr(-cleat_stem_l, +cleat_stem_l)
+       circle(r = tube_dia/2 + 0.1);
+    }
+  }
+}
+
+module VCleatA(){ ////toplevel
+  DummyA();
+  VCleat();
+}
+
 // ---------- hhook ----------
 
 module HHookHookPlan(){
@@ -252,7 +350,7 @@ module HHookHookPlan(){
   }
 }
 
-module HHookPartA(){ ////toplevel
+module HHookA(){ ////toplevel
   DummyA();
   linextr(min_z, max_z) {
     HHookHookPlan();
@@ -272,7 +370,7 @@ module PinSitu(){ ////toplevel
       translate([0,0, -pin_head_th])
        cylinder(r= pin_dia/2, h = total_z + pin_head_th + pin_tail);
       mirror([0,0,1])
-       cylinder(r= hinge_o_r, h = pin_head_th);
+       cylinder(r= hinge_o_r - pin_gap, h = pin_head_th);
     }
     translate([0,0, total_z + pin_tail/2])
       rotate([0,90,0])
@@ -284,7 +382,7 @@ module PinSitu(){ ////toplevel
 }
 
 module Pin(){ ////toplevel
-  rotate([0,0,0]) {
+  rotate([0,90,0]) {
     PinSitu();
   }
 }
@@ -316,9 +414,20 @@ module PlanDemo(){ ////toplevel
 //  translate([max_x - hinge_x + 20, 0]) color("blue") MainPlanA();
 }
 
+module DemoA(){ DummyA(); }
+
 module Demo(){ ////toplevel
   color("red") rotate([180,0,0]) GeneralB();
-  color("blue") DummyA();
+  color("blue") DemoA();
+  color("orange") translate([hinge_x, 0, min_z - hinge_z_gap])
+    rotate([0,0,180]) PinSitu();
+}
+
+module DemoPair(){ ////toplevel
+  color("red") rotate([180,0,0]) DemoA();
+  color("blue") DemoA();
+  color("orange") translate([hinge_x, 0, min_z - hinge_z_gap])
+    rotate([0,0,180]) PinSitu();
 }
 
 //PlanDemo();