X-Git-Url: https://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=scaffold-clamp-common.scad;h=d2640b6a9a08ef3e8b75c0467896634de7a9da05;hp=513273ddb4cecfe6c1ea1a320107bbd97f19b363;hb=HEAD;hpb=d7b0d240a8d8cf34c040e32dd7fcbc146a9bcc28 diff --git a/scaffold-clamp-common.scad b/scaffold-clamp-common.scad index 513273d..79ed1da 100644 --- a/scaffold-clamp-common.scad +++ b/scaffold-clamp-common.scad @@ -10,26 +10,74 @@ pin_gap = 1.5; // around smooth_r = 15; -bolt_dia = 5 + 0.75; +bolt_dia = 5; bolt_flat = 10 + 1; +nbolts = 2; + open_gap = 10; hinge_unit = 10; -uhinge_z_gap = 1; +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; + +cleat_overlap = (1-cos(60)); + +// ---------- hhook ---------- -// calculated +hhook_inside = 40; +hhook_th = 4; +hhook_l = 40; +// ---------- linear bracket ---------- + +linear_bracket_h = 50; +linear_bracket_l = 100; +linear_bracket_t = 15; +linear_bracket_hole_offset = 20; +linear_bracket_hole_dia = 5 + 1.00; + +// ========== defaults ========== + +pin_head_th = th/2; pin_dia = th; +pin_hole_dia = pin_dia/2; +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; 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; @@ -41,6 +89,36 @@ max_z = +total_z/2; pin_flatten = pin_dia/2 * (1 - cos(45)); +bolt_stride = total_z / nbolts; + +// calculated - vhook + +vhook_inside = 15; + +vhook_theta = atan2( smooth_r, main_r ); + +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 + - cleat_horn_d_min[0]/2 * cleat_overlap + - total_z/2 + ); + +// calculated - hhook + +hhook_outer_dia = hhook_inside + hhook_th*2; + +hhook_ctr = -max(main_r + hhook_inside/2, + tube_dia/2 + hhook_outer_dia/2); + $fa = 3; $fs = 0.1; @@ -49,7 +127,7 @@ module SmoothPlan(){ } module TubePlan(){ circle(r = tube_dia/2); } -module MainCirclePlan(){ circle(r = tube_dia/2 + th); } +module MainCirclePlan(){ circle(r = main_r); } module PlanWeldMainCircle(){ intersection(){ @@ -109,38 +187,259 @@ module MainPlanB(flatten){ } } +module HalfClampXPositive(flatten=false){ + translate([0,0, min_z]) { + linextr(0, total_z) mirror([0,1]) MainPlanB(); + for (i=[0 : hinge_units-1]) { + translate([0,0, stride_z*i]) + linextr(0, hinge_unit) MainPlanA(flatten); + } + } +} + +module HalfClampXNegative(){ + for (j=[0:nbolts-1]) { + translate([ bolt_x, 0, min_z + (j + 0.5) * bolt_stride ]) { + translate([0, -tube_dia/2, 0]) + rotate([-90,0,0]) + 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); + } + } +} + module HalfClampX(flatten=false){ difference(){ - translate([0,0, min_z]) { - linextr(0, total_z) mirror([0,1]) MainPlanB(); - for (i=[0 : hinge_units-1]) { - translate([0,0, stride_z*i]) - linextr(0, hinge_unit) MainPlanA(flatten); + HalfClampXPositive(flatten); + HalfClampXNegative(); + } +} + +// ---------- vhook ---------- + +module VHookProfile() { + translate([0, -vhook_inside/2 - vhook_th/2]) + circle(r = vhook_th/2); +} + +module VHookHookMain(outer=false){ ////toplevel + rotate([0,90,0]) + rotate_extrude(convexity=10) + rotate([0,0,90]) + hull(){ + VHookProfile(); + if (outer) { + translate([0,-vhook_outer_dia]) square(center=true, vhook_th); } } - for (dz=[-1,+1]) { - translate([ bolt_x, 0, dz * total_z/4 ]) { - translate([0, -tube_dia/2, 0]) - rotate([-90,0,0]) - cylinder(r= bolt_dia/2, h= tube_dia); - translate([0, -flats_y, 0]) - rotate([90,0,0]) - cylinder(r= bolt_flat/2, h= tube_dia/2); +} + +module VHookA(){ ////toplevel + DummyA(); + + translate([0, vhook_ctr, 0]){ + for (m=[0,1]) { + mirror([0, m, 0]) { + linextr(-0.1, vhook_outer_dia/2) + VHookProfile(); + translate([0, -vhook_inside/2 -vhook_th/2, vhook_outer_dia/2]) + sphere(r= vhook_th/2); + } + } + + intersection(){ + VHookHookMain(outer=true); + linextr_y_xz(0, vhook_outer_dia/2) hull(){ + VHookProfile(); + translate([0,-0.1]) square(center=true, [vhook_th, 0.2]); } } + + intersection(){ + VHookHookMain(); + translate([0,0, -vhook_outer_dia]) + cube(center=true, vhook_outer_dia*2); + } } + + //translate([0, vhook_y0, 50]) rotate([0,0,-90]) color("black") cube(10); + // translate([0,0,-150]) rotate([0,0,180 + theta]) color("blue") cube(100); } -module GeneralPlanDemo(){ ////toplevel - MainPlan(); - translate([0,0,-4]) color("red") Portion(1); - translate([0,0,-2]) color("grey") Portion(0); +module VHookPlanDemo(){ + MainPlanA(); + translate([0, vhook_ctr, 5]) + for (m=[0,1]) { + mirror([0,m]) + color("blue") VHookProfile(); + } +} - translate([0, tube_dia*1.5]) { - MainPlanB(); - MainPlanA(); +// ---------- 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(){ + intersection(){ + 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); + } + } + translate([0,0, total_z * 0.5]) + cube(center=true, + (main_r + cleat_stem_l)*4 * [1,1,0] + + total_z * [0,0,2]); + } +} + +module VCleatA(){ ////toplevel + DummyA(); + VCleat(); +} + +// ---------- hhook ---------- + +module HHookHookPlan(){ + translate([0, hhook_ctr]){ + difference(){ + circle(r = hhook_outer_dia/2); + circle(r = hhook_inside/2); + rectfromto([+hhook_outer_dia, -hhook_outer_dia], + [0, +hhook_outer_dia]); + } + translate([0, -(hhook_inside/2 + hhook_th/2)]){ + hull(){ + for (x=[-0.1, hhook_l]) { + translate([x,0]) square(center=true, hhook_th); + } + } + } + } +} + +module HHookA(){ ////toplevel + DummyA(); + linextr(min_z, max_z) { + HHookHookPlan(); + } +} + +module HHookPlanDemo(){ + MainPlanA(); + HHookHookPlan(); +} + +// ---------- linear bracket ---------- + +module LinearBracketA(){ ////toplevel + difference(){ + union(){ + HalfClampXPositive(); + mirror([1,0,0]) + linextr_y_xz(-open_gap/2 - linear_bracket_t, -open_gap/2) + rectfromto([0, min_z], + [max_x + linear_bracket_l, min_z + linear_bracket_h]); + } + HalfClampXNegative(); + linextr(-1000,1000) + TubePlan(); + mirror([1,0,0]) + linextr_y_xz(-100,100) { + for (t = [ + [1,1] * linear_bracket_hole_offset, + -[1,1] * linear_bracket_hole_offset + + [linear_bracket_l, linear_bracket_h] + ]) { + translate([ max_x, min_z ] + t) + circle(r= linear_bracket_hole_dia/2); + } + } + } +} + +// ---------- misc ---------- + +module PinSitu(){ ////toplevel + difference(){ + union(){ + 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 - pin_gap, h = pin_head_th); + } + translate([0,0, total_z + pin_tail/2]) + rotate([0,90,0]) + translate([0,0, -pin_dia]) + cylinder(r= pin_hole_dia/2, h=pin_dia*2); + translate([pin_dia/2 * cos(45), -50, -pin_head_th*2]) + cube([50,100, total_z*2]); + } +} + +module Pin(){ ////toplevel + rotate([0,90,0]) { + PinSitu(); } -// translate([max_x - hinge_x + 20, 0]) color("blue") MainPlanA(); } module GeneralB(){ ////toplevel @@ -151,9 +450,39 @@ module DummyA(){ ////toplevel HalfClampX(); } +module PlanDemo(){ ////toplevel + MainPlan(); + translate([0,0,-4]) color("red") Portion(1); + translate([0,0,-2]) color("grey") Portion(0); + + translate([0, tube_dia*1.5]) { + MainPlanB(); + MainPlanA(); + } + + translate([0, -tube_dia*1.5]) { + VHookPlanDemo(); + } + translate([tube_dia*4, 0]) { + HHookPlanDemo(); + } +// 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();