crystalballer/Baller.scad

include <BOSL/constants.scad>
use <BOSL/shapes.scad>
use <BOSL/transforms.scad>
use <BOSL/threading.scad>

use <inserts/inserts.scad>
use <threads/threads.scad>


$incolor = true;

// Config
BallDiameter  = 65;
BallClearance = 4;
BallSealWidth = 6;
PlateLip      = 4;
PlateDiameter = BallDiameter + 2*(BallClearance + BallSealWidth + PlateLip);
PlateThick    = BallSealWidth/2 + 1;
PlateSep = 0;

/* [Render Options] */
PreviewFA = 12;
RenderFA = 1;
PreviewFS = 2;
RenderFS = .1;


$fa = ($preview) ? PreviewFA : RenderFA;
$fs = ($preview) ?  PreviewFS : RenderFS;

//plate_full();
pd = PlateDiameter+PlateSep;
pt = PlateThick;
wt=BallSealWidth;
echo("PD=", pd);
//translate([pd+15,0]) plate_top(thickness=pt);
//translate([0,pd+15]) plate_mid(thickness=pt);
//translate([pd+15,pd+i15]) cap_compression(PlateDiameter, pt+8);
//translate([-(pd+15),0]) mold_wall(PlateDiameter, pt, BallDiameter);
//bottom(pd=pd);
//translate([0,-(pd+5)]) plate_under();
//ball(bottom=false);


/*{
	bd=BallDiameter;
	bsd=BallSealWidth;
	gap=10;
	w=6;
	l = 2*(bd+gap+bsd)+gap+w;

	p4_bottom();
	down(12)fwd(l/2 - gap/2 + 3) p4_wall(align=V_TOP);
} */

//xrot(90)p4_wall();
p4_top();
module p4_seal_corner(bd=BallDiameter, bsd=BallSealWidth, gap=10) {
	translate([gap/2+bd/2,gap/2+bd/2,0]) rotate_extrude(angle=90)
		translate([(bd+bsd+gap)/2,0,0])
			circle(d=bsd);
}

module p4_top(bd=BallDiameter, bsd=BallSealWidth, gap=10) {
	xspread(l=bd+gap, n=2)yspread(l=bd+gap, n=2) ball(bottom=false);
	//cyl(h=bd/2, d1=20, d2=10, align=V_TOP);
	difference() {
		cuboid([2*(bd+gap+bsd)+gap,2*(bd+gap+bsd)+gap,bsd/2+1], fillet=5, edges=EDGES_Z_ALL,align=V_BOTTOM);
		p4_seal_corner();
		xspread(l=2*(bd+gap+bsd/2)) cyl(h=bd+gap, d=bsd, orient=ORIENT_Y);
		yspread(l=2*(bd+gap+bsd/2)) cyl(h=bd+gap, d=bsd, orient=ORIENT_X);
		rot(90)p4_seal_corner();
		rot(180)p4_seal_corner();
		rot(270)p4_seal_corner();
	}
}

module p4_bottom(bd=BallDiameter, bsd=BallSealWidth, gap=10) {
	xspread(l=bd+gap, n=2)yspread(l=bd+gap, n=2) ball(bottom=false);
	xspread(l=2*(bd+gap+bsd/2)) cyl(h=bd+gap, d=bsd, orient=ORIENT_Y);
	yspread(l=2*(bd+gap+bsd/2)) cyl(h=bd+gap, d=bsd, orient=ORIENT_X);
	p4_seal_corner();
	rot(90)p4_seal_corner();
	rot(180)p4_seal_corner();
	rot(270)p4_seal_corner();
	cuboid([2*(bd+gap+bsd)+gap,2*(bd+gap+bsd)+gap,bsd/2+1], fillet=5, edges=EDGES_Z_ALL,align=V_BOTTOM);
	
}

module p4_wall(w=6, bd=BallDiameter, bsd=BallSealWidth, gap=10, orient=ORIENT_X, align=V_CENTER) {
	h = bd + bsd;
	l = 2*(bd+gap+bsd)+gap+w/2;
	orient_and_align([l,w,h], align=align, orient=orient, orig_orient=ORIENT_X)
	difference() {
		left(w)cuboid([l, w, h], fillet=1);
		zspread(n=3, l=h-gap) {
			yrot(90)up((l-w)/2)insert_clear(bl=10, bz=-10);
			xrot(90)down(w+4)left((l)/2+3)insert_clear(bl=10, sh=.2, bz=0);
		}
		right(0)back(w/2)down(h/2- 10) cuboid([l,w, bsd/2+1.2]);
	}
}

module stack(pt, ed=10 ,expand=false) {
	d = expand ? pt + ed : pt+.01;
	for (i = [0:$children-1]) {
		translate([0,0,d*i]) children(i);
	}
}

module mold_wall(pd, pt, bd, sd=4, wt=3, $incolor=$incolor) {
	threadc = $incolor ? "green" : undef;
	ptol = 2;
	wh = bd/2+pt+sd;
	od = pd + 2*wt;
	difference() {
		union() {
			translate([0,0,6]) cylinder(d=od, h=wh);
			color(threadc) threaded_rod(
				d=od,
				l=6,
				internal=false, align=V_TOP); 
			//color(threadc) metric_thread(
			//	diameter=pd+ptol,
			//	length=4.01,
			//	internal=false);
		}
		translate([0,0,-2.1+pt]) 
			cylinder(d1=pd-wt, d2=pd-wt-3, h=wh+6+.2);
		down(01)cylinder(d=pd, h=pt+.01);
	}
		
}

module bottom(pd, wt=3, wh=10, fh=2) {
	id = pd + 2*wt + .4;
	od = id + 2*wt;

	difference() {
		cylinder(d=od, h=wh);
		translate([0,0,fh]) cylinder(d=id, h=wh);
	}	
}

module cap_compression(pd, pt, th=9, wt=3, register=true, key=false) {
	td=pd+2*wt;
	difference() {
		cylinder(d=td+wt, h=th+wt/2);
		translate([0,0,th-5-.01]) cylinder(d=3, h=5);
		translate([0,0,th-1+.01]) cylinder(d=6, h=3);
		//translate([0,0,2*pt]) metric_thread(diameter=td,length=th+.01, internal=true);
		translate([0,0,th-1]) threaded_rod(d=td,l=th+.01, internal=true);
		if (register && ! key)
			translate([0,0,2*pt-2]) register_seal();
		cylinder(d=pd-5,h=10);	
	}
	if (register && key)
		translate([0,0,2*pt-2]) register_seal();
}

module plate(
	d=PlateDiameter,
	thickness = PlateThick)
{
	translate([0,0,-thickness])
		cylinder(d=d, h=thickness+.01);
}

module plate_mid(thickness  = 1) {
	th=thickness;
	translate([0,0,thickness]) { 
		//ball(bottom=false);
		difference() {
			union() {
			plate(thickness=thickness);
			register_seal();
			}
			translate([0,0,-thickness]) cylinder(h=10, d=4);
			ranslate([0,0,-th+.01]) cylinder(d=3, h=5);
			translate([0,0,-th]) cylinder(d=6, h=3);
		}
	}
}

module plate_top(thickness  = 1) {
	translate([0,0,thickness]) { 
		//ball(bottom=false);
		difference() {
			plate(thickness=thickness);
			register_seal();
			translate([0,0,-thickness]) cylinder(h=10, d=4);
			translate([0,0,-th/2]) cylinder(d=3, h=5);
			translate([0,0,-thickness-.01])   cylinder(d=6, h=3);
		}
	}
}

module plate_under(thickness  = 1) {
	translate([0,0,thickness]) { 
		underball();
		plate(thickness=thickness);
		register_seal();
	}
}


module ball(
	bd=BallDiameter,
	insert=true,
	top = true, 
	bottom = true) 
{
	insertc = $incolor ? "gold" : undef;
	maxz = top ? bd/2 : 0;
	minz = bottom ? -bd/2 : 0;
	echo("maxz:", maxz);
	echo("minz:", minz);
	difference() {
		intersection() {
			sphere(d=bd);
			translate([0,0,(maxz+minz)/2])
				cube([bd, bd, maxz-minz],center=true);
		}
		color(insertc) { 
			if (insert) for (iz = [-bd/2, bd/2]) {
				rot = (iz < 0) ? 180 : 0;
				translate([0,0,iz]) 
					rotate([0,rot,0])
						thread_insertM25($die=true);
			}
			//if (! bottom) 
			//	rotate([0,0,0]) 
			//		thread_insertM25($die=true);
		}
	}
}

module register_seal(
	bd  = BallDiameter,
	cl  = BallClearance,  // Clearance around ball
	sw  = BallSealWidth,  // Width of register
	) 
{
	rotate_extrude()
		translate([bd/2+cl,0,0])
			circle(d=sw);
	
}

module underball() {
	intersection() {
		translate([0,0,9]) { 
			rotate_extrude(angle=360) 
				translate([10+15/2,0,0])
					circle(d=20);
			translate([0,0,-4]) 
				cylinder(d=55, h=10, center=true);
		}
		cylinder(d=70,h=35);
	}
}