add windscreen code to render upper and lower windscreen frames, add thread cover, lower facets for rendering helixes to use less memory, move some parameters to the windscreen file

SpHEAR_windscreen.scad

@@ -23,17 +23,35 @@
 //   Attribution-NonCommercial-ShareAlike 4.0 International (CC BY-NC-SA 4.0)
 // http://creativecommons.org/licenses/by-nc-sa/4.0/
 
+include <SpHEAR_common.scad>
+
 // http://dkprojects.net/openscad-threads/
 // used for the windscreeen mount threads
 include <threads.scad>;
 
+// default number of facets for rendering
+facets = 128;
+
 ////
 //// default model parameters
 ////
 
+// number of helixes of windscreen frame
+windscreen_sides = 12;
+
+// radius of windscreen beams
+windscreen_beam_radius = 1.3;
+
+// radius of frame connectors
+windscreen_conn_radius = windscreen_beam_radius + 0.8;
+
+// height of connector pin
+windscreen_pin_height = 4.0;
+
+
 // windscreen frame
 
-module sphear_windscreen_frame(sides, radius, height, beam_radius, twist, heights) {
+module sphear_windscreen_frame(sides, height, radius, beam_radius, twist) {
     inc = 360/sides;
     for (r = [0:inc:360]) for (t = [1, -1]) rotate([0, 0, r]) {
         render() {
@@ -42,25 +60,13 @@ module sphear_windscreen_frame(sides, radius, height, beam_radius, twist, height
                     circle(r = beam_radius, $fn = facets/2);
                 }
             }
-            *if (t == -1) for (h = [1/3, 2/3, 1]) {
-                rotate([0, 0, (inc/2) * (t - 1)]) translate([radius, 0, h * height]) {
-                    intersection() {
-                        scale([1.0, 1.55, 1.0]) {
-                            translate([0, 0, -beam_radius * 2]) {
-                                cylinder(r = beam_radius, h = beam_radius * 4, $fn = facets);
-                            }
-                        }
-                        scale([1, 2, 2.5]) sphere(r = beam_radius, $fn = facets);
-                    }
-                }
-            }
         }
     }
 }
 
 // windscreen inset frame
 
-module sphear_windscreen_inset_frame(sides, radius, iradius, height, beam_radius, xscale = 1.0, yscale = 1.0) {
+module sphear_windscreen_inset_frame(sides, height, radius, iradius, beam_radius, xscale = 1.0, yscale = 1.0) {
     inc = 360/sides;
     difference() {
         for (r = [0:inc:360]) for (t = [1, -1]) rotate([0, 0, r]) {
@@ -127,7 +133,7 @@ module sphear_windscreen_dome(sides, radius, beam_radius) {
     }
 }
 
-// windscreen mount to body with thread
+// octagonal windscreen mount to body with thread
 
 module sphear_windscreen_mount(height, radius, beam_radius) {
     octagon_radius = (radius + 2 * beam_radius + wall) * cos(PI/8);
@@ -151,24 +157,182 @@ module sphear_windscreen_mount(height, radius, beam_radius) {
 
 // round windscreen mount to body with thread
 
-module sphear_windscreen_round_mount(height, radius, wall) {
+module sphear_windscreen_round_mount(height, radius, wradius, wall) {
     difference() {
         cylinder(r = radius + wall, h = height, $fn = facets);
         metric_thread(diameter = radius * 2 + windscreen_thread_fit, pitch = windscreen_thread_pitch,
                 length = height, angle = windscreen_thread_angle, internal = true);
     }
-    // add better attachment points for windscreen
+    // outer ring that attaches to windscreen
     difference() {
         union() {
-            cylinder(r = radius + 2 * wall, h = height/2, $fn = facets);
+            cylinder(r = wradius, h = height/2, $fn = facets);
             translate([0, 0, height/2]) {
-                cylinder(r1 = radius + 2 * wall, r2 = radius + wall, h = height/2, $fn = facets);
+                cylinder(r1 = wradius, r2 = radius + wall, h = height/2, $fn = facets);
             }
         }
         cylinder(r = radius + wall, h = height, $fn = facets);
     }
     // marker for center of microphone
-    translate([-(radius + 2 * wall), 0, 0]) {
+    translate([-(wradius), 0, 0]) {
         cylinder(r = 1.0, h = height/2, $fn = facets);
     }
 }
+
+// round windscreen thread cover
+
+module sphear_windscreen_thread_cover(height, radius, wall) {
+    difference() {
+        cylinder(r = radius + wall, h = height, $fn = facets);
+        metric_thread(diameter = radius * 2 + windscreen_thread_fit, pitch = windscreen_thread_pitch,
+                length = height, angle = windscreen_thread_angle, internal = true);
+    }
+    // smooth transition to flare
+    *translate([0, 0, height/2]) {
+        difference() {
+            translate([0, 0, height/2]) {
+                cylinder(r2 = radius - windscreen_thread_depth/2, r1 = radius + wall, h = height/3, $fn = facets);
+            }
+            cylinder(r2 = radius - windscreen_thread_depth, r1 = radius, h = height, $fn = facets);
+        }
+    }
+}
+
+// upper windscreen frame
+
+module sphear_upper_windscreen(sides, height, radius, beam_radius, conn_radius, pin_height, connectors = true) {
+    ang = 360 / sides;
+    // dome at top
+    translate([0, 0, height]) {
+        sphear_windscreen_dome(sides, radius, beam_radius);
+    }
+    // spiral wireframe
+    translate([0, 0, 2]) {
+        difference() {
+            sphear_windscreen_frame(sides, height, radius, beam_radius, 45);
+            if (connectors) {
+                // remove bottom of beams to make space for the connectors
+                for (r = [1:360/sides:360]) rotate([0, 0, r]) {
+                    translate([radius, -beam_radius/2, 0]) {
+                        cylinder(r = conn_radius, h = pin_height - 1.0, $fn = facets);
+                    }
+                }
+            }
+        }
+    }
+    if (connectors) {
+        // connectors to lower frame
+        for (r = [1:360/sides:360]) rotate([0, 0, r]) {
+            translate([radius, -beam_radius/2, 0]) {
+                difference() {
+                    union() {
+                        cylinder(r = conn_radius, h = pin_height + 1.0, $fn = facets);
+                        translate([0, 0, pin_height + 1]) {
+                            sphere(r = conn_radius, $fn = facets);
+                        }
+                    }
+                    cylinder(r = beam_radius + fit, h = pin_height + 0.5, $fn = facets);
+                }
+            }
+        }
+        // bottom ring, prevents connectors to lower frame from toppling when printing
+         difference() {
+            scale([1.0, 1.0, 1.5]) rotate_extrude(convexity = 10, $fn = facets/2) {
+                translate([radius, 0, 0]) {
+                    circle(r = wall, $fn = facets/2);
+                }
+            }
+            translate([0, 0, -2 * wall]) {
+                cylinder(r = radius + wall, h = 2 * wall + thin_mint, $fn = facets/2);
+            }
+            for (r = [1:360/sides:360]) rotate([0, 0, r]) {
+                translate([radius, -beam_radius/2, -2]) {
+                        cylinder(r = conn_radius - thin_mint, h = 6.0 + thin_mint, $fn = facets/2);
+                }
+            }
+        }
+    }
+    // crossing reinforcements
+    // first mid crossing
+    translate([0, 0, height/3 + 2.0]) {
+        sphear_windscreen_frame_reinforcements(sides, radius, beam_radius, ang/2, 0);
+    }
+    // second mid crossing
+    translate([0, 0, height*2/3 + 2.0]) {
+        sphear_windscreen_frame_reinforcements(sides, radius, beam_radius, 0, 0);
+    }
+    // to dome
+    translate([0, 0, height + 2.0]) {
+        sphear_windscreen_frame_reinforcements(sides, radius, beam_radius, ang/2, 0);
+    }
+}
+
+// lower windscreen frame
+
+module sphear_lower_windscreen(sides, height, radius, beam_radius, conn_radius, pin_height, connectors = true) {
+    ang = 360 / sides;
+    // frame
+    rotate([0, 0, ang/2]) {
+        sphear_windscreen_frame(sides, height, radius, beam_radius, 45);
+    }
+    // frame crossing reinforcements
+    rotate([0, 0, ang/2]) {
+        // first mid crossing
+        translate([0, 0, height/3]) {
+            sphear_windscreen_frame_reinforcements(sides, radius, beam_radius, ang/2, 0);
+        }
+        // second mid crossing
+        translate([0, 0, height*2/3]) {
+            sphear_windscreen_frame_reinforcements(sides, radius, beam_radius, 0, 0);
+        }
+    }
+    // connector to upper frame
+    for (r = [1:ang:360]) rotate([0, 0, r]) {
+        translate([radius, -beam_radius/2, height - 1.0 + 0.4]) {
+            render() {
+                difference() {
+                    sphere(r = conn_radius, $fn = facets);
+                    translate([-2 * conn_radius, -2 * conn_radius, (beam_radius) / 2]) {
+                        cube([4 * conn_radius, 4 * conn_radius, 4 * conn_radius]);
+                    }
+                }
+                // pin
+                cylinder(r = beam_radius - fit, h = pin_height, $fn = facets);
+            }
+        }
+    }
+    // mount to body
+    rotate([0, 0, 90]) {
+        sphear_windscreen_round_mount(windscreen_thread_height, windscreen_thread_radius, windscreen_radius, 2 * wall);
+    }
+}
+
+//
+// Render components
+//
+
+// upper windscreen
+
+module render_sphear_upper_windscreen(zoffset) {
+    translate([0, 0, zoffset]) {
+        sphear_upper_windscreen(windscreen_sides, windscreen_height, windscreen_radius,
+            windscreen_beam_radius, windscreen_conn_radius, windscreen_pin_height, connectors = true);
+    }
+}
+
+// lower windscreen
+
+module render_sphear_lower_windscreen(zoffset) {
+    translate([0, 0, zoffset]) {
+        sphear_lower_windscreen(windscreen_sides, windscreen_height, windscreen_radius,
+            windscreen_beam_radius, windscreen_conn_radius, windscreen_pin_height, connectors = true);
+    }
+}
+
+// windscreen thread cover
+
+module render_sphear_windscreen_thread_cover(zoffset) {
+    translate([0, 0, zoffset]) {
+        sphear_windscreen_thread_cover(windscreen_thread_height, windscreen_thread_radius, wall);
+    }
+}