first version of conical capsule holders

TinySpHEAR_common.scad

@@ -266,26 +266,26 @@ module render_tetra_capsule_array_old(z_offset) {
     }
 }
 
-module render_tetra_capsule_array(z_offset) {
+module render_tetra_capsule_array(z_offset, r_offset) {
     translate([0, 0, z_offset]) {
         // all four capsules
         rotate([0, (90 - elev_angle), 45]) {
-            translate([0, 0, mic_radius - capsule_height]) {
+            translate([0, 0, mic_radius - capsule_height + r_offset]) {
                 capsule(leg_angles_top, 60, 0, 0.0, 0.0, 0);
             }
         }
         rotate([0, (90 - elev_angle), -135]) {
-            translate([0, 0, mic_radius - capsule_height]) {
+            translate([0, 0, mic_radius - capsule_height + r_offset]) {
                 capsule(leg_angles_top, 60, 0, 0.0, 0.0, 0);
             }
         }
         rotate([0, (90 + elev_angle), -45]) {
-            translate([0, 0, mic_radius - capsule_height]) {
+            translate([0, 0, mic_radius - capsule_height + r_offset]) {
                 capsule(leg_angles_top, 0, 0, 0.0, 0.0, 0);
             }
         }
         rotate([0, (90 + elev_angle), 135]) {
-            translate([0, 0, mic_radius - capsule_height]) {
+            translate([0, 0, mic_radius - capsule_height + r_offset]) {
                 capsule(leg_angles_top, 0, 0, 0.0, 0.0, 0);
             }
         }
@@ -310,3 +310,201 @@ module render_simple_stand_mount(z_offset) {
     }
 }
 
+// capsule holder with conical mount
+//
+// ratio of capsule radius to transition length
+transition_ratio = 1.0;
+// ratio of capsule radius to bottom radius of holder
+holder_ratio = 0.4;
+
+// diameter of microphone capsule cable (Mogami 2490)
+capsule_cable_diam = 1.7;
+
+module capsule_holder(ratio, transition, hollow = true) {
+    capsule_h = capsule_height;
+    difference() {
+        // main capsule holder, use a conical bore to press fit the capsule
+        f = 0.05;
+        cylinder(r = capsule_radius + fudge + wall, h = capsule_h, $fn = cfacets);
+        if (hollow) cylinder(r1 = capsule_radius + fudge - f, r2 = capsule_radius + fudge, h = capsule_h + thin_mint, $fn = cfacets);
+    }
+    // conical transition into core sphere
+    transition_h = transition * capsule_radius;
+    translate([0, 0, - transition_h]) {
+        difference() {
+            cylinder(r2 = capsule_radius + fudge + wall, r1 = (capsule_radius) * ratio + wall, h = transition_h, $fn = facets);
+            // add overhang so that we have a stop when inserting the capsule
+            overhang = 0.2;
+            if (hollow) cylinder(r2 = capsule_radius + fudge - overhang, r1 = (capsule_radius) * ratio, h = transition_h, $fn = facets);
+            // add holes in the walls of the conical transition
+            if (hollow) {
+                for (r = [0:36:179]) {
+                    rotate([0, 90, r]) {
+                        translate([-transition_h, 0, -capsule_radius - 2 * wall])
+                            scale([3.5, 1.25, 1]) cylinder(r = 1.0, h = (capsule_radius + 2 * wall) * 2, $fn = facets);
+                    }
+                }
+            }
+        }
+        // lip to insert holder into core
+        lip_d = 1.4 * wall;
+        translate([0, 0, hollow == false ? -3 : -lip_d]) {
+            difference() {
+                // if not hollow make the ring longer to cut into core
+                // cylinder(r = (capsule_radius) * ratio + wall + (hollow == true ? 0 : fit/2),
+                cylinder(r = (capsule_radius) * ratio + wall + (hollow == true ? 0 : 0),
+                        h = hollow == true ? lip_d : 4.0, $fn = facets);
+                if (hollow) { cylinder(r = capsule_cable_diam/2 * 1.4, h = lip_d + thin_mint, $fn = facets); }
+            }
+        }
+    }
+}
+
+// new stype capsule array
+
+// the spherical core and mounting stalk
+//
+// render = 0: the full sphere (for visualization)
+// render = 1: upper half
+// render = -1: lower half with stalk
+
+// thickness of ring that connects both halves of the core sphere
+core_ring_height = 5.0;
+
+// holes for screws that hold together both halves of the sphere
+module capsule_holder_screws(radius, wall, screw_r, shift = 0) {
+    h_offset = 1.2;
+        for (r = [90, 270]) {
+            for (t = [0, 45]) {
+                m = t > 0 ? 1 : 0;
+                // 11.5 matches the angle for the flat shaves in the core
+                mirror([0, 0, m]) rotate([0, 11.5, r + t]) translate([-(radius + 2 * wall), 0, shift]) {
+                    rotate([0, 90, 0]) {
+                        cylinder(r = screw_r, h = radius, $fn = facets);
+                    }
+                }
+            }
+        }
+}
+
+// ring that connects the two halves of the core sphere
+module capsule_holder_ring(offset = 3.5, shift = 0) {
+    s_radius = mic_radius - capsule_radius * (1 + transition_ratio) + offset;
+    ring_h = core_ring_height - 0.2;
+    translate([0, 0, -ring_h/2]) difference() {
+        cylinder(r = s_radius - 2.5 * wall - fit, h = ring_h, $fn = facets);
+        cylinder(r = s_radius - 4 * wall - fit, h = ring_h, $fn = facets);
+        // shift the holes slightly so the two halves are pressed together
+        translate([0, 0, ring_h/2]) capsule_holder_screws(s_radius, wall, 0.65, shift);
+    }
+}
+
+// spherical core
+module capsule_holder_core(top_radius, render = 0, offset = 3.5) {
+    s_radius = mic_radius - capsule_radius * (1 + transition_ratio) + offset;
+    difference() {
+        union() {
+            difference() {
+                // core
+                sphere(r = s_radius, $fn = facets);
+                sphere(r = s_radius - 2.5 * wall, $fn = facets);
+                // shave sides as well (cosmetic, really)
+                for (az = [-45, 135]) rotate([0, -elev_angle, az]) {
+                    translate([s_radius - 0.5 * wall, -s_radius/2, -s_radius/2]) {
+                        cube([s_radius, s_radius, s_radius]);
+                    }
+                }
+                for (az = [45, -135]) rotate([0, elev_angle, az]) {
+                    translate([s_radius - 0.5 * wall, -s_radius/2, -s_radius/2]) {
+                        cube([s_radius, s_radius, s_radius]);
+                    }
+                }
+                // remove one half of the sphere
+                if (render == 1) {
+                    translate([-mic_radius, -mic_radius, -mic_radius * 2]) cube([mic_radius * 2, mic_radius * 2, mic_radius * 2]);
+                }
+                if (render == -1) {
+                    translate([-mic_radius, -mic_radius, 0]) cube([mic_radius * 2, mic_radius * 2, mic_radius * 2]);
+                }
+                // make space for connection ring
+                ring_h = core_ring_height;
+                translate([0, 0, -ring_h/2]) {
+                    cylinder(r = s_radius - 2.5 * wall, h = ring_h, $fn = facets);
+                }
+                // hole for stalk
+                if (render == -1) {
+                    translate([0, 0, -mic_radius]) cylinder(r = mount_radius - 2*wall, h = mic_radius, $fn = facets);
+                }
+            }
+            // stalk that transitions into flare
+            if (render == -1) {
+                //stalk_len = 15.0;
+                // normal length plus 10 to insert into flare
+                stalk_len = stalk_height + 10.0 + 10.0;
+                inset = wall;
+                translate([0, 0, - (stalk_len - inset + s_radius)]) {
+                    difference() {
+                        cylinder(r = top_radius, h = stalk_len + inset, $fn = facets);
+                        cylinder(r = top_radius - wall, h = stalk_len + inset + thin_mint, $fn = facets);
+                    }
+                }
+                // add flange for coupling into flare
+                translate([0, 0, - (stalk_height - inset - 0.5 + 10.0 + 10.0)]) {
+                    difference() {
+                        cylinder(r2 = top_radius, r1 = top_radius + wall, h = 10.0, $fn = facets);
+                        cylinder(r2 = top_radius - wall, r1 = top_radius, h = 10.0, $fn = facets);
+                    }
+                }
+                translate([top_radius, 0, - (stalk_height - inset - 0.5 + 10.0 + 10.0 + 10.0)]) {
+                    // add key to stalk so orientation is always correct
+                    difference() {
+                        cylinder(r = 0.4, h = 10.0, $fn = facets);
+                    }
+                }
+            }
+        }
+        // make holes for capsule holders
+        render_tetra_capsule_holder_array(false);
+    }
+    // index for aligning the two halves of core sphere
+    rotate([0, 0, 0]) translate([s_radius, 0, 0]) {
+        difference() {
+            scale([1, 1, 2]) sphere(r = 0.5, $fn = facets);
+            translate([-2.2, -1, -4]) cube([2, 2, 8]);
+            if (render == 1) {
+                translate([-2, -1, -8]) cube([4, 2, 8]);
+            }
+            if (render == -1) {
+                translate([-2, -1, 0]) cube([4, 2, 8]);
+            }
+        }
+    }
+}
+
+holder_ratio = 0.4;
+transition_ratio = 0.8;
+
+module render_tetra_capsule_holder_array(hollow = true) {
+    // all four capsules
+    rotate([0, (90 - elev_angle), 45]) {
+        translate([0, 0, mic_radius - capsule_height]) {
+            capsule_holder(holder_ratio, transition_ratio, hollow);
+        }
+    }
+    rotate([0, (90 - elev_angle), -135]) {
+        translate([0, 0, mic_radius - capsule_height]) {
+            capsule_holder(holder_ratio, transition_ratio, hollow);
+        }
+    }
+    rotate([0, (90 + elev_angle), -45]) {
+        translate([0, 0, mic_radius - capsule_height]) {
+            capsule_holder(holder_ratio, transition_ratio, hollow);
+        }
+    }
+    rotate([0, (90 + elev_angle), 135]) {
+        translate([0, 0, mic_radius - capsule_height]) {
+            capsule_holder(holder_ratio, transition_ratio, hollow);
+        }
+    }
+}
+