sirens/designs/openscad/siren_redesign.scad

/* [Siren General Parameters] */
siren_diameter = 125;         // Base diameter - 121 for rotor to fit original siren 
siren_height = 45;            // Height of the rotor - 60 for rotor to fit original siren
number_of_ports = 3;    // Number of ports
vertical_tolerance = 2;          // Tolerance between stator and rotor
radial_tolerance = 1.5;
fit_reduction = 0.2;
pressure_zone = 0.5;    // Percentage of diameter
round_radius = 4;       // Rounding of top/bottom
$fn = $preview ? 32 : 128;   // Number of fragments

/* [Stator Parameters] */
stator_wall_thickness = 8;      // Stator wall thickness
number_of_mounting_holes = 4;   // Number of mounting holes
screw_diameter = 3.2;           // Diameter of screws - M3 clearance hole (3.2mm diameter)
screw_bore_diameter = 6.5;
screw_insert_diameter = 4.5;
screw_bore_depth = 2.5;
screw_length = 10 - (stator_wall_thickness - screw_bore_depth);
stator_screw_offset = siren_diameter/2 - stator_wall_thickness/2;    //distance to screws

/* [Rotor Parameters] */
rotor_wall_thickness = 3;   // Rotor wall thickness
hub_height = 3;
hub_diameter = 12;
blade_angle = 8;
rotor_height = siren_height - (vertical_tolerance * 2);
port_height = siren_height - (rotor_wall_thickness * 2) - (vertical_tolerance * 2);       // Height of the port

/* [Motor Parameters] */
motor_shaft_diameter = 8;       // Diameter of the motor body
motor_frame_diameter = 60; 
motor_diameter = 28;            // Diameter of the motor body
motor_height = 24;
magnet_diameter = 7;
motor_screw_x_offset = 9.5;
motor_screw_y_offset = 8;
motor_screw_offset = 8;
motor_frame_screw_offset = motor_frame_diameter/2 - stator_wall_thickness/2;    //distance to screws

/* [Base Parameters] */
leg_screw_offset = motor_frame_diameter / 2 + 5;
leg_height = motor_height + 10;

// helper functions
module ports(diameter, height, ports, r_offset = 0) {
    radius = diameter / 2;
    angle = (180 / ports) - (r_offset * 6);
    
    rotate([0, 0, 180 / ports])
    for (i = [0:360/ports:360]) {
        rotate([0, 0, i + (r_offset * 6 / 2)])
        linear_extrude(height)
        polygon(concat(
            [[0, 0]],  // Center point
            [for (j = [0 : $fn]) 
                [radius * cos(angle * j / $fn), 
                 radius * sin(angle * j / $fn)]]
        ));
    }
}

module column(outer_diameter, inner_diameter, height, z_offset = 0) {
    difference(){
        // Outer cylinder
        cylinder(d = outer_diameter, h = height);
        // Subtract inner cylinder
        translate([0, 0, z_offset])
        cylinder(d = inner_diameter, h = height - z_offset);
    }
}

module rounded_column(outer_diameter, inner_diameter, height, z_offset = 0){
    difference() {
        // Rounded top
        intersection() {
        // Unrounded full cylinder
            cylinder(d = outer_diameter, h = height);
            
            // Add Minkowski rounded version
            minkowski() {
                cylinder(h = height - round_radius, d = outer_diameter - round_radius * 2);
                sphere(r = round_radius);
            }
        }
        
        // Subtract inner cylinder
        translate([0, 0, z_offset])
        cylinder(d = inner_diameter, h = height);
    }
}

module counter_bored_holes(screw_offset){
    // Subtract mounting holes for stator
    for (i = [0:360/number_of_mounting_holes:360]) {
        // Subtract screw hole
        rotate([0, 0, i])
        translate([screw_offset, 0, -1]) // Adjusted position
        cylinder(d = screw_diameter, h = stator_wall_thickness + 2);
        
        // Subtract counterbore
        rotate([0, 0, i])
        translate([screw_offset, 0, stator_wall_thickness - screw_bore_depth]) // Adjusted position
        cylinder(d = screw_bore_diameter, h = stator_wall_thickness);
    }
}

module mounting_holes(screw_offset){
    for (i = [0:360/number_of_mounting_holes:360]) {
        rotate([0, 0, i])
        translate([screw_offset, 0, 0])
        cylinder(d = screw_insert_diameter, h = screw_length);
    }
}

// Linear Interpolation
function lerp(a, b, t) = a * (1 - t) + b * t;

// Arc between points function
function arc_between_points(p1, p2, height, steps=20) = 
    [for(t = [0:1/steps:1]) 
        let(
            x = lerp(p1.x, p2.x, t),
            y = lerp(p1.y, p2.y, t),
            // Parabolic arc height calculation
            arc_height = height * (1 - pow(2*t-1, 2))
        ) 
        [x, y + arc_height]
    ];

function bezier_curve(t, p0, p1, p2, p3, p4) = 
    pow(1-t, 4) * p0 + 
    4 * pow(1-t, 3) * t * p1 + 
    6 * pow(1-t, 2) * pow(t, 2) * p2 +
    4 * (1-t) * pow(t, 3) * p3 +
    pow(t, 4) * p4;

function curved_polygon(points, steps, x_shift, y_shift) = 
    let(
        left_curve = [for (t = [0 : 1/steps : 1])
            bezier_curve(t, points[0], points[1], points[2], points[3], points[4])
        ],
        right_curve = [for (pt = left_curve)
            [pt[0] + x_shift, pt[1] + y_shift]
        ]
    )
    concat(left_curve, [for (i = [len(right_curve)-1 : -1 : 0]) right_curve[i]]);

module stator() {
    difference() {
        
        // Create column
        column(siren_diameter,  siren_diameter - (stator_wall_thickness * 2), siren_height); 
        
        // Subtract ports
        translate([0, 0, (siren_height - port_height) / 2])
        ports(siren_diameter, port_height, number_of_ports);
        
        mounting_holes(stator_screw_offset);
        
        translate([0, 0, siren_height - screw_length])
        mounting_holes(stator_screw_offset);
    }
}


module impeller_blade(radius, rotor_height){ 
    // Generate points
    points1 = arc_between_points([0, -hub_diameter / 2], [radius, 0], -blade_angle);
    points2 = [for(p = [len(points1)-1:-1:0]) points1[p] - [0, -rotor_wall_thickness]];
    
    // Create the blade by combining top and bottom points
    linear_extrude(height = rotor_height) 
    polygon(concat(points1, points2));
}

module impeller_blades_curved(radius, rotor_height){ 
    difference() {
        union() {
            // Rotate and create blades
            for (i = [0:360/number_of_ports:360]) {
                rotate([0, 0, i]) 
                impeller_blade(radius, rotor_height);
            }
        }
       
        top_rounding_radius = 5;
        bottom_rounding_radius = rotor_height / 2 - 1;
        //bottom_rounding_radius = rotor_height / 2 - 10; // this needs to be adjusted based on the rotor diameter and height
        top_diameter = (siren_diameter * pressure_zone) + (top_rounding_radius * 2);
        bottom_diameter = (siren_diameter * pressure_zone) - (2 * bottom_rounding_radius);
        top_height = top_rounding_radius + 10;
        bottom_height = rotor_height - bottom_rounding_radius - (top_rounding_radius * 2) + 2;
        translate([0, 0, rotor_height - top_rounding_radius])
        union(){
            difference() {
                // Column
                cylinder(d = top_diameter, h = top_height);
                
                // Top torus
                rotate_extrude()
                translate([top_diameter / 2, 0, 0])
                circle(r = top_rounding_radius);
            }
            
            rotate([180, 0, 0])
            minkowski() {
                // Original cylinder, reduced by twice the rounding radius
                cylinder(d = bottom_diameter, h = bottom_height);
                
                // Sphere for rounding
                sphere(r = bottom_rounding_radius);
            }
        }
    }
}

module rotor() {
    rotor_diameter = siren_diameter - (stator_wall_thickness * 2) - (radial_tolerance * 2);
    rotor_inner_diameter = rotor_diameter - (rotor_wall_thickness * 2);
    
    difference() {
        union(){
            difference() {
                column(rotor_diameter, rotor_inner_diameter, rotor_height, rotor_wall_thickness);

                // Subtract ports
                translate([0, 0, (rotor_height - port_height) / 2])
                ports(rotor_diameter, port_height, number_of_ports);
            }
            
            // Add blades
            impeller_blades_curved(rotor_inner_diameter / 2, rotor_height);
        }
       
        translate([0, 0, 0])
        hub_attachment(fit_reduction);
    }
}

module hub(aug = 0) {
    height = (rotor_wall_thickness * 2) + hub_height;
    difference(){
        union(){
            hub_attachment(aug);
            cylinder(d = motor_shaft_diameter + 2, h = height);
        }
        
        intersection(){
            cylinder(d = motor_shaft_diameter, h = height);
            cube([motor_shaft_diameter, motor_shaft_diameter-1, height * 2], center = true);
        };
        
        cylinder(d = motor_shaft_diameter, h = 2);
    }
}

module hub_attachment(aug = 0) {
    insert_width = 2;
    outer_diameter = hub_diameter + (insert_width * 6) + (aug * 2);
    mid_diameter = hub_diameter + (insert_width * 2) + (aug * 2);
    inner_diameter = outer_diameter - (insert_width * 2) - (aug * 4);
    difference(){
        column(outer_diameter, inner_diameter, rotor_wall_thickness);
        //translate([0, 0, -10])
        ports(outer_diameter, rotor_wall_thickness, number_of_ports, aug * 2);
    }
    translate([0, 0, rotor_wall_thickness])
    cylinder(d = outer_diameter, rotor_wall_thickness);
    cylinder(d = mid_diameter, rotor_wall_thickness * 2);
}

module stator_top() {
    difference(){
        rounded_column(
            siren_diameter, 
            siren_diameter * pressure_zone, 
            stator_wall_thickness
        );
        
        counter_bored_holes(stator_screw_offset);
    }
}

module stator_bottom() {
    //rotate([180, 0, 0])
    difference() {
        rounded_column(
            siren_diameter, 
            motor_diameter + (radial_tolerance * 2), 
            stator_wall_thickness
        );
       
        counter_bored_holes(stator_screw_offset);
        
        // Subtract mounting holes for motor frame
        rotate([180, 0, 0])
        translate([0, 0, -stator_wall_thickness])
        counter_bored_holes(motor_frame_screw_offset);
        
        rotate([180, 0, 0])
        translate([0, 0, -stator_wall_thickness])
        counter_bored_holes(leg_screw_offset);
        
        translate([0, 0, stator_wall_thickness])
        rotate([0, 0, -45/2 - 0.6])
        for (i = [0:360/number_of_mounting_holes:360]) {
            rotate([0, 0, i]) {
                leg(fit_reduction);
            }
        }
    }
}

module motor_frame() {
    //rotate([180, 0, 0])
    //translate([0, 0, -stator_wall_thickness])
    motor_frame_height = motor_height - stator_wall_thickness - vertical_tolerance;
    difference(){
        union(){
            inner_diameter = motor_frame_diameter - (stator_wall_thickness * 2);
            difference(){
                 rounded_column(
                    motor_frame_diameter, 
                    inner_diameter, 
                    motor_frame_height + stator_wall_thickness, 
                    -stator_wall_thickness
                );
                
                translate([0, 0, stator_wall_thickness])
                ports(inner_diameter, motor_frame_height, number_of_mounting_holes);
                
                //translate([0, 0, -stator_wall_thickness])
                //rotate([0, 0, -45/2])
                ports(motor_frame_diameter, motor_frame_height, number_of_mounting_holes);
                
                rotate([0, 0, 45/2])
                mounting_holes(motor_frame_screw_offset);
            }    
            
            translate([0, 0, motor_frame_height])
            column(motor_screw_x_offset * 2 + (radial_tolerance * 2) , magnet_diameter + (radial_tolerance * 2), stator_wall_thickness);
        }
        
        // Subtract mounting holes for motor
        translate([0, 0, motor_frame_height])
        rotate([0, 0, 45/2])
        for (i = [0:360/number_of_mounting_holes:360]) {
            rotate([0, 0, i]) {
                // Use modulo to alternate between x and y offsets
                motor_screw_offset = (floor(i / (360/number_of_mounting_holes)) % 2 == 0) ? 
                    motor_screw_x_offset : motor_screw_y_offset;
                
                translate([motor_screw_offset, 0, 0])
                cylinder(d = screw_diameter, h = stator_wall_thickness);
            }
        }
        
        translate([0, 0, motor_frame_height])
        cylinder(d = magnet_diameter + (radial_tolerance * 2), h = stator_wall_thickness);
    }
}

module leg(aug = 0) {
    motor_spacing = 15;
    
    points = [
        [leg_screw_offset + 10, leg_height],
        [leg_screw_offset + 5, leg_height-5],
        [leg_screw_offset + 0, leg_height / 2],
        [leg_screw_offset + 5, 5],
        [leg_screw_offset + 10, 0]
    ];
    
    rotate_extrude(angle = 360/8) {
        polygon(curved_polygon(
            points,
            steps = 100,
            x_shift = -stator_wall_thickness / 2,
            y_shift = 0
        ));
    }
    
    rotate([0, 0, 12 - (aug / 2)])
    translate([0, 0, -1])
    difference(){
        rotate_extrude(angle = 360/16 + aug) {
            translate([leg_screw_offset - ((screw_insert_diameter + radial_tolerance) / 2) - aug, 0, 0])
            square([screw_insert_diameter + radial_tolerance + aug * 2, leg_height + 2]);
        }
        if(aug == 0){
            rotate([0, 0, 45/4 - aug])
            //translate([0, 0, -2])
            mounting_holes(leg_screw_offset);
            
            rotate([0, 0, 45/4 - aug])
            translate([0, 0, leg_height  - screw_length + 2])
            mounting_holes(leg_screw_offset);
        }
    }
}

module base() {
    difference(){
        rounded_column(
            siren_diameter,
            (leg_screw_offset - ((screw_diameter + radial_tolerance) / 2)) * 2 - 5,
            stator_wall_thickness
        );
        
        counter_bored_holes(stator_screw_offset);
        translate([0, 0, stator_wall_thickness])
        rotate([180, 0, 0])
        //counter_bored_holes(leg_screw_offset - ((screw_diameter + tolerance) / 2));
        //rotate([0, 0, -45/2])
        counter_bored_holes(leg_screw_offset);
        
        translate([0, 0, stator_wall_thickness])
        rotate([0, 0, -45/2 - 0.6])
        for (i = [0:360/number_of_mounting_holes:360]) {
            rotate([0, 0, i]) {
                leg(fit_reduction);
            }
        }
    }
}





//rotate([0, 0, 0])
//translate([0, 0, 0])
//rotor();
//motor_shaft_diameter = 8.2;
hub(0.1);
//stator();
//base();
//stator_bottom();

//rotate([0, 0, 0])
//translate([siren_diameter, 0, vertical_tolerance])
//rotor();
//stator_bottom();
//rotate([0, 0, 67.5])
//motor_frame();

//rotate([0, 0, 0])
//translate([0, 0, siren_height + 2])
//stator_top();


//rotate([180, 0, 0])
//translate([0, 0, 2])
//stator_bottom();


//rotate([180, 0, 45])
//translate([0, 0, stator_wall_thickness + 5])
//motor_frame();
//leg();
//base();
/*
rotate([0, 0, 0])
translate([0, 0, -leg_height - 15 - stator_wall_thickness - 2])
base();

rotate([0, 0, -45/2])
translate([0, 0, -leg_height - 15])
for (i = [0:360/number_of_mounting_holes:360]) {
    rotate([0, 0, i]) {
        leg();
    }
}
*/



/*
//translate([0, 0, 2])
intersection(){
    //color("red")
    rotor();
    cylinder(d = 30, h = 10);
}

translate([040, 0, 0])
hub();
*/