crossbar-computer-led-mount: Tower wip

[reprap-play.git] / crossbar-computer-led-mount.scad

diff --git a/crossbar-computer-led-mount.scad b/crossbar-computer-led-mount.scad
index 36dac88c71f6a09371e7de4ecf1a6563ad4b3530..533519efc0ecaf9c0a8972554d91aeff86d1e64b 100644 (file)
--- a/crossbar-computer-led-mount.scad
+++ b/crossbar-computer-led-mount.scad
@@ -1,26 +1,153 @@
 // -*- C -*-
 
-led_dia = 5;
+led_dia = 5 + 0.6;
 led_depth = 5;
 
-test_width = 15;
-test_height = 12;
+led_tip_z = 70;
+led_angle = -60;
 
-thicks = [1,2,4,6];
+vert_space_inside = 8;
+backfront_space_inside = 12;
 
-module Tests(){
-  for (thicki=[0:len(thicks)-1]) {
-    translate([thicki*test_width-0.1, 0, 0]) {
+backfront_mate_size = 25;
+tower_frontheight = 20;
+tower_width = 18;
+tower_slot_width = 3;
+
+// tuning
+
+tower_over_angle = 45;
+tower_wall_thick = 1.6;
+tower_base_height = 10;
+tower_forehead_angle = 30;
+
+//--- tests ---
+
+test_width = 24;
+test_height = 24;
+
+test_thicks = [9,14,21];
+
+module Tests(){ ////toplevel
+  for (thicki=[0:len(test_thicks)-1]) {
+    translate([thicki*test_width-0.5, 0, 0]) {
       difference(){
        cube([test_width,
-             thicks[thicki] + led_depth,
+             test_thicks[thicki] + led_depth,
              test_height]);
-       %translate([test_width/2, -1, test_height/2])
+       translate([test_width/2, -1, test_height/2])
          rotate([-90,0,0])
-         cylinder(r=led_dia/2, h=led_depth+1);
+         cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
+      }
+    }
+  }
+}
+
+//Tests();
+
+//--- real thing ---
+
+tower_overhang = led_dia * 2.5;
+
+tower_over_max_y = tower_overhang * sin(tower_over_angle);
+tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle);
+tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth;
+tower_rearwall_y = -(backfront_space_inside + tower_wall_thick);
+led_head_y = tower_over_max_y/2;
+led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2;
+backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y));
+
+module TowerWallCrossSection(){
+  // generates a 2D shape - a polygon
+  // x is what is going to be -y
+  // y is what is going to be z
+  polygon([[0,                  0],
+          [0,                  tower_frontheight],
+          [-tower_over_max_y,  tower_over_max_z],
+          [-tower_over_max_y
+           + tan(tower_forehead_angle) * (vert_space_inside + led_depth),
+           tower_total_max_z],
+          [-tower_rearwall_y,  tower_total_max_z],
+          [-tower_rearwall_y,  0],
+          [-tower_rearwall_y, -tower_base_height],
+          [-backfront_mate_extra, -tower_base_height]],
+         convexity=5);
+}
+
+module TowerWallSomeEdge(front){
+  minkowski(){
+    difference(){
+      TowerWallCrossSection();
+      translate([front ? 0.10 : -0.10, 0])
+       TowerWallCrossSection();
+    }
+    circle(r=tower_wall_thick, $fn=8);
+  }
+}
+
+module TowerBulkCrossSection(){
+  intersection(){
+    TowerWallCrossSection();
+    union(){
+      translate([-led_head_y, led_head_z])
+       circle(r = led_depth);
+      TowerWallSomeEdge(true);
+      translate([-50, -50])
+       square([100, 50]);
+    }
+  }
+}
+
+module TowerRearWallCrossSection(){
+  intersection(){
+    TowerWallCrossSection();
+    union(){
+      intersection(){
+       translate([0,-10]) square([100, 10+led_head_z]);
+       TowerWallSomeEdge(false);
       }
+      TowerBulkCrossSection();
+    }
+  }
+}
+
+
+module TowerCrossSectionDemo(){
+  %TowerWallCrossSection();
+  //TowerBulkCrossSection();
+  TowerRearWallCrossSection();
+}
+
+module TowerMain(){
+  for (mir=[0,1])
+    mirror([mir,0,0]) rotate([90,0,-90]) {
+      translate([0,0, tower_width/2-tower_wall_thick])
+       linear_extrude(height=tower_wall_thick)
+       TowerWallCrossSection();
+      translate([0,0,-1])
+       linear_extrude(height=tower_width/2+0.9)
+       TowerBulkCrossSection();
+      translate([0,0, tower_slot_width/2])
+       linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2)
+       TowerRearWallCrossSection();
     }
+}
+
+module LedHole(){
+  translate([0, led_head_y, led_head_z])
+    rotate([90 + led_angle])
+    translate([0,0,-10])
+    cylinder(r=led_dia/2, h=led_depth+0.1+10, $fn=30);
+}
+
+module Tower(){
+  difference(){
+    TowerMain();
+    LedHole();
   }
 }
 
-Tests();
+//TowerCrossSectionDemo();
+//TowerWallSomeEdge(false);
+//TowerWallFrontEdge();
+Tower();