usb_w = 12.01 + 0.19;
usb_wall_w = 0.51;
usb_tongue_d = 8.97 - 0.2;
+usb_tongue_w_slop = +0.5;
usb_wall_h = 4.54 - 2.04;
usb_ceil_th = 0.425;
-side_wall_th = 1.5;
+side_wall_th = 1.5; // XXXX rename wall_th
board_l = 17.56 + 0.2;
board_w = 19.14 + 0.2;
sw_to_edge = board_w/2 + 0.1;
front_wall_th = 0.75;
-egress_w = 8.0;
+// egress_w = 8.0;
-wall_y_min = -board_l - side_wall_th;;
+wall_y_min = -board_l - side_wall_th; // XXXX remove
ceil_y_min = wall_y_min - 5;;
small_walls = [
// [ [3.0, -11.72], [sw_to_edge, -13.38] ],
[ [-sw_to_edge+3.85, -14.90], [sw_to_edge, -13.38] ],
];
-chip_cutout = [[ -sw_to_edge + 4.20, -4.50 ],
+chip_cutout = [[ -sw_to_edge + 4.20, -3.75 ],
[ -sw_to_edge + 11.95, -11.90 ]];
+strain_w = 2.0 + 0.5;
+strain_t = 1.0 + 0.5;
+strain_pitch_across = 5;
+strain_pitch_along = 10;
+strain_groove_d = 2;
+strain_groove_w = 3;
+
+cover_strap_c_d_y = 5.5; // from front of board
+cover_registration_sz_y = 2;
+cover_registration_sz_z = 3;
+
+cable_space_z = 6;
+cable_dia = 5;
+bottom_floor_th = 1.5;
+
+fit_gap_z = 0.5;
+fit_gap_y = 0.25;
+side_x_gap = 0.5;
+
+cover_ceil_th = 0.9;
+
+cover_strap_sz_x = side_wall_th * 3.5;
+
+// calculated
+
+strap_w = strain_w;
+strap_cutout_z = side_wall_th;
+
+top_top_z = usb_wall_h;
+top_base_z = -board_th;
+bottom_base_z = top_base_z - cable_space_z - bottom_floor_th;;
+
+front_y_max = front_wall_th;
+main_y_min = -board_l - side_wall_th;
+
+strain_0_y_c = main_y_min - strain_w/2;
+strain_1_y_c = strain_0_y_c - strain_pitch_along;
+total_y_min = strain_1_y_c - strain_w/2 - side_wall_th;
+
+bottom_wall_top_z = (top_top_z + top_base_z) * 0.5 - fit_gap_z/2;
+cover_wall_bot_z = (top_top_z + top_base_z) * 0.5 + fit_gap_z/2;
+cover_top_z = top_top_z + cover_ceil_th;
+
+top_side_wall_x = +board_w/2 + side_wall_th;
+total_side_wall_x = top_side_wall_x + side_wall_th + side_x_gap;
+
+cover_registration_c_dy = -cover_strap_c_d_y - strap_w/2
+ - side_wall_th - cover_registration_sz_y/2;
+
module BothSides(){
for (m=[0,1]) {
- mirror([m,0]) {
+ mirror([m,0,0]) {
children();
}
}
}
+module StrapCutouts(y_c, z_top, top_sz_x){
+ for (z = [ bottom_base_z, z_top ]) {
+ BothSides(){
+ translate([ -total_side_wall_x, y_c, z_top ])
+ cube([ top_sz_x*2,
+ strap_w,
+ strap_cutout_z*2 ],
+ center=true);
+ translate([ -total_side_wall_x, y_c, bottom_base_z ])
+ cube([ side_wall_th * 0.75,
+ strap_w,
+ strap_cutout_z*2 ],
+ center=true);
+ }
+ }
+}
+
+module CoverStrapCutouts(){
+ StrapCutouts( -cover_strap_c_d_y, cover_top_z, cover_strap_sz_x );
+}
+
+module FrontWallsPlan(slop) {
+ BothSides(){
+ rectfromto([ -board_w/2 - side_wall_th, 0 ],
+ [ -usb_w/2 - slop, front_wall_th ]);
+ }
+}
module TopSmallWallsPlan() {
for (m=[0,1]) {
mirror([m,0]) {
[ -usb_w/2 + usb_wall_w, usb_tongue_d ]);
}
}
+ FrontWallsPlan(0);
for (w=small_walls) {
rectfromto(w[0], w[1]);
}
BothSides(){
rectfromto([ -board_w/2 - side_wall_th, 0 ],
[ -board_w/2, wall_y_min ]);
- rectfromto([ -board_w/2 - side_wall_th, 0 ],
- [ -usb_w/2, front_wall_th ]);
}
- rectfromto([ -board_w/2 - side_wall_th + egress_w, -board_l ],
- [ +board_w/2 + side_wall_th, wall_y_min ]);
+ FrontWallsPlan(usb_tongue_w_slop);
+ rectfromto([ -board_w/2 - side_wall_th + 0, - board_l ],
+ [ +board_w/2 + side_wall_th, total_y_min ]);
+}
+
+module CoverRegistrations(){
+ linextr_y_xz(cover_registration_c_dy - strap_w/2,
+ cover_registration_c_dy + strap_w/2) {
+ difference(){
+ rectfromto([ -total_side_wall_x,
+ cover_wall_bot_z - cover_registration_sz_z ],
+ [ +total_side_wall_x, cover_top_z ]);
+ hull(){
+ TopElevationForCutout();
+ translate([0, -20]) TopElevationForCutout();
+ }
+ }
+ }
}
-module Top(){
- linextr(0, usb_wall_h)
- TopSmallWallsPlan();
- linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
- TopCeilPlan();
- linextr(-board_th, usb_wall_h)
- TopMainWallsPlan();
+module Top(){ ////toplevel
+ difference(){
+ union(){
+ linextr(0, usb_wall_h)
+ TopSmallWallsPlan();
+ linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
+ TopCeilPlan();
+ linextr(-board_th, usb_wall_h)
+ TopMainWallsPlan();
+ BothSides()
+ linextr(cover_wall_bot_z, top_top_z)
+ rectfromto([ -(board_w/2 + 0.1), total_y_min ],
+ [ -total_side_wall_x, main_y_min - fit_gap_y ]);
+ }
+
+ for (y_c = [strain_0_y_c, strain_1_y_c]) {
+ for (x_c = [-1,+1] * strain_pitch_across/2) {
+ translate([x_c, y_c, 0])
+ linextr(-20, 20)
+ square([ strain_t, strain_w ], center=true);
+ }
+ }
+ linextr_y_xz(total_y_min-1, main_y_min)
+ translate([0, top_base_z])
+ scale([1, strain_groove_d/strain_groove_w])
+ circle(strain_groove_w/2, $fn = 8);
+ }
+}
+
+module TopElevationForCutout(){
+ rectfromto([ -(top_side_wall_x + side_x_gap), top_base_z ],
+ [ +(top_side_wall_x + side_x_gap), top_top_z ]);
}
+module BottomMainElevation(){
+ difference(){
+ rectfromto([ -total_side_wall_x, bottom_base_z ],
+ [ +total_side_wall_x, bottom_wall_top_z ]);
-Top();
+ TopElevationForCutout();
+ }
+}
+module Bottom(){ ////toplevel
+ difference(){
+ union(){
+ linextr_y_xz(total_y_min, front_y_max)
+ BottomMainElevation();
+ }
+
+ linextr_y_xz(total_y_min + side_wall_th,
+ front_y_max - side_wall_th)
+ rectfromto([ -board_w/2, bottom_base_z + bottom_floor_th ],
+ [ +board_w/2, 20 ]);
+
+ linextr_y_xz(total_y_min - 1,
+ total_y_min + side_wall_th + 1){
+ translate([ 0, top_base_z ]){
+ hull(){
+ translate([ 0, -cable_dia/2 ])
+ circle(r = cable_dia/2, $fa = 10, $fs = 1);
+ square([ cable_dia, 0.1 ], center=true);
+ }
+ }
+ }
+ minkowski(){
+ CoverRegistrations();
+ cube([ 1, fit_gap_y*2, fit_gap_z*2 ], center=true);
+ }
+ CoverStrapCutouts();
+ }
+}
+
+module CoverMainElevation(){
+ difference(){
+ rectfromto([ -total_side_wall_x, cover_wall_bot_z ],
+ [ +total_side_wall_x, cover_top_z ]);
+
+ TopElevationForCutout();
+ }
+}
+module Cover(){ ////toplevel
+ difference(){
+ union(){
+ linextr_y_xz(main_y_min, front_y_max)
+ CoverMainElevation();
+ CoverRegistrations();
+ }
+ CoverStrapCutouts();
+ }
+}
+
+module BottomDemo(){ ////toplevel
+ translate([0, 0, -0.25]) Bottom();
+ %Top();
+ translate([0, 0, +0.25]) Cover();
+}