fairphone-case: rework hingescrew parameters: rename hingescrew_nut_thick_real to...

[reprap-play.git] / fairphone-case.scad

diff --git a/fairphone-case.scad b/fairphone-case.scad
index b06b1741b5b9df8b53c5cd487a8b494e687cca2f..f248e538ea4e15b234976ef39c72bfd5fa969d58 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -26,7 +26,7 @@ phone_backside_slope_outer = 1.0; // larger means shallower
 camera_pos_tl = [  6.450, 12.750 ]; // measured from tl corner
 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
 
-jack_pos = [ 14.38, 7.96 ];
+jack_pos = [ 13.83, 8.485 ];
 jack_dia = 10.64 + .5; // some jack I had lying around
 
 noisecancelmic_pos = [ 19.54, 7.37 ];   // from rhs
@@ -78,12 +78,19 @@ foldover_lever_gap = 0.50;
 
 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
 hingescrew_shaft_len = 12;
-hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
-hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
+hingescrew_fasteners_extra_thick = 0.40;
+hingescrew_nut_access_dia = 4.72 + 0.50;
+// ^ washer is 4.72 dia
+//   also, want to get pliers or tiny spanner in to do up locknut
+hingescrew_nut_across = 3.92 + 0.25; // incl. slop around recess slop
+hingescrew_nut_thick = 1.93;
 hingescrew_head_th = 1.38 + 0.75;
 hingescrew_head_dia = 3.92;
 lever_cover_th = 0.75;
 hingemount_th = 2.5;
+hingemount_wd = 4.8725;
+
+hingescrew_nut_recess_portion = 2/3; // portion of nut in recess
 
 $fa = 5;
 $fs = 0.1;
@@ -189,9 +196,12 @@ bppO = [ bppN[0], bppP[1] ];
 bppL = lpp10 + [5,0];
 bppK = [ bppL[0], bppN[1] ];
 bppJ = [ bppN[0], bppL[1] ];
+bppU = [ bppJ[0], lpp12[1] ];
+bppV = lpp11;
+bppW = lpp10;
 
 // hinge plan
-hp_rn = hingescrew_nut_dia/2;
+hp_rn = hingescrew_nut_access_dia/2;
 hp_r2_min = hp_rn + lever_cover_th;
 hp_rs = hingescrew_shaft_dia/2;
 hp_r1_min = hp_rs + hingemount_th;
@@ -214,19 +224,28 @@ hppE = [ hppE_x, hppE_y ];
 
 // hinge elevation x coords
 
-hingescrew_portion_len =
-  0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
-
 hex20 = max(epp2o[0],
            phone_cnr_rad,
            kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
-hex21 = hex20 + hingescrew_portion_len;
+hex21 = hex20 + hingemount_wd;
 hex22 = hex21 + hinge_x_gap;
-hex23 = hex22 + hingescrew_portion_len
-  - hingescrew_nut_thick; // bodge, need to divvy this up more sensibly
-hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
-//echo(hex20, hex21, hex22, hex23, hex24);
-//echo(hingescrew_portion_len);
+hex27 = hex20 + hingescrew_shaft_len;
+hex24 = hex27 + hinge_x_postscrew_gap;
+hex23 = hex27 - (hingescrew_nut_thick*2
+                + hingescrew_fasteners_extra_thick);
+hex26 = hex23 + hingescrew_nut_thick * 2/3;
+
+echo(hex20, hex21, hex22, hex23, hex24);
+//  6, 10.8725, 10.9975, 13.74, 18.75
+module chk(act,exp) {
+  if (abs(act-exp) > 1e-9) echo("WRONG", act, exp);
+  else echo("ok", act);
+}
+chk(hex20, 6);
+chk(hex21, 10.8725);
+chk(hex22, 10.9975);
+chk(hex23, 13.74);
+chk(hex24, 18.75);
 
 // catch
 
@@ -321,7 +340,9 @@ module LidEdgeProfile(){
 
 module ButtonCoverProfile(){
   intersection(){
-    polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
+    polygon(concat([ bppM, bppP, bppO, bppJ ],
+                  (enable_support ? [ bppU, bppV, bppW ] : []),
+                  [ bppL, bppK ]));
     hull(){
       EdgeProfile();
       LidEdgeProfile();
@@ -584,19 +605,30 @@ module HingeLeverOuterProfile(){
 }
 
 module HingeLeverInnerProfile(){
-  for (c = [hppT, hppB]) {
-    hull()
+  for (s = [-1,+1]) {
+    c = s > 0 ? hppT : hppB;
+    translate(c)
+      mirror([0,0,s>0])
+      rotate(s<0 ? -40 : 0)
+      hull()
       for (x=[-20,20])
-       for (y=[0, c[1] - hppM[1]])
+       for (y=[0, s * 10])
          translate([x,y])
-           circleat(c, hp_rn);
+           circle(hp_rn);
   }
 }
 
-module Flip_hinge(){
+module HingeLeverNutProfile(){
+  for (c= [hppB, hppT]) {
+    translate(c)
+      circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
+  }
+}
+
+module Flip_hinge(doflip=1){
   hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
   translate(hinge_origin)
-    rotate([180,0,0])
+    rotate([doflip*180,0,0])
     translate(-hinge_origin)
     children();
 }
@@ -882,9 +914,13 @@ module HingeLever(){ ////toplevel
       HingeLeverOuterProfile();
 
     // space for the screws
-    HingePortion(hex23, hex24)
+    HingePortion(hex26, hex24)
       HingeLeverInnerProfile();
 
+    // recesses for the nuts
+    HingePortion(hex23, hex26+1)
+      HingeLeverNutProfile();
+
     // bores for the screws
     HingeScrews();
 
@@ -895,7 +931,8 @@ module HingeLever(){ ////toplevel
 }
 
 module HingeLeverPrint(){ ////toplevel
-  rotate([90,0,0])
+  rotate([-90,0,0])
+    translate([-phone_width/2, phone_height, 0])
     HingeLever();
 }
 
@@ -1125,9 +1162,11 @@ module DemoHingedFrame(){ ///toplevel
 }
 
 module DemoHinge(){ ////toplevel
-  DemoFrame();
-  translate([0,0, -hp_k*3])
-    DemoHingedFrame();
+  translate([ -0.5*phone_width, phone_height, hp_k*3 ]) {
+    DemoFrame();
+    translate([0,0, -hp_k*3])
+      DemoHingedFrame();
+  }
 }
 
 module DemoProfiles(){ ////toplevel
@@ -1161,7 +1200,25 @@ module DemoProfiles(){ ////toplevel
     color("blue") HingeLidProfile();
     color("red")  HingeBaseProfile();
     color("black") translate([0,0,-2]) HingeLeverOuterProfile();
-    color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
+  }
+
+  for (f=[0,1]) {
+    translate([-30, -60 + 30*f]) {
+      translate([0,0,-4]) EdgeProfile();
+      %translate([0,0,-10]) HingeBaseProfile();
+      translate([0,-2] * f * hp_k) {
+       translate([0,0,-4]) LidEdgeProfile();
+       %translate([0,0,-10]) %HingeLidProfile();
+      }
+      translate(+hppB) rotate([0,0,180*f]) translate(-hppB) {
+       translate([0,0,-2]) color("black") HingeLeverOuterProfile(); 
+       translate([0,0,0]) color("red") difference(){
+         HingeLeverOuterProfile();
+         HingeLeverInnerProfile();
+       }
+       translate([0,0,3]) color("yellow") HingeLeverNutProfile();
+      }
+    }
   }
 
   translate([20,-30]) {