X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?a=blobdiff_plain;f=fairphone-case.scad;h=1e11f3f80e4ae00d9ccb305422cf0591d2e3b594;hb=8c05598cbc44e110bed9f86187bc5991e3518abe;hp=c37eb01d7fb8077a9dce70de39a38a10c9e973d0;hpb=5bb518c4f5a8c2b5af4ed2e46da9364568d8763d;p=reprap-play.git

diff --git a/fairphone-case.scad b/fairphone-case.scad
index c37eb01..1e11f3f 100644
--- 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
@@ -79,11 +79,18 @@ 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_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_real = 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;
@@ -117,11 +124,11 @@ prop_recess_slop = 0.200; // each side
 prop_end_dia = 0.5;
 prop_main_th = 3;
 prop_taper_len = 6;
-prop_main_width = 3;
+prop_main_width = 4;
 prop_side_gap = 0.75; // each side
 prop_lidrecess_behind = 0.75;
 prop_caserecess_behind = 0.75;
-prop_caserecess_taper = 0.35; // one side only
+prop_caserecess_taper = 0.45; // one side only
 prop_prop_gap = 0.5;
 prop_prong_heel_slope = 0.5;
 
@@ -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;
@@ -220,12 +230,24 @@ hingescrew_portion_len =
 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
+hex26 = hex23 + hingescrew_nut_thick_real * 2/3;
 hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
-//echo(hex20, hex21, hex22, hex23, hex24);
+
+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);
 //echo(hingescrew_portion_len);
 
 // catch
@@ -263,8 +285,8 @@ prcp2 = [ epp4[0] + prop_buildout_less,
 
 prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
 
-prcp1 = [ epp2o[0],
-	  epp2i[1] - prc_r3 ];
+prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
+	  epp2i[1] - prc_r3 - prop_recess_under];
 
 // prop recess in lid
 
@@ -277,10 +299,10 @@ prlp10 = lpp10 + [1,1] * prl_r10o
 
 // prop
 
-prpp10 = [0,0];
-prpp11 = [0, prop_taper_len];
+$prpp10 = [0,0];
+$prpp11 = [0, prop_taper_len];
 
-prp_r10 = prl_r10;
+$prp_r10 = prl_r10;
 
 // ---------- modules ----------
 
@@ -321,7 +343,9 @@ 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 +608,30 @@ 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 HingeLeverNutProfile(){
+  for (c= [hppB, hppT]) {
+    translate(c)
+      circle($fn=6, r= 0.5 * hingescrew_nut_across / cos(30));
   }
 }
 
-module Flip_hinge(){
+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();
 }
@@ -622,80 +657,102 @@ module CaseBase(){
     EdgeProfile();
 }
 
-module PropProfile(gamma, cut=0){ ////toplevel
+function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
+
+module PropProfileAssignments(gamma){
   // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
-  k = hp_k;
-  p = phone_height - prlp10[0] - hppB[0];
-  x = k / (2 * sin(gamma/2)) - hppT[0];
+  x = prop_x(gamma);
+  p = phone_height + prlp10[0] - hppB[0];
   b = p + x;
 
-  q = phone_height - hppT[0]; // prpp7[0] is 0 by definition
+  q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
   a = q + x;
   c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
-  alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
+  $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
 
-  theta = 90 - alpha;
-  beta = 180 - alpha - gamma;
-  psi = 90 - beta + atan(prop_caserecess_taper);
+  $prp_theta = 90 - $prp_alpha;
+  beta = 180 - $prp_alpha - gamma;
+  psi = 90 - beta;
 
-  echo("abc", a,b,c);
+  //echo("abc", a,b,c);
 
-  prpv1 = [ sin(psi), cos(psi) ];
+  v1 = [ [ cos(psi), -sin(psi) ],    // x
+	 [ sin(psi),  cos(psi) ] ];  // y
 
-  prpp7 = [0, c + (lpp13[1] - prpp10[1]) ];
+  $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
 
-  prp_r1 = prc_r1;
-  prp_r11 = prop_main_th/2;
+  $prp_r1 = prc_r1;
+  $prp_r11 = prop_main_th/2;
 
-  prpp1 = prpp7 + [1,0] *
+  $prpp1 = $prpp7 + [1,0] *
     // this is approximate, but will do
-    (prop_main_th/2 + prop_prop_gap + prcp1[0] - epp4[0]);
-  prpp3 = prpp1 + [ -prp_r1,
-		    (prcp2[1] - prcp1[1]) - prop_prop_gap ];
-  prpp12 = prpp3 + [1,0] *
-    (prop_end_dia + prop_caserecess_taper * (prpp1[1] - prpp3[1]));
-  prp_r8 = prop_main_th;
-  prpp4 = [ prop_main_th/2, prpp3[1] ];
-  prp_r5 = prp_r8;
-  prpp5 = [ prpp12[0] - prp_r5,
-	    prpp3[1] - prop_prong_h + prp_r5 ];
-  prpp6 = prpp4 + [0,-1] * (prop_prong_h +
-         prop_prong_heel_slope * (prpp5[0] - prpp4[0]));
-  prpp8 = prpp4 + [0,-1] * prp_r8;
-  prpp9 = prpp8 + [-1,0] * prp_r8;
-
-  //#circleat(prpp5,1);
-
-  if (!cut) {
-    hull(){
-      translate(prpp8)
-	intersection(){
-	  circle(prp_r8);
-	  rectfromto([-20,-0], [20,20]);
-        }
-      rectfromto(prpp6, prpp9);
-      translate(prpp5) intersection(){
-	circle(prp_r5);
-	rectfromto([-10,-10], [10,0]);
+    (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
+  $prpp3 = $prpp1 +
+    v1[0] * -$prp_r1 +
+    v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
+  $prpp12 = $prpp3 + v1[0] *
+    (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
+  $prp_r8 = prop_main_th;
+  $prpp4 = [ prop_main_th/2, $prpp3[1] ];
+  $prp_r5 = $prp_r8;
+  $prpp5 = [ $prpp12[0] - $prp_r5,
+	    $prpp3[1] - prop_prong_h + $prp_r5 ];
+  $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
+         prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
+  $prpp8 = $prpp4 + [0,-1] * $prp_r8;
+  $prpp9 = $prpp8 + [-1,0] * $prp_r8;
+
+  children();
+}
+
+module PropProfile(gamma, cut=0, rot=0){ ////toplevel
+  PropProfileAssignments(gamma){
+
+    //#circleat($prpp3,1);
+    //#circleat($prpp12,1);
+
+    if (!cut) {
+      hull(){
+	translate($prpp8)
+	  intersection(){
+	    circle($prp_r8);
+	    polygon([[-20,-0], [20,20], [0,0]]);
+	  }
+	rectfromto($prpp6, $prpp9);
+	translate($prpp5) intersection(){
+	  circle($prp_r5);
+	  polygon([[-10,-10], [0,0], [10,0]]);
+	}
+	rectfromto($prpp12 + [0,-0.1], $prpp3);
+      }
+      hull(){
+	circleat($prpp1, $prp_r1);
+	rectfromto($prpp12 + [0,-0.1], $prpp3);
       }
-      rectfromto(prpp12 + [0,-0.1], prpp3);
-    }
-    %hull(){
-      circleat(prpp1, prp_r1);
-      rectfromto(prpp12 + [0,-0.1], prpp3);
     }
-  }
-  // main shaft
-  rotate([0,0, cut ? -theta : 0]){
-    hull(){
-      extra = cut ? prop_recess_slop : 0;
-      rectfromto(prpp6, prpp9);
-      circleat(prpp11, prp_r11 + extra);
-      circleat(prpp10, prp_r10 + extra);
+    // main shaft
+    rotate([0,0, rot*-$prp_theta]){
+      hull(){
+	extra = cut ? prop_recess_slop : 0;
+	rectfromto($prpp6, $prpp9);
+	circleat($prpp11, $prp_r11 + extra);
+	circleat($prpp10, $prp_r10 + extra);
+      }
     }
   }
 }
 
+module PropAggregateProfile(){
+  for (angle = prop_angles)
+    PropProfile(angle, 0,0);
+}
+
+module Prop(){ ////toplevel
+  hw = prop_main_width/2;
+  linextr(-hw, +hw)
+    PropAggregateProfile();
+}
+
 module Case(){ ////toplevel
   difference(){
     union(){
@@ -799,9 +856,9 @@ module Case(){ ////toplevel
     // prop recess
     Flip_rhs(1)
       translate([prop_x_pos,0,0])
+      mirror([0,1,0])
       rotate([90,0,90])
       linextr(-prop_recess_hw, +prop_recess_hw)
-      mirror([1,0])
       hull(){
         for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
 	  circleat(prcp1 + 20*d,
@@ -841,6 +898,15 @@ module Lid(){ ////toplevel
 
     // screw holes in the hinge arms
     HingeScrews();
+
+    // prop recess
+    translate([prop_x_pos, -prlp10[0], prlp10[1]])
+      mirror([0,1,0])
+      rotate([90,0,90])
+      linextr(-prop_recess_hw, +prop_recess_hw)
+      hull()
+      for (pa = prop_angles)
+	PropProfile(pa, 1,1);
   }
 }
 
@@ -851,9 +917,13 @@ 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();
 
@@ -864,7 +934,8 @@ module HingeLever(){ ////toplevel
 }
 
 module HingeLeverPrint(){ ////toplevel
-  rotate([90,0,0])
+  rotate([-90,0,0])
+    translate([-phone_width/2, phone_height, 0])
     HingeLever();
 }
 
@@ -969,19 +1040,6 @@ module LidPrint(){ ////toplevel
     Lid();
 }
 
-module TestSelectPropRecesses(posns){
-  linextr(-100,100){
-    translate([phone_width/2, -phone_height]){
-      square([ 3, 500 ], center=true);
-      for (y=posns)
-	hull()
-	  for (dy=[ -prp5[0], -prp2[0] ])
-	    translate([0,y+dy])
-	      square([prop_main_width+5, 5], center=true);
-    }
-  }
-}
-
 module TestSelectFrame(){
   include = [1,-1] * (epp2i[0] + 4);
 
@@ -995,7 +1053,6 @@ module TestSelectFrame(){
 
 module TestSelectLidFrame(){
   TestSelectFrame();
-  TestSelectPropRecesses(prop_lid_posns);
 }
 
 module TestFrameCase(){ ////toplevel
@@ -1009,6 +1066,15 @@ module TestFrameCase(){ ////toplevel
   }
 }
 
+module TestTopApertures(){ ////toplevel
+  intersection(){
+    Case();
+    TestSelectFrame();
+    translate([-100, -35, -100])
+      cube([400, 100, 200]);
+  }
+}
+
 module TestFrameLidPrint(){ ////toplevel
   rotate([0,180,0]) intersection(){
     Lid();
@@ -1038,6 +1104,48 @@ module HingeScrews(){
   }
 }
 
+module DemoPropAngleSelect(c){
+  color(c) difference(){
+    union(){ children(); }
+    translate([ prop_x_pos, -400, -200 ])
+      cube([ 400,800,400 ]);
+  }
+}
+
+module DemoPropAngle(ang){
+  hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
+  hC = [0, -(phone_height - hppB[0]), hppB[1]];
+
+  translate(hL)
+    rotate([ang/2,0,0])
+    translate(-hL)
+    translate(hC)
+    rotate([ang/2,0,0])
+    translate(-hC) {
+      DemoPropAngleSelect("red") Case();
+
+      color("orange")
+	translate([prop_x_pos, -prcp1[0], prcp1[1]])
+	PropProfileAssignments(ang) {
+          echo($prpp1);
+	  rotate([-$prp_theta, 0, 0])
+	  translate([0, $prpp1[0], -$prpp1[1]])
+	  rotate([90,0,-90])
+	  Prop();
+        }
+    }
+
+  translate([0,0, -hp_k*2])
+    DemoPropAngleSelect("blue")
+    Lid();
+}
+
+module DemoPropAngles(){ ////toplevel
+  for (i=[0 : len(prop_angles)-1])
+    translate(i * [0, -100, 100])
+    DemoPropAngle(prop_angles[i]);
+}
+
 module DemoFrame(){ ////toplevel
   color("red") TestFrameCase();
   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
@@ -1057,9 +1165,11 @@ 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
@@ -1093,7 +1203,25 @@ 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]) {
@@ -1106,13 +1234,16 @@ module DemoProfiles(){ ////toplevel
 
   translate([40,-30]) {
     difference(){
-      %LidEdgeProfile();
-      //translate(prlp10)
-	//PropProfile(10, 1);
+      LidEdgeProfile();
+      translate(prlp10)
+	PropProfile(10, 1, 0);
     }
     translate(prlp10)
       PropProfile(15, 0);
   }
+  translate([60,-30]) {
+    PropAggregateProfile();
+  }
 }
 
 //EdgeProfile();