X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?a=blobdiff_plain;f=powerbank-bike-clamp.scad;h=2a755a878f8186848eb3e1bf4f6dea7dcdcc394d;hb=refs%2Fheads%2Fmaster;hp=f035b71ac7306e8b525731d888cf390950ee15ee;hpb=f9405a3fcb209f469a5c628ef93a46552f548b93;p=reprap-play.git

diff --git a/powerbank-bike-clamp.scad b/powerbank-bike-clamp.scad
index f035b71..2a755a8 100644
--- a/powerbank-bike-clamp.scad
+++ b/powerbank-bike-clamp.scad
@@ -15,6 +15,7 @@ minor_wall_min = 1;
 
 screw = 5.0 + 0.75;
 screw_head = 8.7 + 1.2;
+screw_head_space_above = 10;
 screw_nut_across = 7.9 + 0.75;
 screw_nut_th = 3.9 + 0.75;
 
@@ -26,6 +27,8 @@ clamp_min_width = 20;
 
 clamp_gap = 2;
 
+corner_rounding_r = 10;
+
 lower_th = 1;
 
 overlap_l = 0.1;
@@ -50,24 +53,32 @@ strap_th = 3;
 strap_w = 5;
 strap_above = 2.5;
 
+strap_around_over = 1.0;
+strap_around_attach = 2.0;
+
 retainer_walls = [18, 30];
 
 bank_profile_scale_bodge = 1.0;
 
-bank_input_ctr = [ 12.5, 11.5 ]; // from nearest corner
-bank_input_sz  = [ 8.5, 10.5 ];
+bank_output_ctr = [ 12.5, 11.5 ]; // from nearest corner
+bank_output_sz  = [ 11.0, 10.5 ];
 
-mounted_pos_y_offset = 20;
+mounted_pos_y_offset_lim = -100;
 
 liner_th = 0.8;
 
 brace_r = 5;
 brace_len = 50;
 
+straps_y_adj = [ 3.5,
+		 0,
+		 0 ];
+
 // calculated
 
-straps_y = [ -bank_y_sz * 0.25,
-	     +bank_y_sz * 0.25 ];
+straps_y = [ -bank_y_sz * 0.25, // these entries are special and used
+	     +bank_y_sz * 0.25, //  for the brace struts
+	     0 ];
 
 screw_head_behind = main_th;
 endwall_th = main_th;
@@ -92,8 +103,11 @@ bank_bot_y = strap_above + strap_th;
 strap_r = strap_th;
 
 brace_total_len = brace_len + main_th;
-brace_ctrs_y = [ straps_y[0] - (brace_r + strap_w/2),
-		 straps_y[1] + (brace_r + strap_w/2) ];
+brace_ctrs_y_nom = [ straps_y[0] - (brace_r + strap_w/2),
+		     straps_y[1] + (brace_r + strap_w/2) ];
+
+brace_ctrs_y = [ (straps_y + straps_y_adj)[0] + (brace_r + strap_w/2),
+		 (straps_y + straps_y_adj)[1] + (brace_r + strap_w/2) ];
 
 clamp_width_actual = max(clamp_min_width, holder_x_sz);
 
@@ -105,7 +119,9 @@ hinge_y = tube_dia/2 + hinge_outer_r;
 
 top_cnr_r = min(endwall_th, main_th);
 
-echo(bot_y);
+mounted_pos_y_offset = max(mounted_pos_y_offset_lim,
+			   bot_y - (-(bank_y_sz/2 + endwall_th)));
+
 
 module TubePlan(){ circle(r = tube_dia/2); }
 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
@@ -133,23 +149,28 @@ module TubeClampLeft() { ////toplevel
     TubeClampLeftPlan();
 }
 
-module TubeClampRightPlan(){
+module TubeClampRightPlan(){ ////toplevel
   difference(){
-    union(){
-      rectfromto([ clamp_gap/2,                   bot_y ],
-		 [ clamp_gap/2 + behind_knob_th,  0     ]);
-      intersection(){
-	circle(r= main_r);
-	union(){
-	  rectfromto([0,0],
-		      main_r *  [5,5]);
-	  rectfromto([ clamp_gap/2, main_r*5 ],
-		      main_r * [2,-5]);
+    // It broke at the inside corner, round these a bit
+    offset(r=-corner_rounding_r)
+    offset(r=+corner_rounding_r)
+    difference(){
+      union(){
+	rectfromto([ clamp_gap/2,                   bot_y ],
+		   [ clamp_gap/2 + behind_knob_th,  0     ]);
+	intersection(){
+	  circle(r= main_r); // maybe split off from main_r and increase?
+	  union(){
+	    rectfromto([0,0],
+		       main_r *  [5,5]);
+	    rectfromto([ clamp_gap/2, main_r*5 ],
+		       main_r * [2,-5]);
+	  }
 	}
+	HingeBodyPlan();
       }
-      HingeBodyPlan();
+      TubePlan();
     }
-    TubePlan();
     HingePinPlan();
   }
 }
@@ -165,7 +186,7 @@ module Screws(){
 	      screw_nut_across / cos(30) + bridge_slop*2],
 	     center=true);
 
-    linextr_x_yz(-200,
+    linextr_x_yz(-(main_r + bank_recess_y + screw_head_space_above),
 		 -(clamp_gap/2 + screw_nut_th + screw_head_behind))
       square([screw_head, screw_head + bridge_slop*2],
 	     center=true);
@@ -294,13 +315,28 @@ module PowerBankHolder(){ ////toplevel
 	  }
 	}
 	translate([brace_total_len, 0,0])
-	  linextr_y_xz(brace_ctrs_y[0] - brace_r,
-		       brace_ctrs_y[1] + brace_r)
+	  linextr_y_xz(brace_ctrs_y_nom[0] - brace_r,
+		       brace_ctrs_y_nom[1] + brace_r)
 	  BraceTubePlan();
       }
+
+      for (strap_y = straps_y + straps_y_adj) {
+	translate([0, strap_y, 0]) {
+	  linextr(-holder_x_sz/2,
+		  +holder_x_sz/2){
+	    hull(){
+	      for (dy = [-1,+1] *
+		     (strap_w/2 + strap_around_attach - strap_around_over)) {
+		translate([0, dy, 0])
+		  circle(r=strap_around_over);
+	      }
+	    }
+	  }
+	}
+      }
     }
 
-    for (strap_y = straps_y)
+    for (strap_y = straps_y + straps_y_adj)
       translate([0, strap_y, 0])
 	rotate([0,0,-90])
 	rotate([0,90,0])
@@ -311,8 +347,8 @@ module PowerBankHolder(){ ////toplevel
     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
       linextr_y_xz(-50,50)
        rotate([0,0,90])
-       translate(bank_input_ctr)
-       square(center=true, bank_input_sz);
+       translate(bank_output_ctr)
+       square(center=true, bank_output_sz);
 
     translate([0, -(bank_y_sz/2 + endwall_th), 0] + 0.01 * [-1,-1]) {
       linextr(-200,200){