X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?a=blobdiff_plain;f=sleepphone-cable-box.scad;h=80076c024c56fb7d3019b9a21981ddc323f22fbe;hb=277ef432dea7db5f9be145e5cd9d724769f677e1;hp=fe801f0bde70b4307df9e8ec1b0838cb51ba7e3a;hpb=eaaa8ce9d0bf67705af9ce69b5056086b36db106;p=reprap-play.git

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index fe801f0..80076c0 100644
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -1,28 +1,64 @@
 // -*- C -*-
 
+include <funcs.scad>
+
 wall = 0.75 * [1,1,1];
-phone = [ 76.40, 30.96, 6.26 ];
+wall_bot = 1.0;
+
+phone = [ 76.40, 30.96, 6.00 ]; // includes socket
 phone_button_z = 6.58;
-minwall = 0.25;
+minwall = 0.50;
+
+cutout_dia = 7;
+cutout_between = 5;
+
+button_dz = 1.35;
 
 button_dy_outer = 28.42;
 button_dy_inner = 19.05;
 button_dy_centre = 5.65;
 
-phone_slop = [1,1,1] * 0.5;
+phone_slop = 0.5 * [1,1,0]
+           + 0.5 * [0,0,1];
 
 led = [25.9, 9.44]; // y is from edge
 led_dia = 4.4;
 
+// next values include slop
+plug_maxw = 10.95 + 0.35;
+plug_minw=   6.53 + 0.35;
+plug_sllen=  6.50;
+plug_totlen = 84.90 - 1.5; // to maxw, including phone
+
+plug_h = 6.5;
+plug_tooth_h = 0.5;
+plug_tooth_dy = 0.5;
+
+keeper_prong = 2;
+keeper_stalk_basewidth = 6;
+keeper_stalk_len = 70;
+keeper_stalk_gap = 1;
+keeper_stalk_thick = wall_bot;
+
 // calculated
 
 top_z = max( phone[2] + wall[2],
 	     phone_button_z + minwall )
   + phone_slop[2];
 
+plugkeeper_x_maxw = phone[0] - plug_totlen;
+
+plugkeeper_p_max = [ 0, plug_maxw/2 ];
+plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
+plugkeeper_d_u = unitvector2d(
+                 clockwise2d(
+                 vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
+			     )
+			     );
+
 module MainProfileInnerHalf(){
   p = phone + phone_slop;
-  pb = phone_button_z + phone_slop[2];
+  pb = p[2] + button_dz;
   polygon([[ -2,                 0    ],
 	   [ p[1]/2,             0    ],
 	   [ p[1]/2,             p[2] ],
@@ -37,13 +73,18 @@ module MainProfileInnerHalf(){
 
 module MainProfile(){
   p = phone + phone_slop;
-  for (m=[0,1]) mirror([m,0]) {
-      difference(){
-	translate([-1, -wall[2] ])
-	  square([ p[1]/2 + wall[1] + 1, top_z + wall[2] ]);
+  difference(){
+    for (m=[0,1]) mirror([m,0]) {
+	minkowski(){
+	  translate([ -wall[1], -wall_bot ])
+	    square([ wall[1]*2, wall_bot + wall[2] ]);
+	  MainProfileInnerHalf();
+	}
+      }
+    for (m=[0,1]) mirror([m,0]) {
 	MainProfileInnerHalf();
       }
-    }
+  }
 }
 
 module BoxMain(){
@@ -56,14 +97,85 @@ module BoxMain(){
   }
 }
 
+module PlugKeeperProfileHalf(){
+  p_max = plugkeeper_p_max;
+  p_min = plugkeeper_p_min;
+  d = plugkeeper_d_u * keeper_prong;
+  
+  translate([ plugkeeper_x_maxw, 0 ]) {
+    polygon([ p_min,
+	      p_max,
+	      p_max + d,
+	      p_min + d ]);
+  }
+}
+
+module PlugKeeperStalkProfile(){
+  hull(){
+    for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
+    translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
+      square([ 0.1, keeper_stalk_basewidth ], center=true);
+  }
+}
+
+module PlugKeeper(){
+  for (m=[0,1]) mirror([0,m,0]) {
+      translate([0,0, -keeper_stalk_thick])
+	linear_extrude(height=plug_h + keeper_stalk_thick)
+	PlugKeeperProfileHalf();
+
+      translate([0, 0, plug_h - plug_tooth_h])
+	linear_extrude(height= plug_tooth_h)
+	translate(plugkeeper_d_u * -plug_tooth_dy)
+	PlugKeeperProfileHalf();
+
+    }
+}
+
+module KeeperProjection(){
+  projection()
+    rotate([0,90,0])
+    linear_extrude(height= 20)
+    projection()
+    PlugKeeper();
+}
+
 module Box(){
   difference(){
     BoxMain();
 
     translate([ led[0], phone[1]/2 - led[1], 1 ])
-      cylinder(r = led_dia/2, h= phone[2]*2, $fn=20);
+      rotate([0,0, 360/8/2])
+      cylinder(r = led_dia/2 / cos(360/8/2), h= phone[2]*2, $fn=8);
+
+    for (ys=[-1,+1]) {
+      translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
+	linear_extrude(height = wall[2]*3)
+	PlugKeeperStalkProfile();
+
+      translate([ phone[0] + wall[0],
+		  ys * (cutout_between/2 + cutout_dia/2),
+		  -10 ])
+	cylinder( r= cutout_dia/2, h = 50, $fn = 20 );
+    }
   }
+
+  PlugKeeper();
+
+  translate([0,0, -keeper_stalk_thick])
+    linear_extrude(height = keeper_stalk_thick)
+    PlugKeeperStalkProfile();
+}
+
+module BoxPrint(){
+  // This makes' Cura's support more optimal: specifically,
+  // it then doesn't seem to touch the back (bottom) wall
+  rotate([0,90,0])
+    Box();
 }
 
-//MainProfileInner();
-Box();
+//MainProfileInnerHalf();
+//MainProfile();
+//KeeperProjection();
+//Box();
+BoxPrint();