X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?a=blobdiff_plain;f=sleepphone-cable-box.scad;h=b5bae407f73d4f787b1091bde9728cdc1c6f94e5;hb=29f7697011ed4618a0d2c02eb7fc4bfe3c574d81;hp=9b7c9cde89ae85da068a5628ef04f305b5f1b3dc;hpb=3db5630259f06c51cf1548dfab2f5154bf555ab3;p=reprap-play.git

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index 9b7c9cd..b5bae40 100644
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -3,9 +3,13 @@
 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;
+
+button_dz = 1.35;
 
 button_dy_outer = 28.42;
 button_dy_inner = 19.05;
@@ -21,9 +25,17 @@ led_dia = 4.4;
 plug_maxw = 10.95 + 0.35;
 plug_minw=   6.53 + 0.35;
 plug_sllen=  6.50;
-plug_totlen = 84.90; // to maxw, including phone
+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 = 4;
+keeper_stalk_len = 70;
+keeper_stalk_gap = 2;
+keeper_stalk_thick = wall_bot;
 
 // calculated
 
@@ -33,9 +45,17 @@ top_z = max( phone[2] + wall[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] ],
@@ -50,13 +70,18 @@ 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(){
@@ -69,10 +94,10 @@ module BoxMain(){
   }
 }
 
-module PlugKeeperProfile(){
-  p_max = [ 0, plug_maxw/2 ];
-  p_min = [ -plug_sllen, plug_minw/2 ];
-  d = unitvector2d(clockwise2d(vecdiff2d(p_min, p_max))) * keeper_prong;
+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,
@@ -82,15 +107,49 @@ module PlugKeeperProfile(){
   }
 }
 
+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();
+
+    }
+
+  translate([0,0, -keeper_stalk_thick])
+    linear_extrude(height = keeper_stalk_thick)
+    PlugKeeperStalkProfile();
+}
+
 module Box(){
   difference(){
     BoxMain();
 
     translate([ led[0], phone[1]/2 - led[1], 1 ])
       cylinder(r = led_dia/2, h= phone[2]*2, $fn=20);
+
+    for (ys=[-1,+1])
+      translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
+	linear_extrude(height = wall[2]*3)
+	PlugKeeperStalkProfile();
   }
+
+  PlugKeeper();
 }
 
-//MainProfileInner();
+//MainProfileInnerHalf();
+//MainProfile();
 Box();
-linear_extrude(h=1) PlugKeeperProfile();
+