anke-gps-bracket.scad

   1 // -*- C -*-
   2
   3 // todo
   4 // nestlecube does not fit
   5 // nestlecube doveclip at wrong angle
   6
   7 include <doveclip.scad>
   8
   9 // Dimensions of the main GPS body
  10 outerw = 120;
  11 outerh =  75;
  12 outert =  15;
  13 outerbackbevel = 3;
  14
  15 // Dimensions for the holder
  16 holder_outerw = outerw - 0.0;
  17 holder_outerh = outerh + 0.0;
  18 holder_outert = outert + 0.0;
  19
  20 // Dimensions for the model
  21 model_outerw = outerw + 2.5;
  22 model_outerh = outerh - 0.2;
  23 model_outert = outert - 1.0;
  24
  25 // Dimensions of the bezel area round the edges
  26 bezelw =    11 - 0.5;
  27 bezelboth = 11 - 0.5;
  28 bezeltoph =  7 - 0.5;
  29
  30 // Dimensions of the speaker at the back
  31 spkrdia =  22;
  32 spkr2bot = 19;
  33 spkr2rhs = 25;
  34
  35 // Dimensions of the plug and wire
  36 plugw =      12;
  37 plugh =       9;
  38 plug2bot =   11;
  39 plug2lhs =   11;
  40 plugtotald = 15;
  41 pluggapd =    5;
  42
  43 // Dimensions of the hole in the tray
  44 //   width and height (vertical) at the top
  45 nestleh = 53;
  46 nestlew = 55.4 - 0.5;
  47 //   depths (back to front distance):
  48 nestledl = 38.8 - 0.5;
  49 nestledr = 42.7 - 0.5;
  50 //   differences in width, depth, at bottom:
  51 nestledwl = 3.0;
  52 nestledwr = 2.4;
  53 nestleddf = 4.0;
  54 nestleddbl = 3.3;
  55 nestleddbr = 3.6;
  56
  57 nestlewallmin = 4;
  58 nestleceilmin = 4;
  59
  60 // Adjustment for the GPS attitude and position
  61 gpsazimuth = 45;
  62 gpselevation = 40;
  63 gpsrightwardoffset = 5;
  64 gpsrearwardoffset = 2;
  65 gpsrightwardoffsetonbar = 0;
  66
  67 // Amount of wire protrusion to allow for
  68 plugwiremoreh = 25;
  69
  70 // Slops and steps etc.
  71 plugslop = 0.5;
  72 plughstep = 1.5;
  73 bodylhsrhsslop = 0.5;
  74 holderhgap = 5;
  75 holderbezelmore = 2;
  76
  77 // Dimensions for strength only
  78 screent = 1.0;
  79 plugstrutw = 4;
  80 plugstrutt = min(model_outert, 5);
  81 nestledoveclipw = 20;
  82 holderh = model_outerh * 0.5;
  83 holderwallt = 2.5;
  84 holderbackt = 2.8;
  85 holderdccount = 2;
  86 holderdoveclipl = 15;
  87 chassish = 13;
  88 chassist = 13;
  89
  90 // Consequential values
  91 holderdcw = DoveClipPairSane_width(holderdccount);
  92
  93 module GpsPlugPlug(slop){
  94   effhslop = slop - plughstep;
  95   effplugw = plugw + slop*2;
  96   effplugh = plugh + effhslop*2;
  97   translate([plug2lhs-slop, plug2bot-effhslop, -1])
  98     cube([effplugw, effplugh, model_outert+2]);
  99 }
 100
 101 module GpsBodyOuterBevel(len){
 102   translate([0,-1,0]) {
 103     rotate([-90,0,0]) {
 104       linear_extrude(height=len+2) {
 105         polygon([[-outerbackbevel, 0],
 106                  [ 0, outerbackbevel],
 107                  [outerbackbevel, 0],
 108                  [ 0, -outerbackbevel]]);
 109       }
 110     }
 111   }
 112 }
 113
 114 module GpsBody() { ////toplevel
 115   difference(){
 116     union(){
 117       difference(){
 118         cube([model_outerw, model_outerh, model_outert]);
 119         translate([bezelw, bezelboth, screent])
 120           cube([model_outerw-bezelw*2,
 121                 model_outerh-bezelboth-bezeltoph,
 122                 model_outert]);
 123         translate([model_outerw-spkr2rhs, spkr2bot, -1])
 124           cylinder(r=spkrdia/2, h=model_outert+2);
 125       }
 126       translate([plug2lhs+plugw/2, plug2bot+plugh/2, 0])
 127         cylinder(r=(plugw+plugh)/2, h=model_outert);
 128       for (x=[plug2lhs-plugstrutw, plug2lhs+plugw])
 129         translate([x, 0.1, 0])
 130           cube([plugstrutw, model_outerh-0.2, plugstrutt-0.10]);
 131     }
 132     GpsPlugPlug(0);
 133     for (x=[0,model_outerw]) translate([x,0,0]) GpsBodyOuterBevel(model_outerh);
 134     for (y=[0,model_outerh]) translate([0,y,0])
 135       rotate([0,0,-90]) GpsBodyOuterBevel(model_outerw);
 136   }
 137 }
 138
 139 module GpsPlug() {
 140   plugwireh = plug2bot + plugwiremoreh;
 141   translate([-plugslop,0,0]) GpsPlugPlug(-plugslop);
 142   mirror([0,0,1]) translate([plug2lhs, plug2bot, 0]) {
 143     cube([plugw, plugh, plugtotald-0.05]);
 144     translate([0, -plugwireh, pluggapd])
 145       cube([plugw, plugwireh+0.05, plugtotald-pluggapd]);
 146   }
 147 }
 148
 149 lhsteethu = 2;
 150
 151 module GpsLHSMask(xslop=0){
 152   translate([plug2lhs + plugw+plugh+plugstrutw,
 153              0,
 154              -50]) {
 155     for (iter=[-100/lhsteethu : 100/lhsteethu]) {
 156       translate([0, iter*lhsteethu*2, 0]) {
 157         linear_extrude(height=100) {
 158           polygon([[-300,     0],
 159                    [   0,     0],
 160                    [lhsteethu,lhsteethu],
 161                    [   0,     lhsteethu*2],
 162                    [-300,     lhsteethu*2+0.1]]);
 163         }
 164       }
 165     }
 166   }
 167 }
 168
 169 module GpsAssembled(){ ////toplevel
 170   GpsBody();
 171   GpsPlug();
 172 }
 173
 174 module GpsBodyLT(){
 175   intersection(){
 176     GpsBody();
 177     GpsLHSMask();
 178   }
 179 }
 180
 181 module GpsBodyRT(){
 182   difference(){
 183     GpsBody();
 184     GpsLHSMask(bodylhsrhsslop);
 185   }
 186 }
 187
 188 module GpsPlugT(){ ////toplevel
 189   rotate([0,-90,0]) GpsPlug();
 190 }
 191
 192 module NestleCubeCutout(ca,cb,d){
 193   dist = cb - ca;
 194   mirror([0,1,0]){
 195     rotate([90,0,0]){
 196       linear_extrude(height=d){
 197         polygon([[ca, -nestleh-1],
 198                  [ca, -dist/2],
 199                  [(ca+cb)/2, 0],
 200                  [cb, -dist/2],
 201                  [cb, -nestleh-1]]);
 202       }
 203     }
 204   }
 205 }
 206
 207 module NestleCube(){ ////toplevel
 208   midw = nestlew/2;
 209   midd = min(nestledl,nestledr);
 210   midddb = max(nestleddbl,nestleddbr);
 211
 212   based0 = nestleddf;
 213   based1 = midd - midddb;
 214   basew0 = -nestledwr;
 215   basew1 = +nestledwl-nestlew;
 216
 217   cutd0 = based0 + nestlewallmin;
 218   cutd1 = based1 - nestlewallmin;
 219   cutw0 = basew0 - nestlewallmin;
 220   cutw1 = basew1 + nestlewallmin;
 221
 222   translate([-(basew0+basew1)/2, -(based0+based1)/2, 0]) difference(){
 223     polyhedron
 224       (points=[[          +0      ,            +0,        0], // 0
 225                [          +0      ,            +nestledr, 0], // 1
 226                [          -midw   ,            +midd,     0], // 2
 227                [          -nestlew,            +nestledl, 0], // 3
 228                [          -nestlew,            +0,        0], // 4
 229                [-nestledwr+0      , +nestleddf +0,        -nestleh], // 5
 230                [-nestledwr+0      , -nestleddbr+nestledr, -nestleh], // 6
 231                [          -midw   , -midddb    +midd,     -nestleh], // 7
 232                [+nestledwl-nestlew, -nestleddbl+nestledl, -nestleh], // 8
 233                [+nestledwl-nestlew, +nestleddf +0,        -nestleh]], // 9
 234        triangles=[[0,1,6],[6,5,0],
 235                   [1,2,7],[7,6,1],
 236                   [2,3,8],[8,7,2],
 237                   [3,4,9],[9,8,3],
 238                   [4,0,5],[5,9,4],
 239                   [4,3,2],[2,1,0],[0,4,2],
 240                   [7,8,9],[5,6,7],[7,9,5]],
 241        convexity=3);
 242     intersection(){
 243       NestleCubeCutout(cutw1, cutw0, max(nestledl,nestledr));
 244       rotate([0,0,90]) NestleCubeCutout(cutd0, cutd1, nestlew);
 245     }
 246   }
 247
 248   translate([gpsrightwardoffset,-gpsrearwardoffset,0])
 249     rotate([0,0,gpsazimuth])
 250     translate([nestledoveclipw/2,0,DoveClip_depth()-0.5])
 251     rotate([0,-90,0])
 252     DoveClipPairSane(count=3, h=nestledoveclipw);
 253 }
 254
 255 module NestleCubePin(){ ////toplevel
 256   DoveClipPin(nestledoveclipw*0.4);
 257 }
 258
 259 module HolderSideL(){ ////toplevel
 260   minz = -(bezelw - holderbezelmore) - holderbackt;
 261   holdert = holder_outert + holderwallt*2;
 262   cylr = 0.5*sqrt(holderdcw*holderdcw + holderdoveclipl*holderdoveclipl);
 263   difference(){
 264     translate([-holderh,
 265                -holderwallt,
 266                minz]) {
 267       cube([holderh + holderhgap + cylr,
 268             holdert,
 269             -minz]);
 270       translate([holderh + holderhgap + cylr, holdert/2, 0]) {
 271         cylinder(r=cylr, h=-minz);
 272         rotate([0,0,gpselevation])
 273           translate([0, -holderdoveclipl/2, -minz + DoveClip_depth()])
 274           rotate([0,-90,-90])
 275           DoveClipPairSane(count=holderdccount, h=holderdoveclipl);
 276       }
 277     }
 278     translate([-holderh-1,
 279                0,
 280                minz + holderbackt])
 281       cube([holderh+1,
 282             holder_outert,
 283             bezelw]);
 284   }
 285 }
 286
 287 module HolderSideR(){ ////toplevel
 288   mirror([0,1,0]) HolderSideL();
 289 }
 290
 291 module ChassisBar(){ ////toplevel
 292   dist = holder_outerw - 2*((bezelw - holderbezelmore) + DoveClip_depth());
 293   cliph = holderdcw;
 294   for (mir=[0,1]) {
 295     mirror([mir,0,0]) {
 296       translate([dist/2, cliph/2, 0])
 297         DoveClipPairSane(h=holderdoveclipl, count=holderdccount);
 298       translate([-1, 0, 0])
 299         cube([dist/2 - DoveClip_depth() + 1.1, chassish, chassist]);
 300     }
 301   }
 302   translate([gpsrightwardoffsetonbar, -DoveClip_depth(), 0])
 303     rotate([0,0,-90])
 304     DoveClipPairSane(h=nestledoveclipw, count=3,
 305                      baseextend=chassist/2);
 306 }
 307
 308 module HolderSidePin(){ ////toplevel
 309   DoveClipPin(holderdoveclipl*0.5);
 310 }
 311
 312 module Pins(){ ///toplevel
 313   for (i=[1:4*holderdccount]) {
 314     translate([i*10, 0, 0]) HolderSidePin();
 315   }
 316   for (i=[1:6]) {
 317     translate([i*10, 20, 0]) NestleCubePin();
 318   }
 319 }
 320
 321 //GpsPlugT();
 322 //GpsAssembled();
 323 //GpsBody();
 324 //NestleCube();
 325 //NestleCubePin();
 326 //HolderSideL();
 327 //HolderSideR();
 328 //HolderSidePin();
 329 //ChassisBar();
 330 //Pins();