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 = 60.9;
  47 //   depths (back to front distance):
  48 nestledl = 38.3 + 1.9;
  49 nestledr = 42.2 + 1.7;
  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 nestlebevel = 2;
  77
  78 // Dimensions for strength only
  79 screent = 1.0;
  80 plugstrutw = 4;
  81 plugstrutt = min(model_outert, 5);
  82 nestledoveclipw = 20;
  83 holderh = model_outerh * 0.5;
  84 holderwallt = 2.5;
  85 holderbackt = 2.8;
  86 holderdccount = 2;
  87 holderdoveclipl = 15;
  88 chassish = 13;
  89 chassist = 13;
  90
  91 // Consequential values
  92 holderdcw = DoveClipPairSane_width(holderdccount);
  93
  94 module GpsPlugPlug(slop){
  95   effhslop = slop - plughstep;
  96   effplugw = plugw + slop*2;
  97   effplugh = plugh + effhslop*2;
  98   translate([plug2lhs-slop, plug2bot-effhslop, -1])
  99     cube([effplugw, effplugh, model_outert+2]);
 100 }
 101
 102 module GpsBodyOuterBevel(len){
 103   translate([0,-1,0]) {
 104     rotate([-90,0,0]) {
 105       linear_extrude(height=len+2) {
 106         polygon([[-outerbackbevel, 0],
 107                  [ 0, outerbackbevel],
 108                  [outerbackbevel, 0],
 109                  [ 0, -outerbackbevel]]);
 110       }
 111     }
 112   }
 113 }
 114
 115 module GpsBody() { ////toplevel
 116   difference(){
 117     union(){
 118       difference(){
 119         cube([model_outerw, model_outerh, model_outert]);
 120         translate([bezelw, bezelboth, screent])
 121           cube([model_outerw-bezelw*2,
 122                 model_outerh-bezelboth-bezeltoph,
 123                 model_outert]);
 124         translate([model_outerw-spkr2rhs, spkr2bot, -1])
 125           cylinder(r=spkrdia/2, h=model_outert+2);
 126       }
 127       translate([plug2lhs+plugw/2, plug2bot+plugh/2, 0])
 128         cylinder(r=(plugw+plugh)/2, h=model_outert);
 129       for (x=[plug2lhs-plugstrutw, plug2lhs+plugw])
 130         translate([x, 0.1, 0])
 131           cube([plugstrutw, model_outerh-0.2, plugstrutt-0.10]);
 132     }
 133     GpsPlugPlug(0);
 134     for (x=[0,model_outerw]) translate([x,0,0]) GpsBodyOuterBevel(model_outerh);
 135     for (y=[0,model_outerh]) translate([0,y,0])
 136       rotate([0,0,-90]) GpsBodyOuterBevel(model_outerw);
 137   }
 138 }
 139
 140 module GpsPlug() {
 141   plugwireh = plug2bot + plugwiremoreh;
 142   translate([-plugslop,0,0]) GpsPlugPlug(-plugslop);
 143   mirror([0,0,1]) translate([plug2lhs, plug2bot, 0]) {
 144     cube([plugw, plugh, plugtotald-0.05]);
 145     translate([0, -plugwireh, pluggapd])
 146       cube([plugw, plugwireh+0.05, plugtotald-pluggapd]);
 147   }
 148 }
 149
 150 lhsteethu = 2;
 151
 152 module GpsLHSMask(xslop=0){
 153   translate([plug2lhs + plugw+plugh+plugstrutw,
 154              0,
 155              -50]) {
 156     for (iter=[-100/lhsteethu : 100/lhsteethu]) {
 157       translate([0, iter*lhsteethu*2, 0]) {
 158         linear_extrude(height=100) {
 159           polygon([[-300,     0],
 160                    [   0,     0],
 161                    [lhsteethu,lhsteethu],
 162                    [   0,     lhsteethu*2],
 163                    [-300,     lhsteethu*2+0.1]]);
 164         }
 165       }
 166     }
 167   }
 168 }
 169
 170 module GpsAssembled(){ ////toplevel
 171   GpsBody();
 172   GpsPlug();
 173 }
 174
 175 module GpsBodyLT(){
 176   intersection(){
 177     GpsBody();
 178     GpsLHSMask();
 179   }
 180 }
 181
 182 module GpsBodyRT(){
 183   difference(){
 184     GpsBody();
 185     GpsLHSMask(bodylhsrhsslop);
 186   }
 187 }
 188
 189 module GpsPlugT(){ ////toplevel
 190   rotate([0,-90,0]) GpsPlug();
 191 }
 192
 193 module NestleCubeCutout(ca,cb,d){
 194   dist = cb - ca;
 195   mirror([0,1,0]){
 196     rotate([90,0,0]){
 197       linear_extrude(height=d){
 198         polygon([[ca, -nestleh-1],
 199                  [ca, -dist/2],
 200                  [(ca+cb)/2, 0],
 201                  [cb, -dist/2],
 202                  [cb, -nestleh-1]]);
 203       }
 204     }
 205   }
 206 }
 207
 208 module NestleCubeBevel(){
 209   translate([-nestlebevel, -100, -0.1])
 210     rotate([0,30,0])
 211     cube([nestlebevel*2, 200, nestlebevel*5]);
 212 }
 213
 214 module NestleCube(){ ////toplevel
 215   midw = nestlew/2;
 216   midd = min(nestledl,nestledr);
 217   midddb = max(nestleddbl,nestleddbr);
 218
 219   based0 = nestleddf;
 220   based1 = midd - midddb;
 221   basew0 = -nestledwr;
 222   basew1 = +nestledwl-nestlew;
 223
 224   cutd0 = based0 + nestlewallmin;
 225   cutd1 = based1 - nestlewallmin;
 226   cutw0 = basew0 - nestlewallmin;
 227   cutw1 = basew1 + nestlewallmin;
 228
 229   translate([-(basew0+basew1)/2, -(based0+based1)/2, 0]) {
 230     difference(){
 231       polyhedron
 232         (points=[[          +0      ,            +0,        0], // 0
 233                  [          +0      ,            +nestledr, 0], // 1
 234                  [          -midw   ,            +midd,     0], // 2
 235                  [          -nestlew,            +nestledl, 0], // 3
 236                  [          -nestlew,            +0,        0], // 4
 237                  [-nestledwr+0      , +nestleddf +0,        -nestleh], // 5
 238                  [-nestledwr+0      , -nestleddbr+nestledr, -nestleh], // 6
 239                  [          -midw   , -midddb    +midd,     -nestleh], // 7
 240                  [+nestledwl-nestlew, -nestleddbl+nestledl, -nestleh], // 8
 241                  [+nestledwl-nestlew, +nestleddf +0,        -nestleh]], // 9
 242          triangles=[[0,1,6],[6,5,0],
 243                     [1,2,7],[7,6,1],
 244                     [2,3,8],[8,7,2],
 245                     [3,4,9],[9,8,3],
 246                     [4,0,5],[5,9,4],
 247                     [4,3,2],[2,1,0],[0,4,2],
 248                     [7,8,9],[5,6,7],[7,9,5]],
 249          convexity=3);
 250       intersection(){
 251         NestleCubeCutout(cutw1, cutw0, max(nestledl,nestledr));
 252         rotate([0,0,90]) NestleCubeCutout(cutd0, cutd1, nestlew);
 253       }
 254       translate([0,0,-nestleh]) {
 255         translate([-nestledwr, 0, 0]) NestleCubeBevel();
 256       }
 257     }
 258   }
 259
 260   translate([gpsrightwardoffset,-gpsrearwardoffset,0])
 261     rotate([0,0,gpsazimuth])
 262     translate([nestledoveclipw/2,0,DoveClip_depth()-0.5])
 263     rotate([0,-90,0])
 264     DoveClipPairSane(count=3, h=nestledoveclipw);
 265 }
 266
 267 module NestleCubePin(){ ////toplevel
 268   DoveClipPin(nestledoveclipw*0.4);
 269 }
 270
 271 module HolderSideL(){ ////toplevel
 272   minz = -(bezelw - holderbezelmore) - holderbackt;
 273   holdert = holder_outert + holderwallt*2;
 274   cylr = 0.5*sqrt(holderdcw*holderdcw + holderdoveclipl*holderdoveclipl);
 275   difference(){
 276     translate([-holderh,
 277                -holderwallt,
 278                minz]) {
 279       cube([holderh + holderhgap + cylr,
 280             holdert,
 281             -minz]);
 282       translate([holderh + holderhgap + cylr, holdert/2, 0]) {
 283         cylinder(r=cylr, h=-minz);
 284         rotate([0,0,gpselevation])
 285           translate([0, -holderdoveclipl/2, -minz + DoveClip_depth()])
 286           rotate([0,-90,-90])
 287           DoveClipPairSane(count=holderdccount, h=holderdoveclipl);
 288       }
 289     }
 290     translate([-holderh-1,
 291                0,
 292                minz + holderbackt])
 293       cube([holderh+1,
 294             holder_outert,
 295             bezelw]);
 296   }
 297 }
 298
 299 module HolderSideR(){ ////toplevel
 300   mirror([0,1,0]) HolderSideL();
 301 }
 302
 303 module ChassisBar(){ ////toplevel
 304   dist = holder_outerw - 2*((bezelw - holderbezelmore) + DoveClip_depth());
 305   cliph = holderdcw;
 306   for (mir=[0,1]) {
 307     mirror([mir,0,0]) {
 308       translate([dist/2, cliph/2, 0])
 309         DoveClipPairSane(h=holderdoveclipl, count=holderdccount);
 310       translate([-1, 0, 0])
 311         cube([dist/2 - DoveClip_depth() + 1.1, chassish, chassist]);
 312     }
 313   }
 314   translate([-gpsrightwardoffsetonbar, -DoveClip_depth(), 0])
 315     rotate([0,0,-90])
 316     DoveClipPairSane(h=nestledoveclipw, count=3,
 317                      baseextend=chassist/2);
 318 }
 319
 320 module HolderSidePin(){ ////toplevel
 321   DoveClipPin(holderdoveclipl*0.5);
 322 }
 323
 324 module Pins(){ ///toplevel
 325   for (i=[1:4*holderdccount]) {
 326     translate([i*10, 0, 0]) HolderSidePin();
 327   }
 328   for (i=[1:6]) {
 329     translate([i*10, 20, 0]) NestleCubePin();
 330   }
 331 }
 332
 333 //GpsPlugT();
 334 //GpsAssembled();
 335 //GpsBody();
 336 //NestleCube();
 337 //NestleCubePin();
 338 //HolderSideL();
 339 //HolderSideR();
 340 //HolderSidePin();
 341 //ChassisBar();
 342 //Pins();