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 // Adjustment for the GPS attitude and position
  58 gpsazimuth = 45;
  59 gpselevation = 40;
  60 gpsrightwardoffset = 5;
  61 gpsrearwardoffset = 2;
  62 gpsrightwardoffsetonbar = 0;
  63
  64 // Amount of wire protrusion to allow for
  65 plugwiremoreh = 25;
  66
  67 // Slops and steps etc.
  68 plugslop = 0.5;
  69 plughstep = 1.5;
  70 bodylhsrhsslop = 0.5;
  71 holderhgap = 5;
  72 holderbezelmore = 2;
  73 nestlebevel = 2;
  74
  75 // Dimensions for strength only
  76 screent = 1.0;
  77 plugstrutw = 4;
  78 plugstrutt = min(model_outert, 5);
  79 nestledoveclipw = 20;
  80 holderh = model_outerh * 0.5;
  81 holderwallt = 2.5;
  82 holderbackt = 2.8;
  83 holderdccount = 2;
  84 holderdoveclipl = 15;
  85 chassish = 13;
  86 chassist = 13;
  87 nestlefloorh = 2.0;
  88 nestleceilh = 2.0;
  89 nestlewallmin = 3.0;
  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   cuth = -nestleh + nestlefloorh;
 196   mirror([0,1,0]){
 197     translate([0,1,0])
 198     rotate([90,0,0]){
 199       linear_extrude(height=d+2){
 200         polygon([[ca+nestlebevel, cuth],
 201                  [ca, cuth+nestlebevel*2],
 202                  [ca, -dist/2-nestleceilh],
 203                  [(ca+cb)/2, -nestleceilh],
 204                  [cb, -dist/2-nestleceilh],
 205                  [cb, cuth+nestlebevel*2],
 206                  [cb-nestlebevel, cuth]]);
 207       }
 208     }
 209   }
 210 }
 211
 212 module NestleCube(){ ////toplevel
 213   midw = nestlew/2;
 214   midd = min(nestledl,nestledr);
 215   midddb = max(nestleddbl,nestleddbr);
 216
 217   based0 = nestleddf;
 218   based1 = midd - midddb;
 219   basew0 = -nestledwr;
 220   basew1 = +nestledwl-nestlew;
 221
 222   cutd0 = based0 + nestlewallmin;
 223   cutd1 = based1 - nestlewallmin;
 224   cutw0 = basew0 - nestlewallmin;
 225   cutw1 = basew1 + nestlewallmin;
 226
 227   bevth = -nestleh + nestlebevel*2;
 228   bevw = nestlebevel;
 229   bevd = nestlebevel;
 230
 231   translate([-(basew0+basew1)/2, -(based0+based1)/2, 0]) {
 232     difference(){
 233       polyhedron
 234         (points=
 235          [[          +0      ,            +0,        0], // 0
 236           [          +0      ,            +nestledr, 0], // 1
 237           [          -midw   ,            +midd,     0], // 2
 238           [          -nestlew,            +nestledl, 0], // 3
 239           [          -nestlew,            +0,        0], // 4
 240           [-nestledwr+0      , +nestleddf +0,        bevth], // 5
 241           [-nestledwr+0      , -nestleddbr+nestledr, bevth], // 6
 242           [          -midw   , -midddb    +midd,     bevth], // 7
 243           [+nestledwl-nestlew, -nestleddbl+nestledl, bevth], // 8
 244           [+nestledwl-nestlew, +nestleddf +0,        bevth], // 9
 245           [-nestledwr+0      -bevw, +nestleddf +0       +bevd, -nestleh], // 10
 246           [-nestledwr+0      -bevw, -nestleddbr+nestledr-bevd, -nestleh], // 11
 247           [          -midw        , -midddb    +midd    -bevd, -nestleh], // 12
 248           [+nestledwl-nestlew+bevw, -nestleddbl+nestledl-bevd, -nestleh], // 13
 249           [+nestledwl-nestlew+bevw, +nestleddf +0       +bevd, -nestleh]], // 14
 250          triangles=[// main side panels
 251                     [0,1,6],[6,5,0],
 252                     [1,2,7],[7,6,1],
 253                     [2,3,8],[8,7,2],
 254                     [3,4,9],[9,8,3],
 255                     [4,0,5],[5,9,4],
 256                     [0,1,6],[6,5,0],
 257                     // bevels
 258                     [6,7,12],[12,11,6],
 259                     [7,8,13],[13,12,7],
 260                     [8,9,14],[14,13,8],
 261                     [9,5,10],[10,14,9],
 262                     [5,6,11],[11,10,5],
 263                     // top and bottom
 264                     [4,3,2],[2,1,0],[0,4,2],
 265                     [12,13,14],[10,11,12],[12,14,10]],
 266          convexity=3);
 267       intersection(){
 268         #NestleCubeCutout(cutw1, cutw0, max(nestledl,nestledr));
 269         #rotate([0,0,90]) NestleCubeCutout(cutd0, cutd1, nestlew);
 270       }
 271     }
 272   }
 273
 274   translate([gpsrightwardoffset,-gpsrearwardoffset,0])
 275     rotate([0,0,gpsazimuth])
 276     translate([nestledoveclipw/2,0,DoveClip_depth()-0.5])
 277     rotate([0,-90,0])
 278     DoveClipPairSane(count=3, h=nestledoveclipw);
 279 }
 280
 281 module NestleCubePin(){ ////toplevel
 282   DoveClipPin(nestledoveclipw*0.4);
 283 }
 284
 285 module HolderSideL(){ ////toplevel
 286   minz = -(bezelw - holderbezelmore) - holderbackt;
 287   holdert = holder_outert + holderwallt*2;
 288   cylr = 0.5*sqrt(holderdcw*holderdcw + holderdoveclipl*holderdoveclipl);
 289   difference(){
 290     translate([-holderh,
 291                -holderwallt,
 292                minz]) {
 293       cube([holderh + holderhgap + cylr,
 294             holdert,
 295             -minz]);
 296       translate([holderh + holderhgap + cylr, holdert/2, 0]) {
 297         cylinder(r=cylr, h=-minz);
 298         rotate([0,0,gpselevation])
 299           translate([0, -holderdoveclipl/2, -minz + DoveClip_depth()])
 300           rotate([0,-90,-90])
 301           DoveClipPairSane(count=holderdccount, h=holderdoveclipl);
 302       }
 303     }
 304     translate([-holderh-1,
 305                0,
 306                minz + holderbackt])
 307       cube([holderh+1,
 308             holder_outert,
 309             bezelw]);
 310   }
 311 }
 312
 313 module HolderSideR(){ ////toplevel
 314   mirror([0,1,0]) HolderSideL();
 315 }
 316
 317 module ChassisBar(){ ////toplevel
 318   dist = holder_outerw - 2*((bezelw - holderbezelmore) + DoveClip_depth());
 319   cliph = holderdcw;
 320   for (mir=[0,1]) {
 321     mirror([mir,0,0]) {
 322       translate([dist/2, cliph/2, 0])
 323         DoveClipPairSane(h=holderdoveclipl, count=holderdccount);
 324       translate([-1, 0, 0])
 325         cube([dist/2 - DoveClip_depth() + 1.1, chassish, chassist]);
 326     }
 327   }
 328   translate([-gpsrightwardoffsetonbar, -DoveClip_depth(), 0])
 329     rotate([0,0,-90])
 330     DoveClipPairSane(h=nestledoveclipw, count=3,
 331                      baseextend=chassist/2);
 332 }
 333
 334 module HolderSidePin(){ ////toplevel
 335   DoveClipPin(holderdoveclipl*0.5);
 336 }
 337
 338 module Pins(){ ///toplevel
 339   for (i=[1:4*holderdccount]) {
 340     translate([i*10, 0, 0]) HolderSidePin();
 341   }
 342   for (i=[1:6]) {
 343     translate([i*10, 20, 0]) NestleCubePin();
 344   }
 345 }
 346
 347 //GpsPlugT();
 348 //GpsAssembled();
 349 //GpsBody();
 350 //NestleCube();
 351 //NestleCubePin();
 352 //HolderSideL();
 353 //HolderSideR();
 354 //HolderSidePin();
 355 //ChassisBar();
 356 //Pins();