crossbar-computer-led-mount.scad

   1 // -*- C -*-
   2
   3 led_dia = 5 + 0.6;
   4 led_depth = 5;
   5
   6 led_tip_height_above_crossbar = 70;
   7 led_angle = -60;
   8 crossbar_dia = 25; // fixme
   9
  10 vert_space_inside = 8;
  11 backfront_space_inside = 12;
  12 width_space_inside = 10;
  13
  14 backfront_mate_size = 25;
  15 tower_frontheight = 20;
  16 tower_slot_width = 3;
  17
  18 cableclamp_ctie_width = 3 + 0.5;
  19 cableclamp_ctie_thick = 2 + 0.5;
  20
  21 lidclamp_ctie_width = 4.0 + 0.5;
  22 lidclamp_ctie_thick = 2.5 + 0.5;
  23
  24 base_ctie_width = 4.0 + 0.5;
  25 base_ctie_thick = 2.5 + 0.5;
  26
  27 tube_ctie_width = 5 + 0.5;
  28 tube_ctie_thick = 3 + 0.5;
  29
  30 // tuning
  31
  32 tower_over_angle = 45;
  33 tower_wall_thick = 1.6;
  34 tower_base_height = 10;
  35 tower_forehead_angle = 30;
  36 lid_wall_thick = 1.6;
  37 lid_slop = 0.75;
  38 base_ctie_anchor = 5;
  39 tube_ctie_anchor = 5;
  40
  41 //--- tests ---
  42
  43 test_width = 24;
  44 test_height = 24;
  45
  46 test_thicks = [9,14,21];
  47
  48 module Tests(){ ////toplevel
  49   for (thicki=[0:len(test_thicks)-1]) {
  50     translate([thicki*test_width-0.5, 0, 0]) {
  51       difference(){
  52         cube([test_width,
  53               test_thicks[thicki] + led_depth,
  54               test_height]);
  55         translate([test_width/2, -1, test_height/2])
  56           rotate([-90,0,0])
  57           cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
  58       }
  59     }
  60   }
  61 }
  62
  63 //Tests();
  64
  65 //--- real thing ---
  66
  67 // calculated
  68
  69 tower_overhang = led_dia * 2.5;
  70 tower_width = width_space_inside + tower_wall_thick*2;
  71
  72 tower_over_max_y = tower_overhang * sin(tower_over_angle);
  73 tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle);
  74 tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth;
  75 tower_rearwall_y = -(backfront_space_inside + tower_wall_thick);
  76 led_head_y = tower_over_max_y/2;
  77 led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2;
  78 backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y));
  79
  80 tower_height_contribution = led_head_z + tower_base_height;
  81
  82 base_ctie_anchor_eff = base_ctie_anchor+base_ctie_thick/2;
  83 tube_ctie_anchor_eff = tube_ctie_anchor+tube_ctie_thick/2;
  84
  85 base_width = 0.7 * crossbar_dia;
  86 base_backfront = backfront_mate_extra - tower_rearwall_y;
  87 base_height = led_tip_height_above_crossbar - tower_height_contribution;
  88
  89 echo(tower_height_contribution, base_height);
  90
  91 module TowerWallCrossSection(){
  92   // generates a 2D shape - a polygon
  93   // x is what is going to be -y
  94   // y is what is going to be z
  95   polygon([[0,                  0],
  96            [0,                  tower_frontheight],
  97            [-tower_over_max_y,  tower_over_max_z],
  98            [-tower_over_max_y
  99             + tan(tower_forehead_angle) * (vert_space_inside + led_depth),
 100             tower_total_max_z],
 101            [-tower_rearwall_y,  tower_total_max_z],
 102            [-tower_rearwall_y,  0],
 103            [-tower_rearwall_y, -tower_base_height],
 104            [-backfront_mate_extra, -tower_base_height]],
 105           convexity=5);
 106 }
 107
 108 module TowerWallSomeEdge(front){
 109   minkowski(){
 110     difference(){
 111       TowerWallCrossSection();
 112       translate([front ? 0.10 : -0.10, 0])
 113         TowerWallCrossSection();
 114     }
 115     circle(r=tower_wall_thick, $fn=8);
 116   }
 117 }
 118
 119 module TowerBulkCrossSection(){
 120   intersection(){
 121     TowerWallCrossSection();
 122     union(){
 123       translate([-led_head_y, led_head_z])
 124         circle(r = led_depth);
 125       TowerWallSomeEdge(true);
 126       translate([-50, -50])
 127         square([100, 50]);
 128     }
 129   }
 130 }
 131
 132 module TowerRearWallCrossSection(){
 133   intersection(){
 134     TowerWallCrossSection();
 135     union(){
 136       intersection(){
 137         translate([0,-10]) square([100, 10+led_head_z]);
 138         TowerWallSomeEdge(false);
 139       }
 140       TowerBulkCrossSection();
 141     }
 142   }
 143 }
 144
 145
 146 module TowerCrossSectionDemo(){
 147   %TowerWallCrossSection();
 148   //TowerBulkCrossSection();
 149   TowerRearWallCrossSection();
 150 }
 151
 152 module TowerMain(){
 153   for (mir=[0,1])
 154     mirror([mir,0,0]) rotate([90,0,-90]) {
 155       translate([0,0, tower_width/2-tower_wall_thick])
 156         linear_extrude(height=tower_wall_thick) {
 157         TowerWallCrossSection();
 158       }
 159       translate([0,0,-1])
 160         linear_extrude(height=tower_width/2+0.9)
 161         union(){
 162           TowerBulkCrossSection();
 163           hull(){
 164             intersection(){
 165               TowerWallCrossSection();
 166               translate([-30, -30])
 167                 square([30 + 0.1, 30 + tower_frontheight]);
 168             }
 169           }
 170         }
 171       translate([0,0, tower_slot_width/2])
 172         linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2)
 173         TowerRearWallCrossSection();
 174     }
 175 }
 176
 177 module LedHole(){
 178   translate([0, led_head_y, led_head_z])
 179     rotate([90 + led_angle])
 180     translate([0,0,-10])
 181     cylinder(r=led_dia/2, h=led_depth+0.1+10, $fn=30);
 182 }
 183
 184 module Tower(){ ////toplevel
 185   difference(){
 186     TowerMain();
 187     LedHole();
 188     // passages for cable ties
 189     translate([0,
 190                tower_rearwall_y/2,
 191                tower_frontheight/2
 192                + cableclamp_ctie_width/2 + lidclamp_ctie_thick/2])
 193       cube([50, lidclamp_ctie_width, lidclamp_ctie_thick], center=true);
 194     translate([0,
 195                 (backfront_mate_extra+tower_rearwall_y)/2,
 196                 -tower_base_height/2])
 197       cube([50, base_ctie_width, base_ctie_thick], center=true);
 198     for (mir=[0,1])
 199       mirror([mir,0,0]) {
 200         translate([tower_width/4, 20, tower_frontheight/2])
 201           cube([cableclamp_ctie_thick,
 202                 tower_wall_thick*2+1+40,
 203                 cableclamp_ctie_width],
 204                center=true);
 205       }
 206   }
 207 }
 208
 209 module TowerMainHull(){
 210   hull(){ TowerMain(); }
 211 }
 212
 213 module Lid(){
 214   intersection(){
 215     difference(){
 216       minkowski(){
 217         TowerMainHull();
 218         sphere(r=lid_wall_thick+lid_slop, $fn=4);
 219       }
 220       minkowski(){
 221         TowerMainHull();
 222         sphere(r=lid_slop, $fn=4);
 223       }
 224     }
 225     translate([-50,-50,led_head_z]) cube([100,100,100]);
 226   }
 227 }
 228
 229 module LidT(){ ////toplevel
 230   rotate([180,0,0]) Lid();
 231 }
 232
 233 module Base(){ ////toplevel
 234   difference(){
 235     mirror([0,0,1]){
 236       hull(){
 237         translate([-tower_width/2, 0, 0])
 238           cube([tower_width, base_backfront, 0.1]);
 239         translate([-base_width/2, 0, base_height])
 240           cube([base_width, base_backfront, crossbar_dia/2]);
 241       }
 242     }
 243     translate([-50, base_backfront/2, -base_ctie_anchor_eff])
 244       cube([100, base_ctie_width, base_ctie_thick], center=true);
 245     translate([-50, base_backfront/2, -base_height + tube_ctie_anchor_eff])
 246       cube([100, tube_ctie_width, tube_ctie_thick], center=true);
 247     translate([0, -1, -(base_height + crossbar_dia/2)])
 248       rotate([-90,0,0])
 249       cylinder(r=crossbar_dia/2, h=101);
 250   }
 251 }
 252
 253 module BaseT(){ ////toplevel
 254   rotate([90,0,0]) Base();
 255 }
 256
 257 module Demo(){
 258   Tower();
 259   translate([0,0, 25]) Lid();
 260   translate([0, tower_rearwall_y, -(tower_base_height+5)]) Base();
 261 }
 262
 263 //TowerCrossSectionDemo();
 264 //TowerWallSomeEdge(false);
 265 //TowerWallFrontEdge();
 266 //TowerMainHull();
 267 //LidT();
 268 //Tower();
 269 //Lid();
 270 //Base();
 271 //BaseT();
 272 Demo();