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 = 10;
  16 tower_base_height = 20;
  17 tower_slot_width = 3;
  18
  19 cableclamp_ctie_width = 4.0 + 1.0;
  20 cableclamp_ctie_thick = 2.5 + 0.5;
  21
  22 lidclamp_ctie_width = 4.0 + 1.0;
  23 lidclamp_ctie_thick = 2.5 + 0.5;
  24
  25 base_ctie_width = 4.0 + 1.0;
  26 base_ctie_thick = 2.5 + 0.5;
  27
  28 tube_ctie_width = 4.0 + 1.0;
  29 tube_ctie_thick = 2.5 + 0.5;
  30
  31 // tuning
  32
  33 tower_over_angle = 45;
  34 tower_wall_thick = 1.6;
  35 tower_forehead_angle = 30;
  36 lid_wall_thick = 1.6;
  37 lid_slop = 0.75;
  38 //cableclamp_ctie_anchor = 5;
  39 lidclamp_cableclamp_ctie_between = 0;
  40 base_ctie_anchor = 5;
  41 tube_ctie_anchor = 5;
  42 protrusion_size = 2;
  43 protrusion_none_frontback = 10;
  44 protrusion_slop = 0.25;
  45 cableclamp_ctie_z = tower_frontheight/2;
  46
  47 towerleg_backfront = 5;
  48 towerleg_width = 3;
  49 towerleg_foot_gap = 2;
  50 towerleg_foot_backfront = 20;
  51 towerleg_foot_width = 40;
  52 towerleg_foot_height = 10;
  53 towerleg_yslope = 0.7;
  54 towerleg_xslope = 0.3;
  55 echo(sqrt(towerleg_yslope*towerleg_yslope+towerleg_xslope*towerleg_xslope));
  56
  57 //--- tests ---
  58
  59 test_width = 24;
  60 test_height = 24;
  61
  62 test_thicks = [9,14,21];
  63
  64 module Tests(){ ////toplevel
  65   for (thicki=[0:len(test_thicks)-1]) {
  66     translate([thicki*test_width-0.5, 0, 0]) {
  67       difference(){
  68         cube([test_width,
  69               test_thicks[thicki] + led_depth,
  70               test_height]);
  71         translate([test_width/2, -1, test_height/2])
  72           rotate([-90,0,0])
  73           cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
  74       }
  75     }
  76   }
  77 }
  78
  79 //Tests();
  80
  81 //--- real thing ---
  82
  83 // calculated
  84
  85 tower_overhang = led_dia * 2.5;
  86 tower_width = width_space_inside + tower_wall_thick*2;
  87
  88 tower_over_max_y = tower_overhang * sin(tower_over_angle);
  89 tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle);
  90 tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth;
  91 tower_rearwall_y = -(backfront_space_inside + tower_wall_thick);
  92 led_head_y = tower_over_max_y/2;
  93 led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2;
  94 backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y));
  95
  96 tower_height_contribution = led_head_z + tower_base_height;
  97
  98 base_ctie_anchor_eff = base_ctie_anchor+base_ctie_thick/2;
  99 tube_ctie_anchor_eff = tube_ctie_anchor+tube_ctie_thick/2;
 100
 101 base_width = 0.7 * crossbar_dia;
 102 base_backfront = backfront_mate_extra - tower_rearwall_y;
 103 base_height = led_tip_height_above_crossbar - tower_height_contribution;
 104
 105 protrusion_frontback = base_backfront - protrusion_none_frontback;
 106
 107 echo(tower_height_contribution, base_height);
 108
 109 module TowerWallCrossSection(){
 110   // generates a 2D shape - a polygon
 111   // x is what is going to be -y
 112   // y is what is going to be z
 113   polygon([[0,                  0],
 114            [0,                  tower_frontheight],
 115            [-tower_over_max_y,  tower_over_max_z],
 116            [-tower_over_max_y
 117             + tan(tower_forehead_angle) * (vert_space_inside + led_depth),
 118             tower_total_max_z],
 119            [-tower_rearwall_y,  tower_total_max_z],
 120            [-tower_rearwall_y,  0],
 121            [-tower_rearwall_y, -tower_base_height],
 122            [-backfront_mate_extra, -tower_base_height]],
 123           convexity=5);
 124 }
 125
 126 module TowerWallSomeEdge(front){
 127   minkowski(){
 128     difference(){
 129       TowerWallCrossSection();
 130       translate([front ? 0.10 : -0.10, 0])
 131         TowerWallCrossSection();
 132     }
 133     circle(r=tower_wall_thick, $fn=8);
 134   }
 135 }
 136
 137 module TowerBulkCrossSection(){
 138   intersection(){
 139     TowerWallCrossSection();
 140     union(){
 141       translate([-led_head_y, led_head_z])
 142         circle(r = led_depth);
 143       TowerWallSomeEdge(true);
 144       translate([-50, -50])
 145         square([100, 50]);
 146     }
 147   }
 148 }
 149
 150 module TowerRearWallCrossSection(){
 151   intersection(){
 152     TowerWallCrossSection();
 153     union(){
 154       intersection(){
 155         translate([0,-10]) square([100, 10+led_head_z]);
 156         TowerWallSomeEdge(false);
 157       }
 158       TowerBulkCrossSection();
 159     }
 160   }
 161 }
 162
 163
 164 module TowerCrossSectionDemo(){
 165   %TowerWallCrossSection();
 166   //TowerBulkCrossSection();
 167   TowerRearWallCrossSection();
 168 }
 169
 170 module TowerMain(){
 171   for (mir=[0,1])
 172     mirror([mir,0,0]) rotate([90,0,-90]) {
 173       translate([0,0, tower_width/2-tower_wall_thick])
 174         linear_extrude(height=tower_wall_thick) {
 175         TowerWallCrossSection();
 176       }
 177       translate([0,0,-1])
 178         linear_extrude(height=tower_width/2+0.9)
 179         union(){
 180           TowerBulkCrossSection();
 181           hull(){
 182             intersection(){
 183               TowerWallCrossSection();
 184               translate([-30, -30])
 185                 square([30 + 0.1, 30 + tower_frontheight]);
 186             }
 187           }
 188         }
 189       translate([0,0, tower_slot_width/2])
 190         linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2)
 191         TowerRearWallCrossSection();
 192     }
 193 }
 194
 195 module LedHole(){
 196   translate([0, led_head_y, led_head_z])
 197     rotate([90 + led_angle, 0, 0])
 198     translate([0,0,-10])
 199     cylinder(r=led_dia/2, h=led_depth+1+10, $fn=26, $fa=10);
 200 }
 201
 202 module TowerProper(){
 203   difference(){
 204     TowerMain();
 205     LedHole();
 206     // passages for cable ties
 207     translate([0,
 208                tower_rearwall_y/2,
 209                cableclamp_ctie_z
 210                + cableclamp_ctie_width/2 + lidclamp_ctie_thick/2
 211                + lidclamp_cableclamp_ctie_between])
 212       cube([50, lidclamp_ctie_width, lidclamp_ctie_thick], center=true);
 213     translate([0,
 214                 (backfront_mate_extra+tower_rearwall_y)/2,
 215                 -tower_base_height
 216                + max(protrusion_size + protrusion_slop + 0.1,
 217                      base_ctie_anchor_eff)])
 218       cube([50, base_ctie_width, base_ctie_thick], center=true);
 219 //    for (extra_y=[0, -(cableclamp_ctie_thick + cableclamp_ctie_anchor)]) {
 220 //      translate([-tower_width/2,
 221 //               -cableclamp_ctie_thick/2 - tower_wall_thick + extra_y,
 222 //               cableclamp_ctie_z])
 223 //      cube([tower_wall_thick+2,
 224 //            cableclamp_ctie_thick,
 225 //            cableclamp_ctie_width], center=true);
 226 //    }
 227     for (mir=[0,1])
 228      mirror([mir,0,0]) {
 229         translate([tower_width/4, 20, cableclamp_ctie_z])
 230           cube([cableclamp_ctie_thick,
 231                 tower_wall_thick*2+1+40,
 232                 cableclamp_ctie_width],
 233                center=true);
 234       }
 235     translate([0, tower_rearwall_y, -tower_base_height])
 236       BaseRegistrationProtrusion(protrusion_slop);
 237   }
 238 }
 239
 240 module Tower(){ ////toplevel
 241   TowerProper();
 242   for (mir=[0,1]) {
 243     mirror([mir,0,0]){
 244       translate([0,
 245                  tower_rearwall_y + 0.1,
 246                  -1])
 247         mirror([0,0,1])
 248         multmatrix([[1,0, towerleg_xslope,0],
 249                     [0,1,-towerleg_yslope,0],
 250                     [0,0,1,0],
 251                     [0,0,0,1]])
 252         cube([towerleg_width, towerleg_backfront, tower_base_height-2]);
 253     }
 254   }
 255   translate([-towerleg_foot_width/2,
 256              tower_rearwall_y - towerleg_foot_gap,
 257              -tower_base_height])
 258     mirror([0,1,0])
 259     cube([towerleg_foot_width, towerleg_foot_backfront, towerleg_foot_height]);
 260 }
 261
 262 module TowerMainHull(){
 263   hull(){ TowerMain(); }
 264 }
 265
 266 module Lid(){
 267   intersection(){
 268     difference(){
 269       minkowski(){
 270         TowerMainHull();
 271         sphere(r=lid_wall_thick+lid_slop, $fn=8);
 272       }
 273       minkowski(){
 274         TowerMainHull();
 275         sphere(r=lid_slop, $fn=6);
 276       }
 277     }
 278     translate([-50,-50,led_head_z]) cube([100,100,100]);
 279   }
 280 }
 281
 282 module LidT(){ ////toplevel
 283   rotate([180,0,0]) Lid();
 284 }
 285
 286 module BaseRegistrationProtrusion(extra){
 287   size = protrusion_size + extra;
 288   translate([0, base_backfront/2, 0]){
 289     hull(){
 290       translate([0,0, -0.5])
 291         cube([protrusion_size*2, protrusion_frontback, 1.0], center=true);
 292       translate([0, 0, protrusion_size-0.5])
 293         cube([0.05, protrusion_frontback-protrusion_size*2, 1.0], center=true);
 294     }
 295   }
 296 }
 297
 298 module Base(){
 299   difference(){
 300     mirror([0,0,1]){
 301       hull(){
 302         translate([-tower_width/2, 0, 0])
 303           cube([tower_width, base_backfront, 0.1]);
 304         translate([-base_width/2, 0, base_height])
 305           cube([base_width, base_backfront, crossbar_dia/2]);
 306       }
 307     }
 308     translate([0, base_backfront/2, -base_ctie_anchor_eff])
 309       cube([100, base_ctie_width, base_ctie_thick], center=true);
 310     translate([0, base_backfront/2, -base_height + tube_ctie_anchor_eff])
 311       cube([100, tube_ctie_width, tube_ctie_thick], center=true);
 312     translate([0, -1, -(base_height + crossbar_dia/2)])
 313       rotate([-90,0,0])
 314       cylinder(r=crossbar_dia/2, h=101);
 315   }
 316   BaseRegistrationProtrusion(0.0);
 317 }
 318
 319 module BaseT(){ ////toplevel
 320   rotate([90,0,0]) Base();
 321 }
 322
 323 module Demo(){
 324   Tower();
 325   %Lid();
 326   translate([0,0, 25]) Lid();
 327   translate([0, tower_rearwall_y, -(tower_base_height+5)]) Base();
 328 }
 329
 330 //TowerCrossSectionDemo();
 331 //TowerWallSomeEdge(false);
 332 //TowerWallFrontEdge();
 333 //TowerMainHull();
 334 //LidT();
 335 //Tower();
 336 //Lid();
 337 //BaseRegistrationProtrusion();
 338 //Base();
 339 //BaseT();
 340 //Demo();