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 = 15;
  16 tower_base_height = 15;
  17 tower_slot_width = 3;
  18
  19 cableclamp_ctie_width = 3 + 0.5;
  20 cableclamp_ctie_thick = 2 + 0.5;
  21
  22 lidclamp_ctie_width = 4.0 + 0.5;
  23 lidclamp_ctie_thick = 2.5 + 0.5;
  24
  25 base_ctie_width = 4.0 + 0.5;
  26 base_ctie_thick = 2.5 + 0.5;
  27
  28 tube_ctie_width = 5 + 0.5;
  29 tube_ctie_thick = 3 + 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 = 0.5;
  45 cableclamp_ctie_z = tower_frontheight/2;
  46
  47 //--- tests ---
  48
  49 test_width = 24;
  50 test_height = 24;
  51
  52 test_thicks = [9,14,21];
  53
  54 module Tests(){ ////toplevel
  55   for (thicki=[0:len(test_thicks)-1]) {
  56     translate([thicki*test_width-0.5, 0, 0]) {
  57       difference(){
  58         cube([test_width,
  59               test_thicks[thicki] + led_depth,
  60               test_height]);
  61         translate([test_width/2, -1, test_height/2])
  62           rotate([-90,0,0])
  63           cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
  64       }
  65     }
  66   }
  67 }
  68
  69 //Tests();
  70
  71 //--- real thing ---
  72
  73 // calculated
  74
  75 tower_overhang = led_dia * 2.5;
  76 tower_width = width_space_inside + tower_wall_thick*2;
  77
  78 tower_over_max_y = tower_overhang * sin(tower_over_angle);
  79 tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle);
  80 tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth;
  81 tower_rearwall_y = -(backfront_space_inside + tower_wall_thick);
  82 led_head_y = tower_over_max_y/2;
  83 led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2;
  84 backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y));
  85
  86 tower_height_contribution = led_head_z + tower_base_height;
  87
  88 base_ctie_anchor_eff = base_ctie_anchor+base_ctie_thick/2;
  89 tube_ctie_anchor_eff = tube_ctie_anchor+tube_ctie_thick/2;
  90
  91 base_width = 0.7 * crossbar_dia;
  92 base_backfront = backfront_mate_extra - tower_rearwall_y;
  93 base_height = led_tip_height_above_crossbar - tower_height_contribution;
  94
  95 protrusion_frontback = base_backfront - protrusion_none_frontback;
  96
  97 echo(tower_height_contribution, base_height);
  98
  99 module TowerWallCrossSection(){
 100   // generates a 2D shape - a polygon
 101   // x is what is going to be -y
 102   // y is what is going to be z
 103   polygon([[0,                  0],
 104            [0,                  tower_frontheight],
 105            [-tower_over_max_y,  tower_over_max_z],
 106            [-tower_over_max_y
 107             + tan(tower_forehead_angle) * (vert_space_inside + led_depth),
 108             tower_total_max_z],
 109            [-tower_rearwall_y,  tower_total_max_z],
 110            [-tower_rearwall_y,  0],
 111            [-tower_rearwall_y, -tower_base_height],
 112            [-backfront_mate_extra, -tower_base_height]],
 113           convexity=5);
 114 }
 115
 116 module TowerWallSomeEdge(front){
 117   minkowski(){
 118     difference(){
 119       TowerWallCrossSection();
 120       translate([front ? 0.10 : -0.10, 0])
 121         TowerWallCrossSection();
 122     }
 123     circle(r=tower_wall_thick, $fn=8);
 124   }
 125 }
 126
 127 module TowerBulkCrossSection(){
 128   intersection(){
 129     TowerWallCrossSection();
 130     union(){
 131       translate([-led_head_y, led_head_z])
 132         circle(r = led_depth);
 133       TowerWallSomeEdge(true);
 134       translate([-50, -50])
 135         square([100, 50]);
 136     }
 137   }
 138 }
 139
 140 module TowerRearWallCrossSection(){
 141   intersection(){
 142     TowerWallCrossSection();
 143     union(){
 144       intersection(){
 145         translate([0,-10]) square([100, 10+led_head_z]);
 146         TowerWallSomeEdge(false);
 147       }
 148       TowerBulkCrossSection();
 149     }
 150   }
 151 }
 152
 153
 154 module TowerCrossSectionDemo(){
 155   %TowerWallCrossSection();
 156   //TowerBulkCrossSection();
 157   TowerRearWallCrossSection();
 158 }
 159
 160 module TowerMain(){
 161   for (mir=[0,1])
 162     mirror([mir,0,0]) rotate([90,0,-90]) {
 163       translate([0,0, tower_width/2-tower_wall_thick])
 164         linear_extrude(height=tower_wall_thick) {
 165         TowerWallCrossSection();
 166       }
 167       translate([0,0,-1])
 168         linear_extrude(height=tower_width/2+0.9)
 169         union(){
 170           TowerBulkCrossSection();
 171           hull(){
 172             intersection(){
 173               TowerWallCrossSection();
 174               translate([-30, -30])
 175                 square([30 + 0.1, 30 + tower_frontheight]);
 176             }
 177           }
 178         }
 179       translate([0,0, tower_slot_width/2])
 180         linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2)
 181         TowerRearWallCrossSection();
 182     }
 183 }
 184
 185 module LedHole(){
 186   translate([0, led_head_y, led_head_z])
 187     rotate([90 + led_angle])
 188     translate([0,0,-10])
 189     cylinder(r=led_dia/2, h=led_depth+0.1+10, $fn=30);
 190 }
 191
 192 module Tower(){ ////toplevel
 193   difference(){
 194     TowerMain();
 195     LedHole();
 196     // passages for cable ties
 197     translate([0,
 198                tower_rearwall_y/2,
 199                cableclamp_ctie_z
 200                + cableclamp_ctie_width/2 + lidclamp_ctie_thick/2
 201                + lidclamp_cableclamp_ctie_between])
 202       cube([50, lidclamp_ctie_width, lidclamp_ctie_thick], center=true);
 203     translate([0,
 204                 (backfront_mate_extra+tower_rearwall_y)/2,
 205                 -tower_base_height
 206                + max(protrusion_size + protrusion_slop + 0.1,
 207                      base_ctie_anchor_eff)])
 208       cube([50, base_ctie_width, base_ctie_thick], center=true);
 209 //    for (extra_y=[0, -(cableclamp_ctie_thick + cableclamp_ctie_anchor)]) {
 210 //      translate([-tower_width/2,
 211 //               -cableclamp_ctie_thick/2 - tower_wall_thick + extra_y,
 212 //               cableclamp_ctie_z])
 213 //      cube([tower_wall_thick+2,
 214 //            cableclamp_ctie_thick,
 215 //            cableclamp_ctie_width], center=true);
 216 //    }
 217     for (mir=[0,1])
 218      mirror([mir,0,0]) {
 219         translate([tower_width/4, 20, cableclamp_ctie_z])
 220           cube([cableclamp_ctie_thick,
 221                 tower_wall_thick*2+1+40,
 222                 cableclamp_ctie_width],
 223                center=true);
 224       }
 225     translate([0, tower_rearwall_y, -tower_base_height])
 226       BaseRegistrationProtrusion(protrusion_slop);
 227   }
 228 }
 229
 230 module TowerMainHull(){
 231   hull(){ TowerMain(); }
 232 }
 233
 234 module Lid(){
 235   intersection(){
 236     difference(){
 237       minkowski(){
 238         TowerMainHull();
 239         sphere(r=lid_wall_thick+lid_slop, $fn=4);
 240       }
 241       minkowski(){
 242         TowerMainHull();
 243         sphere(r=lid_slop, $fn=4);
 244       }
 245     }
 246     translate([-50,-50,led_head_z]) cube([100,100,100]);
 247   }
 248 }
 249
 250 module LidT(){ ////toplevel
 251   rotate([180,0,0]) Lid();
 252 }
 253
 254 module BaseRegistrationProtrusion(extra){
 255   size = protrusion_size + extra;
 256   translate([0, base_backfront/2, 0]){
 257     hull(){
 258       translate([0,0, -0.5])
 259         cube([protrusion_size*2, protrusion_frontback, 1.0], center=true);
 260       translate([0, 0, protrusion_size-0.5])
 261         cube([0.05, protrusion_frontback-protrusion_size*2, 1.0], center=true);
 262     }
 263   }
 264 }
 265
 266 module Base(){
 267   difference(){
 268     mirror([0,0,1]){
 269       hull(){
 270         translate([-tower_width/2, 0, 0])
 271           cube([tower_width, base_backfront, 0.1]);
 272         translate([-base_width/2, 0, base_height])
 273           cube([base_width, base_backfront, crossbar_dia/2]);
 274       }
 275     }
 276     translate([-50, base_backfront/2, -base_ctie_anchor_eff])
 277       cube([100, base_ctie_width, base_ctie_thick], center=true);
 278     translate([-50, base_backfront/2, -base_height + tube_ctie_anchor_eff])
 279       cube([100, tube_ctie_width, tube_ctie_thick], center=true);
 280     translate([0, -1, -(base_height + crossbar_dia/2)])
 281       rotate([-90,0,0])
 282       cylinder(r=crossbar_dia/2, h=101);
 283   }
 284   BaseRegistrationProtrusion(0.0);
 285 }
 286
 287 module BaseT(){ ////toplevel
 288   rotate([90,0,0]) Base();
 289 }
 290
 291 module Demo(){
 292   Tower();
 293   %Lid();
 294   translate([0,0, 25]) Lid();
 295   translate([0, tower_rearwall_y, -(tower_base_height+5)]) Base();
 296 }
 297
 298 //TowerCrossSectionDemo();
 299 //TowerWallSomeEdge(false);
 300 //TowerWallFrontEdge();
 301 //TowerMainHull();
 302 //LidT();
 303 //Tower();
 304 //Lid();
 305 //BaseRegistrationProtrusion();
 306 //Base();
 307 //BaseT();
 308 //Demo();