crossbar-computer-led-mount.scad

   1 // -*- C -*-
   2
   3 led_dia = 5 + 0.6;
   4 led_depth = 5;
   5
   6 led_tip_z = 70;
   7 led_angle = -60;
   8
   9 vert_space_inside = 8;
  10 backfront_space_inside = 12;
  11
  12 backfront_mate_size = 25;
  13 tower_frontheight = 20;
  14 tower_width = 18;
  15 tower_slot_width = 3;
  16
  17 // tuning
  18
  19 tower_over_angle = 45;
  20 tower_wall_thick = 1.6;
  21 tower_base_height = 10;
  22 tower_forehead_angle = 30;
  23
  24 //--- tests ---
  25
  26 test_width = 24;
  27 test_height = 24;
  28
  29 test_thicks = [9,14,21];
  30
  31 module Tests(){ ////toplevel
  32   for (thicki=[0:len(test_thicks)-1]) {
  33     translate([thicki*test_width-0.5, 0, 0]) {
  34       difference(){
  35         cube([test_width,
  36               test_thicks[thicki] + led_depth,
  37               test_height]);
  38         translate([test_width/2, -1, test_height/2])
  39           rotate([-90,0,0])
  40           cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
  41       }
  42     }
  43   }
  44 }
  45
  46 //Tests();
  47
  48 //--- real thing ---
  49
  50 tower_overhang = led_dia * 2.5;
  51
  52 tower_over_max_y = tower_overhang * sin(tower_over_angle);
  53 tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle);
  54 tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth;
  55 tower_rearwall_y = -(backfront_space_inside + tower_wall_thick);
  56 led_head_y = tower_over_max_y/2;
  57 led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2;
  58 backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y));
  59
  60 module TowerWallCrossSection(){
  61   // generates a 2D shape - a polygon
  62   // x is what is going to be -y
  63   // y is what is going to be z
  64   polygon([[0,                  0],
  65            [0,                  tower_frontheight],
  66            [-tower_over_max_y,  tower_over_max_z],
  67            [-tower_over_max_y
  68             + tan(tower_forehead_angle) * (vert_space_inside + led_depth),
  69             tower_total_max_z],
  70            [-tower_rearwall_y,  tower_total_max_z],
  71            [-tower_rearwall_y,  0],
  72            [-tower_rearwall_y, -tower_base_height],
  73            [-backfront_mate_extra, -tower_base_height]],
  74           convexity=5);
  75 }
  76
  77 module TowerWallSomeEdge(front){
  78   minkowski(){
  79     difference(){
  80       TowerWallCrossSection();
  81       translate([front ? 0.10 : -0.10, 0])
  82         TowerWallCrossSection();
  83     }
  84     circle(r=tower_wall_thick, $fn=8);
  85   }
  86 }
  87
  88 module TowerBulkCrossSection(){
  89   intersection(){
  90     TowerWallCrossSection();
  91     union(){
  92       translate([-led_head_y, led_head_z])
  93         circle(r = led_depth);
  94       TowerWallSomeEdge(true);
  95       translate([-50, -50])
  96         square([100, 50]);
  97     }
  98   }
  99 }
 100
 101 module TowerRearWallCrossSection(){
 102   intersection(){
 103     TowerWallCrossSection();
 104     union(){
 105       intersection(){
 106         translate([0,-10]) square([100, 10+led_head_z]);
 107         TowerWallSomeEdge(false);
 108       }
 109       TowerBulkCrossSection();
 110     }
 111   }
 112 }
 113
 114
 115 module TowerCrossSectionDemo(){
 116   %TowerWallCrossSection();
 117   //TowerBulkCrossSection();
 118   TowerRearWallCrossSection();
 119 }
 120
 121 module TowerMain(){
 122   for (mir=[0,1])
 123     mirror([mir,0,0]) rotate([90,0,-90]) {
 124       translate([0,0, tower_width/2-tower_wall_thick])
 125         linear_extrude(height=tower_wall_thick)
 126         TowerWallCrossSection();
 127       translate([0,0,-1])
 128         linear_extrude(height=tower_width/2+0.9)
 129         TowerBulkCrossSection();
 130       translate([0,0, tower_slot_width/2])
 131         linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2)
 132         TowerRearWallCrossSection();
 133     }
 134 }
 135
 136 module LedHole(){
 137   translate([0, led_head_y, led_head_z])
 138     rotate([90 + led_angle])
 139     translate([0,0,-10])
 140     cylinder(r=led_dia/2, h=led_depth+0.1+10, $fn=30);
 141 }
 142
 143 module Tower(){
 144   difference(){
 145     TowerMain();
 146     LedHole();
 147   }
 148 }
 149
 150 //TowerCrossSectionDemo();
 151 //TowerWallSomeEdge(false);
 152 //TowerWallFrontEdge();
 153 Tower();