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