pattress-boxes-3-cover.scad

   1 // -*- C -*-
   2
   3 patbox_side = 87;
   4 patbox_centres = 60.3;
   5
   6 lid_thinboxbase_overlap = 5;
   7 lid_fatbox_overlap = 12;
   8
   9 lid_thinbox_h = 9;
  10 lid_fatbox_h = 24;
  11 lid_fatbox_switches_h = 6+2;
  12
  13 lid_max_switches_w = 70;
  14 lid_switches_y_slop = 3;
  15
  16 total_len = 260;
  17 thinbox_len = 87;
  18
  19 lid_top_wall = 1.5;
  20 lid_front_wall = 1.5;
  21 lid_side_wall = 1.5;
  22
  23 peg_engage_depth = 1;
  24 peg_engage_dia = 6.5;
  25 peg_main_dia = 9;
  26 peg_max_dia = 15;
  27 peg_inner_dia = 3.5;
  28 peg_top_thick = 1;
  29 peg_straight_len = 3;
  30
  31 peg_inner_slop = 0.2;
  32 peg_outer_slop = 0.1;
  33
  34 peg_slope = 1;
  35
  36 lid_side_slop = 0.5;
  37 lid_rail_behindslop = 0.5;
  38
  39 // computed
  40
  41 lid_inner_max_h =
  42   lid_thinboxbase_overlap + lid_fatbox_h + lid_fatbox_switches_h;
  43 lid_inner_min_h = lid_fatbox_overlap + lid_fatbox_switches_h;
  44
  45 lid_inner_kink = [thinbox_len, thinbox_len*2];
  46
  47 lid_inner_w_nom = patbox_side;
  48 lid_inner_w = lid_inner_w_nom + lid_side_slop * 2;
  49
  50 lid_seatline_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;
  51
  52 lid_seatline_h = lid_fatbox_switches_h;
  53
  54 echo(lid_seatline_w);
  55
  56 peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;
  57
  58 echo(peg_main_height);
  59
  60 module LidSideProfile(){
  61   polygon([[-lid_top_wall,     lid_inner_max_h],
  62            [lid_inner_kink[0], lid_inner_max_h],
  63            [lid_inner_kink[1], lid_inner_min_h],
  64            [total_len,         lid_inner_min_h],
  65            [total_len,         -lid_front_wall],
  66            [-lid_top_wall,     -lid_front_wall]]);
  67 }
  68
  69 module RailProfile(){
  70   yt_base = lid_seatline_h + lid_fatbox_h - lid_thinbox_h;
  71   yt = yt_base - lid_rail_behindslop;
  72   pegx = (lid_inner_w - patbox_centres)/2;
  73
  74   polygon([[-0.1,                  yt],
  75            [pegx - peg_main_dia/2, yt],
  76            [pegx - peg_main_dia/2, yt_base - peg_straight_len],
  77            [-0.1,
  78             yt_base - peg_straight_len - (pegx - peg_main_dia/2)/peg_slope
  79            -0.1]]);
  80 }
  81
  82 module LidSide(){
  83   overlap = [0.1, 0.1, 0.1];
  84
  85   // main side profile
  86   rotate([90,0,0])
  87     linear_extrude(height= lid_side_wall)
  88     LidSideProfile();
  89
  90   // seatline
  91   translate(-overlap)
  92     cube(overlap + [total_len, lid_seatline_w, lid_seatline_h]);
  93
  94   // lid front
  95   translate([-0.1, -0.1, -lid_front_wall])
  96     cube([total_len+0.1, lid_inner_w/2 + 0.2, lid_front_wall]);
  97
  98   // lid top
  99   translate([-lid_top_wall, -lid_side_wall, -lid_front_wall])
 100     cube([lid_top_wall, lid_inner_w/2 + 10, lid_front_wall + lid_inner_max_h]);
 101
 102   // rail
 103   rotate([90,0,90])
 104     translate([0,0,-0.1])
 105     linear_extrude(height=100.1) //todo
 106     RailProfile();
 107 }
 108
 109 module PegProfile(){
 110   polygon([[-peg_engage_depth, (peg_engage_dia - peg_outer_slop)/2],
 111            [0,                 (peg_engage_dia - peg_outer_slop)/2],
 112            [0,                 (peg_main_dia - peg_outer_slop)/2],
 113            [peg_straight_len,  (peg_main_dia - peg_outer_slop)/2],
 114            [peg_main_height,   (peg_max_dia - peg_outer_slop)/2],
 115            [peg_main_height+peg_top_thick, (peg_max_dia - peg_outer_slop)/2],
 116            [peg_main_height+peg_top_thick, (peg_inner_dia + peg_inner_slop)/2],
 117            [-peg_engage_depth,  (peg_inner_dia + peg_inner_slop)/2]]);
 118 }
 119
 120 module Peg(){
 121   rotate_extrude($fn=50)
 122     rotate([0,0,-90])
 123     PegProfile();
 124 }
 125
 126 module AtFixingCentres(){
 127   for (fc=[-1,+1]) {
 128     translate([patbox_side/2 + fc*patbox_centres/2,
 129                patbox_side/2,
 130                0])
 131       children();
 132   }
 133 }
 134
 135 module TopPattressBox(){
 136   difference(){
 137     translate([0,0, -lid_thinbox_h])
 138       cube([patbox_side, patbox_side, lid_thinbox_h]);
 139     AtFixingCentres(){
 140       translate([0,0,-10]) cylinder(r=peg_engage_dia/2, h=20);
 141     }
 142   }
 143 }
 144
 145 module Demo(){
 146   translate([0, -lid_inner_w/2, 0]) LidSide();
 147   translate([0,0, lid_fatbox_h])
 148     rotate([0,180,0]) translate([0, -patbox_side/2, 0])
 149     rotate([0,0,90]) union(){
 150       %TopPattressBox();
 151       color("blue") AtFixingCentres(){
 152         rotate([180,0,0]) Peg();
 153       }
 154   }
 155 }
 156
 157 //LidSide();
 158 //PegProfile();
 159 //Peg();
 160 //TopPattressBox();
 161 //RailProfile();
 162 Demo();