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+4;
  12
  13 lid_max_switches_w = 70;
  14 lid_switches_y_slop = 3;
  15
  16 total_len = 260;
  17 thinbox_len = 87;
  18
  19 rail_overlap = 8;
  20
  21 lid_top_wall = 1.5;
  22 lid_front_wall = 1.5;
  23 lid_side_wall = 1.5;
  24
  25 peg_engage_depth = 1;
  26 peg_engage_dia = 6.5;
  27 peg_main_dia = 9;
  28 peg_max_dia = 15;
  29 peg_inner_dia = 3.5;
  30 peg_top_thick = 1;
  31 peg_straight_len = 3;
  32
  33 $peg_inner_slop = 0.75;
  34 $peg_outer_slop = -0.9;
  35 $peg_outer_slop_engage = 0.1;
  36
  37 peg_slope = 1;
  38
  39 lid_side_slop = 0.5;
  40 lid_rail_behindslop = 0.5;
  41 lid_rail_strongwall = 2.5;
  42
  43 // computed
  44
  45 lid_inner_max_h =
  46   lid_thinboxbase_overlap + lid_fatbox_h + lid_fatbox_switches_h;
  47 lid_inner_min_h = lid_fatbox_overlap + lid_fatbox_switches_h;
  48
  49 lid_inner_kink = [thinbox_len, thinbox_len*2];
  50
  51 lid_inner_w_nom = patbox_side;
  52 lid_inner_w = lid_inner_w_nom + lid_side_slop * 2;
  53
  54 lid_seatline_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;
  55
  56 lid_seatline_h = lid_fatbox_switches_h;
  57
  58 peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;
  59
  60 thinbox_front_z = lid_fatbox_switches_h + lid_fatbox_h - lid_thinbox_h;
  61
  62 raillen = patbox_side/2 + rail_overlap;
  63
  64 module LidSideProfile(){
  65   polygon([[-lid_top_wall,     lid_inner_max_h],
  66            [min(lid_inner_kink[0],total_len), lid_inner_max_h],
  67            [min(lid_inner_kink[1],total_len), lid_inner_min_h],
  68            [total_len,         lid_inner_min_h],
  69            [total_len,         -lid_front_wall],
  70            [-lid_top_wall,     -lid_front_wall]]);
  71 }
  72
  73 module RailProfile(lslop=0.1){
  74   yt_base = thinbox_front_z;
  75   yt = yt_base - lid_rail_behindslop;
  76   pegx = (lid_inner_w_nom - patbox_centres)/2;
  77   sw = lid_rail_strongwall;
  78
  79   polygon([[-lslop,                  yt],
  80            [pegx - peg_main_dia/2, yt],
  81            [pegx - peg_main_dia/2, yt_base - peg_straight_len],
  82            [sw,
  83             yt_base - peg_straight_len - (pegx - peg_main_dia/2)/peg_slope
  84             +sw],
  85            [sw,
  86             lid_seatline_h - 1],
  87            [-lslop,
  88             lid_seatline_h - 1]]);
  89 }
  90
  91 module LidSide(){
  92   overlap = [0.1, 0.1, 0.1];
  93
  94   // main side profile
  95   rotate([90,0,0])
  96     linear_extrude(height= lid_side_wall)
  97     LidSideProfile();
  98
  99   // seatline
 100   translate(-overlap)
 101     cube(overlap + [total_len, lid_seatline_w, lid_seatline_h]);
 102
 103   // lid front
 104   translate([-0.1, -0.1, -lid_front_wall])
 105     cube([total_len+0.1, lid_inner_w/2 + 0.2, lid_front_wall]);
 106
 107   // lid top
 108   translate([-lid_top_wall, -lid_side_wall, -lid_front_wall])
 109     cube([lid_top_wall, lid_inner_w/2 + 10, lid_front_wall + lid_inner_max_h]);
 110
 111   // rail
 112   rotate([90,0,90])
 113     translate([0,0,-0.1])
 114     linear_extrude(height=raillen+0.1) //todo
 115     RailProfile();
 116
 117   // rail end
 118   translate([raillen, 0,0])
 119     intersection(){
 120       rotate_extrude($fn=50)
 121         RailProfile(lslop=0);
 122       translate([0, 25-0.1, 0])
 123         cube(50, center=true);
 124     }
 125 }
 126
 127 module Lid(){ ////toplevel
 128   for (m=[0,1])
 129     mirror([0,m,0])
 130       translate([0, -lid_inner_w/2, 0]) LidSide();
 131 }
 132
 133 module PegProfile(){
 134   polygon([[-peg_engage_depth, (peg_engage_dia - $peg_outer_slop_engage)/2],
 135            [0,                 (peg_engage_dia - $peg_outer_slop_engage)/2],
 136            [0,                 (peg_main_dia - $peg_outer_slop)/2],
 137            [peg_straight_len,  (peg_main_dia - $peg_outer_slop)/2],
 138            [peg_main_height,   (peg_max_dia - $peg_outer_slop)/2],
 139            [peg_main_height+peg_top_thick, (peg_max_dia - $peg_outer_slop)/2],
 140            [peg_main_height+peg_top_thick, (peg_inner_dia + $peg_inner_slop)/2],
 141            [-peg_engage_depth,  (peg_inner_dia + $peg_inner_slop)/2]]);
 142 }
 143
 144 module Peg(){ ////toplevel
 145   echo($peg_outer_slop_engage);
 146   rotate_extrude($fn=50)
 147     rotate([0,0,-90])
 148     PegProfile();
 149 }
 150
 151 module Pegs(){ ////toplevel
 152   baseslop = 0.1;
 153   dslops = [0, -0.5, -1.0, -1.5];
 154   stride = peg_max_dia + 4;
 155   for (i=[0:len(dslops)-1]) {
 156     translate([i*stride,0,0])
 157       assign($peg_outer_slop_engage= baseslop + dslops[i])
 158       Peg();
 159   }
 160 }
 161
 162 module AtFixingCentres(){
 163   for (fc=[-1,+1]) {
 164     translate([patbox_side/2 + fc*patbox_centres/2,
 165                patbox_side/2,
 166                0])
 167       children();
 168   }
 169 }
 170
 171 module TopPattressBox(){
 172   difference(){
 173     translate([0,0, -lid_thinbox_h])
 174       cube([patbox_side, patbox_side, lid_thinbox_h]);
 175     AtFixingCentres(){
 176       translate([0,0,-10]) cylinder(r=peg_engage_dia/2, h=20);
 177     }
 178   }
 179 }
 180
 181 module Demo(){
 182   Lid();
 183   translate([0,0, thinbox_front_z])
 184     rotate([0,180,0]) translate([0, -patbox_side/2, 0])
 185     rotate([0,0,90]) union(){
 186       %TopPattressBox();
 187       color("blue") AtFixingCentres(){
 188         rotate([180,0,0]) Peg();
 189       }
 190   }
 191 }
 192
 193 //LidSide();
 194 //PegProfile();
 195 //Peg();
 196 //Pegs();
 197 //TopPattressBox();
 198 //RailProfile();
 199 //Demo();
 200 //Lid();
 201 //translate([0,0,-lid_fatbox_switches_h]) Lid();