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