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