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
  38 // computed
  39
  40 lid_inner_max_h =
  41   lid_thinboxbase_overlap + lid_fatbox_h + lid_fatbox_switches_h;
  42 lid_inner_min_h = lid_fatbox_overlap + lid_fatbox_switches_h;
  43
  44 lid_inner_kink = [thinbox_len, thinbox_len*2];
  45
  46 lid_inner_w = patbox_side + lid_side_slop;
  47
  48 lid_rail_w = (lid_inner_w - lid_max_switches_w)/2 - lid_switches_y_slop;
  49
  50 lid_rail_h = lid_fatbox_switches_h;
  51
  52 echo(lid_rail_w);
  53
  54 peg_main_height = peg_straight_len + (peg_max_dia - peg_main_dia)/2/peg_slope;
  55
  56 echo(peg_main_height);
  57
  58 module LidSideProfile(){
  59   polygon([[-lid_top_wall,     lid_inner_max_h],
  60            [lid_inner_kink[0], lid_inner_max_h],
  61            [lid_inner_kink[1], lid_inner_min_h],
  62            [total_len,         lid_inner_min_h],
  63            [total_len,         -lid_front_wall],
  64            [-lid_top_wall,     -lid_front_wall]]);
  65 }
  66
  67 module LidSide(){
  68   overlap = [0.1, 0.1, 0.1];
  69
  70   // main side profile
  71   rotate([90,0,0])
  72     linear_extrude(height= lid_side_wall)
  73     LidSideProfile();
  74
  75   // rail
  76   translate(-overlap)
  77     cube(overlap + [total_len, lid_rail_w, lid_rail_h]);
  78
  79   // lid front
  80   translate([-0.1, -0.1, -lid_front_wall])
  81     cube([total_len+0.1, lid_inner_w/2 + 0.2, lid_front_wall]);
  82
  83   // lid top
  84   translate([-lid_top_wall, -lid_side_wall, -lid_front_wall])
  85     cube([lid_top_wall, lid_inner_w/2 + 10, lid_front_wall + lid_inner_max_h]);
  86 }
  87
  88 module PegProfile(){
  89   polygon([[-peg_engage_depth, (peg_engage_dia - peg_outer_slop)/2],
  90            [0,                 (peg_engage_dia - peg_outer_slop)/2],
  91            [0,                 (peg_main_dia - peg_outer_slop)/2],
  92            [peg_straight_len,  (peg_main_dia - peg_outer_slop)/2],
  93            [peg_main_height,   (peg_max_dia - peg_outer_slop)/2],
  94            [peg_main_height+peg_top_thick, (peg_max_dia - peg_outer_slop)/2],
  95            [peg_main_height+peg_top_thick, (peg_inner_dia + peg_inner_slop)/2],
  96            [-peg_engage_depth,  (peg_inner_dia + peg_inner_slop)/2]]);
  97 }
  98
  99 module Peg(){
 100   rotate_extrude($fn=50)
 101     rotate([0,0,-90])
 102     PegProfile();
 103 }
 104
 105 module AtFixingCentres(){
 106   for (fc=[-1,+1]) {
 107     translate([patbox_side/2 + fc*patbox_centres/2,
 108                patbox_side/2,
 109                0])
 110       children();
 111   }
 112 }
 113
 114 module TopPattressBox(){
 115   difference(){
 116     translate([0,0, -lid_thinbox_h])
 117       cube([patbox_side, patbox_side, lid_thinbox_h]);
 118     AtFixingCentres(){
 119       translate([0,0,-10]) cylinder(r=peg_engage_dia/2, h=20);
 120     }
 121   }
 122 }
 123
 124 module Demo(){
 125   translate([0, -lid_inner_w/2, 0]) LidSide();
 126   translate([0,0, lid_fatbox_h])
 127     rotate([0,180,0]) translate([0, -patbox_side/2, 0])
 128     rotate([0,0,90]) union(){
 129       %TopPattressBox();
 130   }
 131 }
 132
 133 //LidSide();
 134 //PegProfile();
 135 //Peg();
 136 //TopPattressBox();
 137 Demo();