powerbank-bike-clamp.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 tube_dia = 22.4;
   6
   7 hinge_around = 2.5;
   8 hinge_pin = 1.8 + 0.75;
   9 main_th = 3;
  10 minor_wall_min = 1;
  11
  12 screw = 5.0 + 0.75;
  13 screw_head = 8.7 + 1.2;
  14 screw_nut_across = 7.9 + 0.75;
  15 screw_nut_th = 3.9 + 0.75;
  16 screw_head_h = 3.6 + 0.75;
  17
  18 knob_behind_across = 12.2 + 0.75;
  19 behind_knob_th = 5;
  20
  21 clamp_width = 20;
  22
  23 clamp_gap = 2;
  24
  25 lower_th = 1;
  26
  27 overlap_l = 0.1;
  28
  29 bridge_slop = 1.2;
  30
  31 hinge_lobes = 2;
  32 hinge_gap_z = 0.75;
  33 hinge_gap_xy = 0.75;
  34
  35 $fs = 0.1;
  36 $fa = 5;
  37
  38 bank_eps_bbox_x = [149, 598];
  39 bank_eps_bbox_y = [274, 1452];
  40
  41 bank_y_sz = 102.25 + 0.50;
  42 bank_x_sz = (24.9 + 0.5);
  43 bank_recess_y = 5;
  44
  45 strap_th = 3;
  46 strap_above = 2.5;
  47
  48 retainer_walls = [18, 30];
  49
  50 bank_profile_scale_bodge = 1.1;
  51
  52 // calculated
  53
  54 endwall_th = main_th;
  55
  56 bank_recess_dx = minor_wall_min;
  57
  58 pspt_to_mm = 25.4 / 72;
  59
  60 hinge_stride = (clamp_width + hinge_gap_z) / hinge_lobes;
  61
  62 main_r = tube_dia/2 + main_th;
  63
  64 hinge_outer_r = hinge_around + hinge_pin/2;
  65 hinge_y = tube_dia/2 + hinge_outer_r;
  66
  67 screw_max_y_lhs = -main_r -screw_nut_across/2;
  68 screw_max_y_rhs = -main_r -knob_behind_across/2;
  69
  70 screw_y = min(screw_max_y_lhs,
  71               screw_max_y_rhs);
  72
  73 bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
  74   -minor_wall_min;
  75
  76 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  77 bank_bot_y = strap_above + strap_th;
  78 strap_r = strap_th;
  79
  80 echo(bot_y);
  81
  82 module TubePlan(){ circle(r = tube_dia/2); }
  83 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
  84 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
  85
  86 module TubeClampLeftPlan(){
  87   difference(){
  88     union(){
  89       polygon([[ 0,                    hinge_y + hinge_outer_r ],
  90                [ -main_r + overlap_l,  hinge_y + hinge_outer_r ],
  91                [ -main_r + overlap_l,  bot_y                   ],
  92                [ -clamp_gap/2,         bot_y                   ],
  93                [ -clamp_gap/2,         0,                      ],
  94                [ 0,                    0,                      ],
  95                ]);
  96       HingeBodyPlan();
  97     }
  98     TubePlan();
  99     HingePinPlan();
 100   }
 101 }
 102
 103 module TubeClampLeft() { ////toplevel
 104   linextr(-clamp_width/2, clamp_width/2)
 105     TubeClampLeftPlan();
 106 }
 107
 108 module TubeClampRightPlan(){
 109   difference(){
 110     union(){
 111       rectfromto([ clamp_gap/2,                   bot_y ],
 112                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 113       intersection(){
 114         circle(r= main_r);
 115         union(){
 116           rectfromto([0,0],
 117                       main_r *  [5,5]);
 118           rectfromto([ clamp_gap/2, main_r*5 ],
 119                       main_r * [2,-5]);
 120         }
 121       }
 122       HingeBodyPlan();
 123     }
 124     TubePlan();
 125     HingePinPlan();
 126   }
 127 }
 128
 129 module SomeClamp(hinge_alt=false){
 130   difference(){
 131     linextr(-clamp_width/2, clamp_width/2)
 132       children(0);
 133
 134     linextr_x_yz(-main_r*5, main_r*5)
 135       translate([screw_y, 0])
 136       circle(r= screw/2);
 137
 138     for (i=[0 : hinge_lobes-1]) {
 139       translate([0,
 140                  hinge_y,
 141                  -clamp_width/2 + i * hinge_stride
 142                  + (hinge_alt ? hinge_stride/2 : 0)
 143                  ])
 144         linextr(-hinge_gap_z, hinge_stride/2)
 145         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 146     }
 147   }
 148 }
 149
 150 module PowerBankItselfSidePlan(){
 151   translate([0, bank_bot_y])
 152     scale( bank_profile_scale_bodge *
 153            bank_x_sz / ( (
 154                           bank_eps_bbox_x[1] -
 155                           bank_eps_bbox_x[0]
 156                           ) * pspt_to_mm ))
 157     translate(pspt_to_mm *
 158               [-0.5 * (bank_eps_bbox_x[0] +
 159                        bank_eps_bbox_x[1]),
 160                -bank_eps_bbox_y[0]])
 161     import("powerbank-anker-10000.dxf", convexity=5);
 162 }
 163
 164 module PowerBankItself(){ ////toplevel
 165   rotate([0,90,0])
 166     linextr_y_xz(-bank_y_sz/2,
 167                  +bank_y_sz/2)
 168     PowerBankItselfSidePlan();
 169 }
 170
 171 module PowerBankSidePlan(){ ////toplevel
 172   render() difference(){
 173     rectfromto([ -holder_x_sz/2,  0 ],
 174                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 175
 176     PowerBankItselfSidePlan();
 177   }
 178 }
 179
 180 module PowerBankStrapCut(){ ////toplevel
 181   difference(){
 182     rectfromto([ -holder_x_sz, -0.05 ],
 183                [ +holder_x_sz, strap_th + strap_r ]);
 184     hull(){
 185       for (sx=[-1,+1]) {
 186         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 187                    strap_th + strap_r])
 188           circle(strap_r);
 189       }
 190     }
 191   }
 192 }
 193
 194 module PowerBankHolderTest(){ ////toplevel
 195   difference(){
 196     linextr(-1,5) PowerBankSidePlan();
 197     linextr(0, strap_th) PowerBankStrapCut();
 198   }
 199 }
 200
 201 module EndRetainer(depth){ ////toplevel
 202   translate([0, -bank_y_sz/2, 0]) {
 203     linextr_y_xz(-endwall_th, 0)
 204     rectfromto([ 0,         -holder_x_sz/2 ],
 205                [ -depth,    +holder_x_sz/2 ]);
 206
 207     for (m=[0,1]) {
 208       mirror([0,0,m]) {
 209         linextr(-holder_x_sz/2, -bank_x_sz/2){
 210           hull(){
 211             rectfromto([ 0, -endwall_th ],
 212                        [ depth, 0 ]);
 213             rectfromto([ 0, 0 ],
 214                        [ 0.1, depth-0.1 ]);
 215           }
 216         }
 217       }
 218     }
 219   }
 220 }
 221
 222 module PowerBankHolder(){ ////toplevel
 223   difference(){
 224     union(){
 225       rotate([0,90,0])
 226         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 227                      +(bank_y_sz/2 + 0.1))
 228         PowerBankSidePlan();
 229
 230       EndRetainer(retainer_walls[0]);
 231       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 232     }
 233     //linextr(0, strap_th) PowerBankStrapCut();
 234   }
 235 }
 236
 237 module TubeClampLeft() { ////toplevel
 238   // We want this to print with the recess overhand to the right
 239   // where the workpiece cooling fan is
 240   rotate([0,0,180]){
 241     difference(){
 242       SomeClamp(true)
 243         TubeClampLeftPlan();
 244
 245       translate([0, screw_y, 0]) {
 246         linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 247           square([screw_nut_across,
 248                   screw_nut_across / cos(30) + bridge_slop*2],
 249                  center=true);
 250
 251         linextr_x_yz(-main_r, -main_r + screw_head_h)
 252           square([screw_head, screw_head + bridge_slop*2],
 253                  center=true);
 254       }
 255     }
 256   }
 257 }
 258
 259 module TubeClampRight() { ////toplevel
 260   rotate([0,0,180])
 261     rotate([180,0,0])
 262     SomeClamp()
 263     TubeClampRightPlan();
 264 }
 265
 266 module TubeClampDemo() { ////toplevel
 267   TubeClampLeft();
 268   rotate([180,0,0])
 269     TubeClampRight();
 270 }