sleepphone-cable-box.scad

   1 // -*- C -*-
   2
   3 include <funcs.scad>
   4
   5 wall = 0.75 * [1,1,1];
   6 phone = [ 76.40, 30.96, 6.26 ]; // includes socket
   7 phone_button_z = 6.58;
   8 minwall = 0.25;
   9
  10 button_dy_outer = 28.42;
  11 button_dy_inner = 19.05;
  12 button_dy_centre = 5.65;
  13
  14 phone_slop = 0.5 * [1,1,0]
  15            + 0.5 * [0,0,1];
  16
  17 led = [25.9, 9.44]; // y is from edge
  18 led_dia = 4.4;
  19
  20 // next values include slop
  21 plug_maxw = 10.95 + 0.35;
  22 plug_minw=   6.53 + 0.35;
  23 plug_sllen=  6.50;
  24 plug_totlen = 84.90; // to maxw, including phone
  25
  26 plug_h = 6.5;
  27 plug_tooth_h = 0.5;
  28 plug_tooth_dy = 0.5;
  29
  30 keeper_prong = 2;
  31 keeper_stalk_basewidth = 4;
  32 keeper_stalk_len = 70;
  33 keeper_stalk_gap = 2;
  34
  35 // calculated
  36
  37 top_z = max( phone[2] + wall[2],
  38              phone_button_z + minwall )
  39   + phone_slop[2];
  40
  41 plugkeeper_x_maxw = phone[0] - plug_totlen;
  42
  43 plugkeeper_p_max = [ 0, plug_maxw/2 ];
  44 plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
  45 plugkeeper_d_u = unitvector2d(
  46                  clockwise2d(
  47                  vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
  48                              )
  49                              );
  50
  51 module MainProfileInnerHalf(){
  52   p = phone + phone_slop;
  53   pb = phone_button_z + phone_slop[2];
  54   polygon([[ -2,                 0    ],
  55            [ p[1]/2,             0    ],
  56            [ p[1]/2,             p[2] ],
  57            [ button_dy_outer/2,  p[2] ],
  58            [ button_dy_outer/2,  pb   ],
  59            [ button_dy_inner/2,  pb   ],
  60            [ button_dy_inner/2,  p[2] ],
  61            [ button_dy_centre/2, p[2] ],
  62            [ button_dy_centre/2, pb   ],
  63            [ -2,                 pb   ]]);
  64 }
  65
  66 module MainProfile(){
  67   p = phone + phone_slop;
  68   for (m=[0,1]) mirror([m,0]) {
  69       difference(){
  70         translate([-1, -wall[2] ])
  71           square([ p[1]/2 + wall[1] + 1, top_z + wall[2] ]);
  72         MainProfileInnerHalf();
  73       }
  74     }
  75 }
  76
  77 module BoxMain(){
  78   rotate([0,0,90]) rotate([90,0,0]) {
  79     linear_extrude(height = phone[0] + wall[0], convexity=20)
  80       MainProfile();
  81     translate([0,0, phone[0]])
  82       linear_extrude(height = wall[0], convexity=20)
  83       hull() MainProfile();
  84   }
  85 }
  86
  87 module PlugKeeperProfileHalf(){
  88   p_max = plugkeeper_p_max;
  89   p_min = plugkeeper_p_min;
  90   d = plugkeeper_d_u * keeper_prong;
  91
  92   translate([ plugkeeper_x_maxw, 0 ]) {
  93     polygon([ p_min,
  94               p_max,
  95               p_max + d,
  96               p_min + d ]);
  97   }
  98 }
  99
 100 module PlugKeeperStalkProfile(){
 101   hull(){
 102     for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
 103     translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
 104       square([ 0.1, keeper_stalk_basewidth/2 ], center=true);
 105   }
 106 }
 107
 108 module PlugKeeper(){
 109   for (m=[0,1]) mirror([0,m,0]) {
 110       translate([0,0, -wall[2]])
 111         linear_extrude(height=plug_h + wall[2])
 112         PlugKeeperProfileHalf();
 113
 114       translate([0, 0, plug_h - plug_tooth_h])
 115         linear_extrude(height= plug_tooth_h)
 116         translate(plugkeeper_d_u * -plug_tooth_dy)
 117         PlugKeeperProfileHalf();
 118
 119     }
 120
 121   translate([0,0, -wall[2]])
 122     linear_extrude(height = wall[2])
 123     PlugKeeperStalkProfile();
 124 }
 125
 126 module Box(){
 127   difference(){
 128     BoxMain();
 129
 130     translate([ led[0], phone[1]/2 - led[1], 1 ])
 131       cylinder(r = led_dia/2, h= phone[2]*2, $fn=20);
 132
 133     for (ys=[-1,+1])
 134       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
 135         linear_extrude(height = wall[2]*3)
 136         PlugKeeperStalkProfile();
 137   }
 138
 139   PlugKeeper();
 140 }
 141
 142 //MainProfileInner();
 143 Box();
 144