sleepphone-cable-box.scad

   1 // -*- C -*-
   2
   3 include <funcs.scad>
   4
   5 wall = 0.75 * [1,1,1];
   6 wall_bot = 1.0;
   7
   8 phone = [ 76.40, 30.96, 6.00 ]; // includes socket
   9 phone_button_z = 6.58;
  10 minwall = 0.50;
  11
  12 cutout_dia = 7;
  13 cutout_between = 5;
  14
  15 button_dz = 1.35;
  16
  17 button_dy_outer = 28.42;
  18 button_dy_inner = 19.05;
  19 button_dy_centre = 5.65;
  20
  21 phone_slop = 0.5 * [1,1,0]
  22            + 0.5 * [0,0,1];
  23
  24 led = [25.9, 9.44]; // y is from edge
  25 led_dia = 4.4;
  26
  27 // next values include slop
  28 plug_maxw = 10.95 + 0.35;
  29 plug_minw=   6.53 + 0.35;
  30 plug_sllen=  6.50;
  31 plug_totlen = 84.90 + 1.5; // to maxw, including phone
  32
  33 plug_h = 6.5;
  34 plug_tooth_h = 0.5;
  35 plug_tooth_dy = 0.5;
  36
  37 keeper_prong = 2;
  38 keeper_stalk_basewidth = 6;
  39 keeper_stalk_len = 70;
  40 keeper_stalk_gap = 1;
  41 keeper_stalk_thick = wall_bot;
  42
  43 // calculated
  44
  45 top_z = max( phone[2] + wall[2],
  46              phone_button_z + minwall )
  47   + phone_slop[2];
  48
  49 plugkeeper_x_maxw = phone[0] - plug_totlen;
  50
  51 plugkeeper_p_max = [ 0, plug_maxw/2 ];
  52 plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
  53 plugkeeper_d_u = unitvector2d(
  54                  clockwise2d(
  55                  vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
  56                              )
  57                              );
  58
  59 module MainProfileInnerHalf(){
  60   p = phone + phone_slop;
  61   pb = p[2] + button_dz;
  62   polygon([[ -2,                 0    ],
  63            [ p[1]/2,             0    ],
  64            [ p[1]/2,             p[2] ],
  65            [ button_dy_outer/2,  p[2] ],
  66            [ button_dy_outer/2,  pb   ],
  67            [ button_dy_inner/2,  pb   ],
  68            [ button_dy_inner/2,  p[2] ],
  69            [ button_dy_centre/2, p[2] ],
  70            [ button_dy_centre/2, pb   ],
  71            [ -2,                 pb   ]]);
  72 }
  73
  74 module MainProfile(){
  75   p = phone + phone_slop;
  76   difference(){
  77     for (m=[0,1]) mirror([m,0]) {
  78         minkowski(){
  79           translate([ -wall[1], -wall_bot ])
  80             square([ wall[1]*2, wall_bot + wall[2] ]);
  81           MainProfileInnerHalf();
  82         }
  83       }
  84     for (m=[0,1]) mirror([m,0]) {
  85         MainProfileInnerHalf();
  86       }
  87   }
  88 }
  89
  90 module BoxMain(){
  91   rotate([0,0,90]) rotate([90,0,0]) {
  92     linear_extrude(height = phone[0] + wall[0], convexity=20)
  93       MainProfile();
  94     translate([0,0, phone[0]])
  95       linear_extrude(height = wall[0], convexity=20)
  96       hull() MainProfile();
  97   }
  98 }
  99
 100 module PlugKeeperProfileHalf(){
 101   p_max = plugkeeper_p_max;
 102   p_min = plugkeeper_p_min;
 103   d = plugkeeper_d_u * keeper_prong;
 104
 105   translate([ plugkeeper_x_maxw, 0 ]) {
 106     polygon([ p_min,
 107               p_max,
 108               p_max + d,
 109               p_min + d ]);
 110   }
 111 }
 112
 113 module PlugKeeperStalkProfile(){
 114   hull(){
 115     for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
 116     translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
 117       square([ 0.1, keeper_stalk_basewidth ], center=true);
 118   }
 119 }
 120
 121 module PlugKeeper(){
 122   for (m=[0,1]) mirror([0,m,0]) {
 123       translate([0,0, -keeper_stalk_thick])
 124         linear_extrude(height=plug_h + keeper_stalk_thick)
 125         PlugKeeperProfileHalf();
 126
 127       translate([0, 0, plug_h - plug_tooth_h])
 128         linear_extrude(height= plug_tooth_h)
 129         translate(plugkeeper_d_u * -plug_tooth_dy)
 130         PlugKeeperProfileHalf();
 131
 132     }
 133 }
 134
 135 module Box(){
 136   difference(){
 137     BoxMain();
 138
 139     translate([ led[0], phone[1]/2 - led[1], 1 ])
 140       rotate([0,0, 360/8/2])
 141       cylinder(r = led_dia/2 / cos(360/8/2), h= phone[2]*2, $fn=8);
 142
 143     for (ys=[-1,+1]) {
 144       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
 145         linear_extrude(height = wall[2]*3)
 146         PlugKeeperStalkProfile();
 147
 148       translate([ phone[0] + wall[0],
 149                   ys * (cutout_between/2 + cutout_dia/2),
 150                   -10 ])
 151         cylinder( r= cutout_dia/2, h = 50, $fn = 20 );
 152     }
 153   }
 154
 155   PlugKeeper();
 156
 157   translate([0,0, -keeper_stalk_thick])
 158     linear_extrude(height = keeper_stalk_thick)
 159     PlugKeeperStalkProfile();
 160 }
 161
 162 module BoxPrint(){
 163   // This makes' Cura's support more optimal: specifically,
 164   // it then doesn't seem to touch the back (bottom) wall
 165   rotate([0,90,0])
 166     Box();
 167 }
 168
 169 //MainProfileInnerHalf();
 170 //MainProfile();
 171 //Box();
 172 BoxPrint();