sleepphone-cable-box.scad

   1 // -*- C -*-
   2
   3 include <funcs.scad>
   4
   5 wall = 0.75 * [1,1,1];
   6 wall_bot = 0.75;
   7
   8 phone = [ 76.40, 30.96, 6.00 ]; // includes socket
   9 phone_button_z = 6.58;
  10 minwall = 0.50;
  11
  12 button_dz = 1.35;
  13
  14 button_dy_outer = 28.42;
  15 button_dy_inner = 19.05;
  16 button_dy_centre = 5.65;
  17
  18 phone_slop = 0.5 * [1,1,0]
  19            + 0.5 * [0,0,1];
  20
  21 led = [25.9, 9.44]; // y is from edge
  22 led_dia = 4.4;
  23
  24 // next values include slop
  25 plug_maxw = 10.95 + 0.35;
  26 plug_minw=   6.53 + 0.35;
  27 plug_sllen=  6.50;
  28 plug_totlen = 84.90 - 1.5; // to maxw, including phone
  29
  30 plug_h = 6.5;
  31 plug_tooth_h = 0.5;
  32 plug_tooth_dy = 0.5;
  33
  34 keeper_prong = 2;
  35 keeper_stalk_basewidth = 4;
  36 keeper_stalk_len = 70;
  37 keeper_stalk_gap = 2;
  38
  39 // calculated
  40
  41 top_z = max( phone[2] + wall[2],
  42              phone_button_z + minwall )
  43   + phone_slop[2];
  44
  45 plugkeeper_x_maxw = phone[0] - plug_totlen;
  46
  47 plugkeeper_p_max = [ 0, plug_maxw/2 ];
  48 plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
  49 plugkeeper_d_u = unitvector2d(
  50                  clockwise2d(
  51                  vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
  52                              )
  53                              );
  54
  55 module MainProfileInnerHalf(){
  56   p = phone + phone_slop;
  57   pb = p[2] + button_dz;
  58   polygon([[ -2,                 0    ],
  59            [ p[1]/2,             0    ],
  60            [ p[1]/2,             p[2] ],
  61            [ button_dy_outer/2,  p[2] ],
  62            [ button_dy_outer/2,  pb   ],
  63            [ button_dy_inner/2,  pb   ],
  64            [ button_dy_inner/2,  p[2] ],
  65            [ button_dy_centre/2, p[2] ],
  66            [ button_dy_centre/2, pb   ],
  67            [ -2,                 pb   ]]);
  68 }
  69
  70 module MainProfile(){
  71   p = phone + phone_slop;
  72   difference(){
  73     for (m=[0,1]) mirror([m,0]) {
  74         minkowski(){
  75           translate([ -wall[1], -wall_bot ])
  76             square([ wall[1]*2, wall_bot + wall[2] ]);
  77           MainProfileInnerHalf();
  78         }
  79       }
  80     for (m=[0,1]) mirror([m,0]) {
  81         MainProfileInnerHalf();
  82       }
  83   }
  84 }
  85
  86 module BoxMain(){
  87   rotate([0,0,90]) rotate([90,0,0]) {
  88     linear_extrude(height = phone[0] + wall[0], convexity=20)
  89       MainProfile();
  90     translate([0,0, phone[0]])
  91       linear_extrude(height = wall[0], convexity=20)
  92       hull() MainProfile();
  93   }
  94 }
  95
  96 module PlugKeeperProfileHalf(){
  97   p_max = plugkeeper_p_max;
  98   p_min = plugkeeper_p_min;
  99   d = plugkeeper_d_u * keeper_prong;
 100
 101   translate([ plugkeeper_x_maxw, 0 ]) {
 102     polygon([ p_min,
 103               p_max,
 104               p_max + d,
 105               p_min + d ]);
 106   }
 107 }
 108
 109 module PlugKeeperStalkProfile(){
 110   hull(){
 111     for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
 112     translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
 113       square([ 0.1, keeper_stalk_basewidth ], center=true);
 114   }
 115 }
 116
 117 module PlugKeeper(){
 118   for (m=[0,1]) mirror([0,m,0]) {
 119       translate([0,0, -wall[2]])
 120         linear_extrude(height=plug_h + wall[2])
 121         PlugKeeperProfileHalf();
 122
 123       translate([0, 0, plug_h - plug_tooth_h])
 124         linear_extrude(height= plug_tooth_h)
 125         translate(plugkeeper_d_u * -plug_tooth_dy)
 126         PlugKeeperProfileHalf();
 127
 128     }
 129
 130   translate([0,0, -wall[2]])
 131     linear_extrude(height = wall[2])
 132     PlugKeeperStalkProfile();
 133 }
 134
 135 module Box(){
 136   difference(){
 137     BoxMain();
 138
 139     translate([ led[0], phone[1]/2 - led[1], 1 ])
 140       cylinder(r = led_dia/2, h= phone[2]*2, $fn=20);
 141
 142     for (ys=[-1,+1])
 143       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
 144         linear_extrude(height = wall[2]*3)
 145         PlugKeeperStalkProfile();
 146   }
 147
 148   PlugKeeper();
 149 }
 150
 151 //MainProfileInnerHalf();
 152 //MainProfile();
 153 Box();
 154