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 expose = 4.00;
  13
  14 cutout_dia = 7;
  15 cutout_between = 5;
  16
  17 button_dz = 1.35;
  18 button_dz_centre = 1.35 + 0.75;
  19 button_dz_outer  = 1.35;
  20
  21 button_dy_outer = 28.42;
  22 button_dy_inner = 19.05;
  23 button_dy_centre = 5.65;
  24
  25 phone_slop = 0.5 * [1,1,0]
  26            + 0.5 * [0,0,1];
  27
  28 led = [25.9, 9.44]; // y is from edge
  29 led_dia = 4.4;
  30
  31 // next values include slop
  32 plug_maxw = 10.95 + 0.35;
  33 plug_minw=   6.53 + 0.35;
  34 plug_sllen=  6.50;
  35 plug_totlen = 84.90 + 1.5; // to maxw, including phone
  36
  37 plug_h = 6.5;
  38 plug_tooth_h = 0.5;
  39 plug_tooth_dy = 0.5;
  40
  41 keeper_prong = 2;
  42 keeper_stalk_basewidth = 6;
  43 keeper_stalk_len = 70;
  44 keeper_stalk_gap = 1;
  45 keeper_stalk_thick = wall_bot;
  46
  47 keeper_stalk_base_reinforce_len = 5;
  48 keeper_stalk_base_reinforce_thick = 2.0;
  49
  50 // calculated
  51
  52 top_z = max( phone[2] + wall[2],
  53              phone_button_z + minwall )
  54   + phone_slop[2];
  55
  56 plugkeeper_x_maxw = phone[0] - plug_totlen;
  57
  58 plugkeeper_p_max = [ 0, plug_maxw/2 ];
  59 plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
  60 plugkeeper_d_u = unitvector2d(
  61                  clockwise2d(
  62                  vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
  63                              )
  64                              );
  65
  66 module MainProfileInnerHalf(){
  67   p = phone + phone_slop;
  68   pbc = p[2] + button_dz_centre;
  69   pbo = p[2] + button_dz_outer;
  70   polygon([[ -2,                 0    ],
  71            [ p[1]/2,             0    ],
  72            [ p[1]/2,             p[2] ],
  73            [ button_dy_outer/2,  p[2] ],
  74            [ button_dy_outer/2,  pbo  ],
  75            [ button_dy_inner/2,  pbo  ],
  76            [ button_dy_inner/2,  p[2] ],
  77            [ button_dy_centre/2, p[2] ],
  78            [ button_dy_centre/2, pbc  ],
  79            [ -2,                 pbc  ]]);
  80 }
  81
  82 module MainProfile(){
  83   p = phone + phone_slop;
  84   difference(){
  85     for (m=[0,1]) mirror([m,0]) {
  86         minkowski(){
  87           translate([ -wall[1], -wall_bot ])
  88             square([ wall[1]*2, wall_bot + wall[2] ]);
  89           MainProfileInnerHalf();
  90         }
  91       }
  92     for (m=[0,1]) mirror([m,0]) {
  93         MainProfileInnerHalf();
  94       }
  95   }
  96 }
  97
  98 module BoxMain(){
  99   rotate([0,0,90]) rotate([90,0,0]) {
 100     translate([0,0, expose])
 101       linear_extrude(height = phone[0] + wall[0] - expose, convexity=20)
 102       MainProfile();
 103     translate([0,0, phone[0]])
 104       linear_extrude(height = wall[0], convexity=20)
 105       hull() MainProfile();
 106   }
 107 }
 108
 109 module PlugKeeperProfileHalf(){
 110   p_max = plugkeeper_p_max;
 111   p_min = plugkeeper_p_min;
 112   d = plugkeeper_d_u * keeper_prong;
 113
 114   translate([ plugkeeper_x_maxw, 0 ]) {
 115     polygon([ p_min,
 116               p_max,
 117               p_max + d,
 118               p_min + d ]);
 119   }
 120 }
 121
 122 module PlugKeeperStalkProfile(){
 123   hull(){
 124     for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
 125     translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
 126       square([ 0.1, keeper_stalk_basewidth ], center=true);
 127   }
 128 }
 129
 130 module PlugKeeper(){
 131   for (m=[0,1]) mirror([0,m,0]) {
 132       translate([0,0, -keeper_stalk_thick])
 133         linear_extrude(height=plug_h + keeper_stalk_thick)
 134         PlugKeeperProfileHalf();
 135
 136       translate([0, 0, plug_h - plug_tooth_h])
 137         linear_extrude(height= plug_tooth_h)
 138         translate(plugkeeper_d_u * -plug_tooth_dy)
 139         PlugKeeperProfileHalf();
 140
 141     }
 142 }
 143
 144 module Box(){
 145   sidewall_cutout_z = phone[2] + phone_slop[2] + button_dz_outer;
 146
 147   difference(){
 148     BoxMain();
 149
 150     translate([ led[0], phone[1]/2 - led[1], 1 ])
 151       rotate([0,0, 360/8/2])
 152       cylinder(r = led_dia/2 / cos(360/8/2), h= phone[2]*2, $fn=8);
 153
 154     for (ys=[-1,+1]) {
 155       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
 156         linear_extrude(height = wall[2]*3)
 157         PlugKeeperStalkProfile();
 158
 159       translate([ phone[0] + wall[0],
 160                   ys * (cutout_between/2 + cutout_dia/2),
 161                   -10 ])
 162         cylinder( r= cutout_dia/2, h = 50, $fn = 20 );
 163
 164       translate([expose, ys*phone[1]/2, sidewall_cutout_z/2])
 165         rotate([90,0,0])
 166         translate([0,0,-3])
 167         cylinder( r= sidewall_cutout_z/2 - 0.1, h=6 , $fn=20 );
 168     }
 169   }
 170
 171   PlugKeeper();
 172
 173   translate([0,0, -keeper_stalk_thick])
 174     linear_extrude(height = keeper_stalk_thick)
 175     PlugKeeperStalkProfile();
 176
 177   translate([ plugkeeper_x_maxw + keeper_stalk_len +
 178                -keeper_stalk_base_reinforce_len/2,
 179                -keeper_stalk_basewidth/2,
 180                0 ])
 181     mirror([0,0,1])
 182     cube([ keeper_stalk_base_reinforce_len,
 183            keeper_stalk_basewidth,
 184            keeper_stalk_base_reinforce_thick ]);
 185 }
 186
 187 module BoxPrint(){
 188   // This makes' Cura's support more optimal: specifically,
 189   // it then doesn't seem to touch the back (bottom) wall
 190   translate([0,0,phone[0]])
 191     rotate([0,90,0])
 192     Box();
 193 }
 194
 195 //MainProfileInnerHalf();
 196 //MainProfile();
 197 //Box();
 198 BoxPrint();