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