// -*- C -*- led_dia = 5 + 0.6; led_depth = 5; led_tip_height_above_crossbar = 70; led_angle = -60; crossbar_dia = 25; // fixme vert_space_inside = 8; backfront_space_inside = 12; width_space_inside = 10; backfront_mate_size = 25; tower_frontheight = 10; tower_base_height = 20; tower_slot_width = 3; cableclamp_ctie_width = 4.0 + 1.0; cableclamp_ctie_thick = 2.5 + 0.5; lidclamp_ctie_width = 4.0 + 1.0; lidclamp_ctie_thick = 2.5 + 0.5; base_ctie_width = 4.0 + 1.0; base_ctie_thick = 2.5 + 0.5; tube_ctie_width = 4.0 + 1.0; tube_ctie_thick = 2.5 + 0.5; // tuning tower_over_angle = 45; tower_wall_thick = 1.6; tower_forehead_angle = 30; lid_wall_thick = 1.6; lid_slop = 0.75; //cableclamp_ctie_anchor = 5; lidclamp_cableclamp_ctie_between = 0; base_ctie_anchor = 5; tube_ctie_anchor = 5; protrusion_size = 2; protrusion_none_frontback = 10; protrusion_slop = 0.25; cableclamp_ctie_z = tower_frontheight/2; towerleg_backfront = 5; towerleg_width = 3; towerleg_foot_gap = 2; towerleg_foot_backfront = 20; towerleg_foot_width = 40; towerleg_foot_height = 10; towerleg_yslope = 0.7; towerleg_xslope = 0.3; echo(sqrt(towerleg_yslope*towerleg_yslope+towerleg_xslope*towerleg_xslope)); //--- tests --- test_width = 24; test_height = 24; test_thicks = [9,14,21]; module Tests(){ ////toplevel for (thicki=[0:len(test_thicks)-1]) { translate([thicki*test_width-0.5, 0, 0]) { difference(){ cube([test_width, test_thicks[thicki] + led_depth, test_height]); translate([test_width/2, -1, test_height/2]) rotate([-90,0,0]) cylinder(r=led_dia/2, h=led_depth+1, $fn=30); } } } } //Tests(); //--- real thing --- // calculated tower_overhang = led_dia * 2.5; tower_width = width_space_inside + tower_wall_thick*2; tower_over_max_y = tower_overhang * sin(tower_over_angle); tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle); tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth; tower_rearwall_y = -(backfront_space_inside + tower_wall_thick); led_head_y = tower_over_max_y/2; led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2; backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y)); tower_height_contribution = led_head_z + tower_base_height; base_ctie_anchor_eff = base_ctie_anchor+base_ctie_thick/2; tube_ctie_anchor_eff = tube_ctie_anchor+tube_ctie_thick/2; base_width = 0.7 * crossbar_dia; base_backfront = backfront_mate_extra - tower_rearwall_y; base_height = led_tip_height_above_crossbar - tower_height_contribution; protrusion_frontback = base_backfront - protrusion_none_frontback; echo(tower_height_contribution, base_height); module TowerWallCrossSection(){ // generates a 2D shape - a polygon // x is what is going to be -y // y is what is going to be z polygon([[0, 0], [0, tower_frontheight], [-tower_over_max_y, tower_over_max_z], [-tower_over_max_y + tan(tower_forehead_angle) * (vert_space_inside + led_depth), tower_total_max_z], [-tower_rearwall_y, tower_total_max_z], [-tower_rearwall_y, 0], [-tower_rearwall_y, -tower_base_height], [-backfront_mate_extra, -tower_base_height]], convexity=5); } module TowerWallSomeEdge(front){ minkowski(){ difference(){ TowerWallCrossSection(); translate([front ? 0.10 : -0.10, 0]) TowerWallCrossSection(); } circle(r=tower_wall_thick, $fn=8); } } module TowerBulkCrossSection(){ intersection(){ TowerWallCrossSection(); union(){ translate([-led_head_y, led_head_z]) circle(r = led_depth); TowerWallSomeEdge(true); translate([-50, -50]) square([100, 50]); } } } module TowerRearWallCrossSection(){ intersection(){ TowerWallCrossSection(); union(){ intersection(){ translate([0,-10]) square([100, 10+led_head_z]); TowerWallSomeEdge(false); } TowerBulkCrossSection(); } } } module TowerCrossSectionDemo(){ %TowerWallCrossSection(); //TowerBulkCrossSection(); TowerRearWallCrossSection(); } module TowerMain(){ for (mir=[0,1]) mirror([mir,0,0]) rotate([90,0,-90]) { translate([0,0, tower_width/2-tower_wall_thick]) linear_extrude(height=tower_wall_thick) { TowerWallCrossSection(); } translate([0,0,-1]) linear_extrude(height=tower_width/2+0.9) union(){ TowerBulkCrossSection(); hull(){ intersection(){ TowerWallCrossSection(); translate([-30, -30]) square([30 + 0.1, 30 + tower_frontheight]); } } } translate([0,0, tower_slot_width/2]) linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2) TowerRearWallCrossSection(); } } module LedHole(){ translate([0, led_head_y, led_head_z]) rotate([90 + led_angle, 0, 0]) translate([0,0,-10]) cylinder(r=led_dia/2, h=led_depth+1+10, $fn=26, $fa=10); } module TowerProper(){ difference(){ TowerMain(); LedHole(); // passages for cable ties translate([0, tower_rearwall_y/2, cableclamp_ctie_z + cableclamp_ctie_width/2 + lidclamp_ctie_thick/2 + lidclamp_cableclamp_ctie_between]) cube([50, lidclamp_ctie_width, lidclamp_ctie_thick], center=true); translate([0, (backfront_mate_extra+tower_rearwall_y)/2, -tower_base_height + max(protrusion_size + protrusion_slop + 0.1, base_ctie_anchor_eff)]) cube([50, base_ctie_width, base_ctie_thick], center=true); // for (extra_y=[0, -(cableclamp_ctie_thick + cableclamp_ctie_anchor)]) { // translate([-tower_width/2, // -cableclamp_ctie_thick/2 - tower_wall_thick + extra_y, // cableclamp_ctie_z]) // cube([tower_wall_thick+2, // cableclamp_ctie_thick, // cableclamp_ctie_width], center=true); // } for (mir=[0,1]) mirror([mir,0,0]) { translate([tower_width/4, 20, cableclamp_ctie_z]) cube([cableclamp_ctie_thick, tower_wall_thick*2+1+40, cableclamp_ctie_width], center=true); } translate([0, tower_rearwall_y, -tower_base_height]) BaseRegistrationProtrusion(protrusion_slop); } } module Tower(){ ////toplevel TowerProper(); for (mir=[0,1]) { mirror([mir,0,0]){ translate([0, tower_rearwall_y + 0.1, -1]) mirror([0,0,1]) multmatrix([[1,0, towerleg_xslope,0], [0,1,-towerleg_yslope,0], [0,0,1,0], [0,0,0,1]]) cube([towerleg_width, towerleg_backfront, tower_base_height-2]); } } translate([-towerleg_foot_width/2, tower_rearwall_y - towerleg_foot_gap, -tower_base_height]) mirror([0,1,0]) cube([towerleg_foot_width, towerleg_foot_backfront, towerleg_foot_height]); } module TowerMainHull(){ hull(){ TowerMain(); } } module Lid(){ intersection(){ difference(){ minkowski(){ TowerMainHull(); sphere(r=lid_wall_thick+lid_slop, $fn=8); } minkowski(){ TowerMainHull(); sphere(r=lid_slop, $fn=6); } } translate([-50,-50,led_head_z]) cube([100,100,100]); } } module LidT(){ ////toplevel rotate([180,0,0]) Lid(); } module BaseRegistrationProtrusion(extra){ size = protrusion_size + extra; translate([0, base_backfront/2, 0]){ hull(){ translate([0,0, -0.5]) cube([protrusion_size*2, protrusion_frontback, 1.0], center=true); translate([0, 0, protrusion_size-0.5]) cube([0.05, protrusion_frontback-protrusion_size*2, 1.0], center=true); } } } module Base(){ difference(){ mirror([0,0,1]){ hull(){ translate([-tower_width/2, 0, 0]) cube([tower_width, base_backfront, 0.1]); translate([-base_width/2, 0, base_height]) cube([base_width, base_backfront, crossbar_dia/2]); } } translate([0, base_backfront/2, -base_ctie_anchor_eff]) cube([100, base_ctie_width, base_ctie_thick], center=true); translate([0, base_backfront/2, -base_height + tube_ctie_anchor_eff]) cube([100, tube_ctie_width, tube_ctie_thick], center=true); translate([0, -1, -(base_height + crossbar_dia/2)]) rotate([-90,0,0]) cylinder(r=crossbar_dia/2, h=101); } BaseRegistrationProtrusion(0.0); } module BaseT(){ ////toplevel rotate([90,0,0]) Base(); } module Demo(){ Tower(); %Lid(); translate([0,0, 25]) Lid(); translate([0, tower_rearwall_y, -(tower_base_height+5)]) Base(); } //TowerCrossSectionDemo(); //TowerWallSomeEdge(false); //TowerWallFrontEdge(); //TowerMainHull(); //LidT(); //Tower(); //Lid(); //BaseRegistrationProtrusion(); //Base(); //BaseT(); //Demo();