led_dia = 5 + 0.6;
led_depth = 5;
-test_width = 15;
-test_height = 12;
+led_tip_height_above_crossbar = 70;
+led_angle = -60;
+crossbar_dia = 25; // fixme
-thicks = [1,2,4,6];
+vert_space_inside = 8;
+backfront_space_inside = 12;
+width_space_inside = 10;
-module Tests(){
- for (thicki=[0:len(thicks)-1]) {
- translate([thicki*test_width-0.1, 0, 0]) {
+backfront_mate_size = 25;
+tower_frontheight = 20;
+tower_slot_width = 3;
+
+cableclamp_ctie_width = 3 + 0.5;
+cableclamp_ctie_thick = 2 + 0.5;
+
+lidclamp_ctie_width = 4.0 + 0.5;
+lidclamp_ctie_thick = 2.5 + 0.5;
+
+base_ctie_width = 4.0 + 0.5;
+base_ctie_thick = 2.5 + 0.5;
+
+tube_ctie_width = 5 + 0.5;
+tube_ctie_thick = 3 + 0.5;
+
+// tuning
+
+tower_over_angle = 45;
+tower_wall_thick = 1.6;
+tower_base_height = 10;
+tower_forehead_angle = 30;
+lid_wall_thick = 1.6;
+lid_slop = 0.75;
+base_ctie_anchor = 5;
+tube_ctie_anchor = 5;
+
+//--- 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,
- thicks[thicki] + led_depth,
+ test_thicks[thicki] + led_depth,
test_height]);
- %translate([test_width/2, -1, test_height/2])
+ translate([test_width/2, -1, test_height/2])
rotate([-90,0,0])
cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
}
}
}
-Tests();
+//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;
+
+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])
+ translate([0,0,-10])
+ cylinder(r=led_dia/2, h=led_depth+0.1+10, $fn=30);
+}
+
+module Tower(){ ////toplevel
+ difference(){
+ TowerMain();
+ LedHole();
+ // passages for cable ties
+ translate([0,
+ tower_rearwall_y/2,
+ tower_frontheight/2
+ + cableclamp_ctie_width/2 + lidclamp_ctie_thick/2])
+ cube([50, lidclamp_ctie_width, lidclamp_ctie_thick], center=true);
+ translate([0,
+ (backfront_mate_extra+tower_rearwall_y)/2,
+ -tower_base_height/2])
+ cube([50, base_ctie_width, base_ctie_thick], center=true);
+ for (mir=[0,1])
+ mirror([mir,0,0]) {
+ translate([tower_width/4, 20, tower_frontheight/2])
+ cube([cableclamp_ctie_thick,
+ tower_wall_thick*2+1+40,
+ cableclamp_ctie_width],
+ center=true);
+ }
+ }
+}
+
+module TowerMainHull(){
+ hull(){ TowerMain(); }
+}
+
+module Lid(){
+ intersection(){
+ difference(){
+ minkowski(){
+ TowerMainHull();
+ sphere(r=lid_wall_thick+lid_slop, $fn=4);
+ }
+ minkowski(){
+ TowerMainHull();
+ sphere(r=lid_slop, $fn=4);
+ }
+ }
+ translate([-50,-50,led_head_z]) cube([100,100,100]);
+ }
+}
+
+module LidT(){ ////toplevel
+ rotate([180,0,0]) Lid();
+}
+
+module Base(){ ////toplevel
+ 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([-50, base_backfront/2, -base_ctie_anchor_eff])
+ cube([100, base_ctie_width, base_ctie_thick], center=true);
+ translate([-50, 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);
+ }
+}
+
+module BaseT(){ ////toplevel
+ rotate([90,0,0]) Base();
+}
+
+module Demo(){
+ Tower();
+ translate([0,0, 25]) Lid();
+ translate([0, tower_rearwall_y, -(tower_base_height+5)]) Base();
+}
+
+//TowerCrossSectionDemo();
+//TowerWallSomeEdge(false);
+//TowerWallFrontEdge();
+//TowerMainHull();
+//LidT();
+//Tower();
+//Lid();
+//Base();
+//BaseT();
+Demo();
~ianmdlvl / reprap-play.git / blobdiff