fairphone-case: hinge: printable lever

[reprap-play.git] / fairphone-case.scad

diff --git a/fairphone-case.scad b/fairphone-case.scad
index 9cfc23a220a6a74f14f8f84d91ac762e19a44a2a..04fb14b4ac42494d2e6a2ab85c1b4369c32b3f5e 100644 (file)
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -28,7 +28,7 @@ noisecancelmic_dia = 1.75;
 
 fingerpushhole_dias = [ 14, 17 ];
 
-rearspeaker_pos_bl = [ 14.92, 18.72 ];
+rearspeaker_pos_bl = [ 12.64, 18.72 ];
 rearspeaker_size   = [  3.76,  7.36 ];
 
 case_th_bottom = 2.5;
@@ -62,7 +62,11 @@ foldover_gap = 0.50;
 foldover_lever_gap = 0.50;
 
 hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
+hingescrew_shaft_len = 12;
+hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
 hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
+hingescrew_head_th = 1.38 + 0.75;
+hingescrew_head_dia = 3.92;
 lever_cover_th = 0.75;
 hingemount_th = 2.5;
 
@@ -74,6 +78,11 @@ buttonishleg_default_l_is_fudge = 10;
 
 strut_min_at_end = 1.5;
 
+hinge_x_gap = 0.125;
+hinge_x_postscrew_gap = 0.75;
+hinge_x_arms_gap = 0.35;
+hinge_r_arms_gap = 0.55;
+
 rearspeaker_gap    = [ 1.0, 1.0 ]; // each side
 
 // ---------- calculated ----------
@@ -145,6 +154,21 @@ hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
 hppT = hppM + 0.5 * [0,+1] * hp_k;
 hppB = hppM + 0.5 * [0,-1] * hp_k;
 
+// hinge elevation x coords
+
+hingescrew_portion_len =
+  0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
+
+hex20 = max(epp2o[0],
+           phone_cnr_rad,
+           kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
+hex21 = hex20 + hingescrew_portion_len;
+hex22 = hex21 - hinge_x_gap;
+hex23 = hex22 + hingescrew_portion_len;
+hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
+echo(hex20, hex21, hex22, hex23, hex24);
+echo(hingescrew_portion_len);
+
 // ---------- modules ----------
 
 module KeeperProfile(slant=0){
@@ -313,7 +337,7 @@ module SideButton(y, y_ref_sign, l){
   eff_y = y_ref_sign > 0 ?         -bumper [1] -y -l/2 :
          y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
          y;
-  echo(eff_y);
+  //echo(eff_y);
   translate([0, eff_y, 0])
     children();
 }
@@ -418,8 +442,13 @@ module HingeLeverInnerProfile(){
   }
 }
 
-module HingePortion(){
-  Flip_rhs();
+module HingePortion(x0,x1){
+  Flip_rhs() Flip_bot(1)
+    translate([x0,0,0])
+    mirror([1,0,0])
+    rotate([90,0,-90])
+    linear_extrude(height=x1-x0)
+    children(0);
 }
 
 module CaseBase(){
@@ -448,7 +477,7 @@ module Case(){ ////toplevel
       }
 
       // hinge
-      // HingePortion(hex20, hex21) HingerBaseProfile();
+      HingePortion(hex20, hex21) HingeBaseProfile();
     }
 
     // slot for keeper
@@ -492,6 +521,17 @@ module Case(){ ////toplevel
       CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
 
     OrdinaryRearApertures();
+
+    // gaps for the lid's hinge arms
+    HingePortion(hex20 - hinge_x_arms_gap,
+                hex21 + hinge_x_arms_gap)
+      minkowski(){
+        HingeLidProfile();
+       circle(r= hinge_r_arms_gap, $fn= 8);
+      }
+
+    // screw holes in the hinge arms
+    DemoHingeScrews();
   }
 }
 
@@ -514,11 +554,37 @@ module Lid(){ ////toplevel
            ButtonCoverProfile();
        }
       }
+
+      // hinge arms
+      HingePortion(hex20, hex21) HingeLidProfile();
     }
     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
+
+    // screw holes in the hinge arms
+    DemoHingeScrews();
+  }
+}
+
+module HingeLever(){ ////toplevel
+  difference() {
+    // outer body, positive
+    HingePortion(hex22, hex22 + phone_width/2)
+      HingeLeverOuterProfile();
+
+    // space for the screws
+    HingePortion(hex23, hex24)
+      HingeLeverInnerProfile();
+
+    // bores for the screws
+    DemoHingeScrews();
   }
 }
 
+module HingeLeverPrint(){ ////toplevel
+  rotate([90,0,0])
+    HingeLever();
+}
+
 module TestSelectLength(){
   translate([-30, -200, -20])
     cube([30 + 15, 250, 40]);
@@ -643,7 +709,7 @@ module TestFrameCase(){ ////toplevel
 }
 
 module TestFrameLidPrint(){ ////toplevel
-  rotate([0,0,180]) intersection(){
+  rotate([0,180,0]) intersection(){
     Lid();
     TestSelectFrame();
   }
@@ -659,6 +725,51 @@ module ButtonPlanForDemo(z, deep, cut){
     ButtonPlan(8, deep, cut);
 }
 
+module DemoHingeScrews(){
+  Flip_rhs() Flip_bot(1){
+    for (c= [ hppT, hppB ])
+      translate([ hex20,
+                 -c[0],
+                 c[1] ]){
+       rotate([0,90,0])
+         translate([0,0,-.2])
+         cylinder( r= hingescrew_shaft_dia/2,
+                   h = hingescrew_shaft_len+0.2 );
+       rotate([0,-90,0])
+         translate([0,0,+.1])
+         cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
+      }
+  }
+}
+
+module DemoFrame(){ ////toplevel
+  color("red") TestFrameCase();
+  color("blue") intersection(){ Lid(); TestSelectFrame(); }
+  color("black") DemoHingeScrews();
+  %HingeLever();
+}
+
+module DemoHingedFrame(){ ///toplevel
+  hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
+
+  color("red") TestFrameCase();
+  translate([0,0, -2*hp_k])
+  color("blue") intersection(){ Lid(); TestSelectFrame(); }
+  
+  translate(hinge_origin)
+    rotate([180,0,0])
+    translate(-hinge_origin) {
+      color("orange") HingeLever();
+      color("black") DemoHingeScrews();
+    }
+}
+
+module DemoHinge(){ ////toplevel
+  DemoFrame();
+  translate([0,0, -hp_k*3])
+    DemoHingedFrame();
+}
+
 module DemoProfiles(){ ////toplevel
   LidEdgeProfile();
   %EdgeProfile();