chiark / gitweb /
fairphone-case: fix hex22 (from v11)
[reprap-play.git] / fairphone-case.scad
index aeac8ce..64fe13d 100644 (file)
@@ -1,8 +1,12 @@
 // -*- C -*-
 
-phone = [ 145.0, 75.0 ];
+include <utils.scad>
 
-bumpers = [ 1.5, 1.75 ]; // both sides together
+phone = [ 75.0, 145.0 ];
+
+bumper = [ 0.250, -0.025 ];
+// ^ One side.  Overall size is increased by twice this.
+// If no bumpers, is the gap around the phone.
 
 phone_cnr_rad = 6.0;
 
@@ -13,8 +17,23 @@ phone_total_thick = 12.0;
 phone_backside_slope_inner = 1.5; // larger means shallower
 phone_backside_slope_outer = 1.0; // larger means shallower
 
-camera_pos_tl = [  7.0, 13.0 ]; // measured from tl corner
-camera_pos_br = [ 22.85,37.85]; // tl/br as seen from back
+camera_pos_tl = [  6.450, 12.750 ]; // measured from tl corner
+camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
+
+jack_pos = [ 13.92, 7.96 ];
+jack_dia = 9.1 + .5; // some jack I had lying around
+
+noisecancelmic_pos = [ 19.54, 7.37 ];   // from rhs
+noisecancelmic_dia = 1.75;
+
+fingerpushhole_dias = [ 15, 18 ];
+
+rearspeaker_pos_bl = [ 12.64, 18.72 ];
+rearspeaker_size   = [  3.76,  7.36 ];
+
+microusb_above = 3.27 - 0.25;
+microusb_below = 0.0;
+microusb_width = 16.12 + 0.25;
 
 case_th_bottom = 2.5;
 case_th_lid = 2.5;
@@ -43,17 +62,56 @@ lid_gap_x = 0.25;
 lid_gap_z = 0.25;
 lid_lip = 1.75;
 
+catch_slop = 0.25;
+
+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;
+
 $fa = 5;
 $fs = 0.1;
 
-button_l_fudge = 4.5;
+button_l_fudge = 4.4;
+buttonishleg_default_l_is_fudge = 10;
+
+hinge_base_slope = 1.5; // bigger is steeper
 
 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
+
+catch_len = 7.5;
+catch_width = 15;
+catch_thickness = 1.0;
+catch_side_gap = 0.75; // each side
+
+catch_depth = 1.25;
+catch_height = 0.35;
+catch_finger_height = 1.5;
+catch_finger_depth = 2.5;
+
 // ---------- calculated ----------
 
-phone_height = (phone + bumpers)[0];
-phone_width =  (phone + bumpers)[1];
+phone_width =  (phone + bumper*2)[0];
+phone_height = (phone + bumper*2)[1];
+
+inside_br = [phone_width, -phone_height];
+
+//echo(camera_pos_tl + bumper,
+//     camera_pos_br + bumper);
 
 // ----- could be changed -----
 lid_buttoncover_gap = lid_gap_x;
@@ -87,8 +145,6 @@ lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
 lpp12 = [ epp4[0] + lp_r12,    lpp11[1] ];
 lpp13 = [ lpp12[0],            lpp12[1] + lp_r12 ];
 
-echo(lpp13 - lpp10);
-
 // button profile
 bppM = epp4 + [0,5];
 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
@@ -101,12 +157,65 @@ bppL = lpp10 + [5,0];
 bppK = [ bppL[0], bppN[1] ];
 bppJ = [ bppN[0], bppL[1] ];
 
-module rectfromto(a,b) {
-  ab = b - a;
-  translate([min(a[0], b[0]), min(a[1], b[1])])
-    square([abs(ab[0]), abs(ab[1])]);
-}
-module circleat(c,r) { translate(c) circle(r); }
+// hinge plan
+hp_rn = hingescrew_nut_dia/2;
+hp_r2_min = hp_rn + lever_cover_th;
+hp_rs = hingescrew_shaft_dia/2;
+hp_r1_min = hp_rs + hingemount_th;
+
+hp_r1 = max(hp_r1_min, hp_r2_min);
+hp_r2 = hp_r1;
+
+hppU = lpp13;
+hppS = epp2o + [0,-1] * case_th_bottom;
+hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
+
+hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
+        0.5 * (hppU + hppS)[1] ];
+hppT = [ hppM[0], hppU[1] - hp_r1 ];
+hppB = hppT + [0,-1] * hp_k;
+
+hppE_y = epp2o[1] - case_th_bottom + hp_r1;
+hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
+hppE = [ hppE_x, hppE_y ];
+
+// 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);
+
+// catch
+
+cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
+cppA = cppJ + [lid_gap_x, -lid_gap_z];
+cppB = [ epp0[0], cppA[1] ];
+cppP = [ epp4[0], cppJ[1] ];
+
+cppS = cppJ + [0,-1] * catch_len;
+cppD = [ cppA[0], cppS[1] + catch_slop ];
+cppC = [ cppB[0], cppD[1] ];
+cppT = cppS + [1,0] * catch_depth;
+cppU = cppT + [0,-1] * catch_height;
+cppV = [ cppS[0], cppU[1] - catch_depth ];
+
+cppR = 0.5*(cppP + cppJ);
+
+cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
+cppQ = [ cppR[0],
+        cppV[1] - (catch_finger_height - cp_rQ) ];
+cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
+
+// ---------- modules ----------
 
 module KeeperProfile(slant=0){
   use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
@@ -199,19 +308,44 @@ module ButtonPlan(l, deep, cut){
   }
 }
 
-module CaseBase_rhsflip(yn=[0,1]) {
-  for (rhs=yn) {
+module CatchCatchProfile(){
+  hull(){
+    for (c=[ cppR, cppQ ])
+      circleat(c, cp_rQ);
+  }
+  hull(){
+    circleat(lpp12, lp_r12);
+    circleat(lpp12 + [5,0], lp_r12);
+    rectfromto(cppP, cppP + [5,0.1]);
+  }
+  polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
+}
+
+module CatchCutProfile(){
+  polygon([ cppB,
+           cppA,
+           cppD,
+           cppF,
+           cppF + [0,-10],
+           cppF + [-10,-10],
+           lpp12 + [-10,0],
+           lpp12 + [10,0]
+           ]);
+}
+
+module Flip_rhs(yn=[0,1]) {
+  for ($rhsflip=yn) {
     translate([phone_width/2, 0, 0])
-      mirror([rhs,0,0])
+      mirror([$rhsflip,0,0])
       translate([-phone_width/2, 0, 0])
       children();
   }
 }
 
-module CaseBase_botflip() {
-  for (bot=[0,1]) {
+module Flip_bot(yn=[0,1]) {
+  for ($botflip=yn) {
     translate([0, -phone_height/2, 0])
-      mirror([0, bot, 0])
+      mirror([0, $botflip, 0])
       translate([0, phone_height/2, 0])
       children();
   }
@@ -219,14 +353,14 @@ module CaseBase_botflip() {
 
 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
   // sides
-  CaseBase_rhsflip(){
+  Flip_rhs(){
     translate([0, -phone_cnr_rad, 0])
       rotate([90,0,0])
       linear_extrude(height = phone_height - phone_cnr_rad*2)
       children(0);
   }
   // corners
-  CaseBase_rhsflip() CaseBase_botflip() {
+  Flip_rhs() Flip_bot() {
     translate([+1,-1] * phone_cnr_rad)
       intersection(){
        rotate_extrude()
@@ -241,7 +375,7 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
       }
   }
   // top and bottom
-  CaseBase_botflip(){
+  Flip_bot(){
     translate([ phone_width - phone_cnr_rad, 0,0 ])
       rotate([90,0,-90])
       linear_extrude(height = phone_width - phone_cnr_rad*2)
@@ -255,14 +389,41 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
               [phone_width, -phone_height] + [-1,+1] * phone_cnr_rad);
 }
 
-module SideButton(y,l){
+module CaseAperture(pos, dia, $fn) {
+  theta = 180/$fn;
+  translate([ pos[0] + bumper[0],
+             -epp2i[0],
+             -pos[1] ])
+    rotate([-90, theta, 0])
+    cylinder(r = dia/2 / cos(theta),
+            h = 60);
+}
+
+module SideButton(y, y_ref_sign, l){
+  // y_ref_sign:
+  //   +1  measured from top    of actual phone to top    of button
+  //   -1  measured from bottom of actual phone to bottom of button
+  //    0  y is centre of button in coordinate system
   $button_l= l;
-  translate([0, -y, 0])
+  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);
+  translate([0, eff_y, 0])
     children();
 }
 
+module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
+  $button_leg_only = true;
+  SideButton(y, y_ref_sign, l) children();
+}
+
 module Buttons(){
-  CaseBase_rhsflip([1]) SideButton(20.6, 8.8) children(); // power
+  Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
+  Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
+  Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
+  Flip_rhs(   ) LidButtonishLeg(20, -1) children();
+//  Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
 }
 
 module Struts(x_start, z_min, th){
@@ -283,6 +444,111 @@ module Struts(x_start, z_min, th){
   }
 }
 
+module OrdinaryRearAperture(rhs,bot, pos){
+  Flip_rhs(rhs) Flip_bot(bot)
+    linextr(-20, 20)
+    mirror([0,1])
+    translate(pos + bumper)
+    children();
+}
+
+module MicroUSB(){
+  Flip_bot(1){
+    rotate([90,0,0])
+      mirror([0,0,1])
+      linextr(-epp2i[0], 60)
+      translate([0.5 * phone_width, 0, 0])
+      rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
+                [+microusb_width/2, epp0[1] + -microusb_above]);
+  }
+}
+
+module OrdinaryRearApertures(){
+  // rear speaker
+  OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
+    rectfromto(-rearspeaker_gap,
+              rearspeaker_size + rearspeaker_gap);
+
+  // finger hole to remove phone
+  OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
+                             phone[1]/2 ])
+    scale(fingerpushhole_dias)
+    circle(r= 0.5 );
+}
+
+module RearCameraAperture(){
+  Flip_rhs(1)
+    mirror([0, 0, 1])
+    linear_extrude(height = 20)
+    mirror([0, 1, 0])
+    translate(bumper)
+    rectfromto(camera_pos_tl, camera_pos_br);
+}
+
+module HingeLidProfile(){
+  hull(){
+    circleat(hppT, hp_r1);
+    circleat(lpp12, lp_r12);
+    polygon([lpp10,
+            lpp13 + [2,0],
+            lpp12,
+            hppT]);
+  }
+}
+
+module HingeBaseProfile(){
+  difference(){
+    hull(){
+      circleat(hppB, hp_r1);
+      circleat(hppE, hp_r1);
+      circleat(epp2o, case_th_bottom);
+      circleat(hppB + [10,0], hp_r1);
+    }
+    polygon([epp5, epp1, epp2i, epp3, bppL]);
+  }
+}
+
+module HingeLeverOuterProfile(){
+  hull(){
+    circleat(hppT, hp_r2);
+    circleat(hppB, hp_r2);
+  }
+}
+
+module HingeLeverInnerProfile(){
+  for (c = [hppT, hppB]) {
+    hull()
+      for (x=[0,20])
+       translate([x,0])
+         circleat(c, hp_rn);
+       circleat(hppB, hp_rn);
+  }
+}
+
+module Flip_hinge(){
+  hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
+  translate(hinge_origin)
+    rotate([180,0,0])
+    translate(-hinge_origin)
+    children();
+}
+
+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 CatchPortion(width){
+  translate([phone_width/2, 0,0])
+    rotate([90,0,-90])
+    linextr(-width/2, width/2)
+    children(0);
+}
+
 module CaseBase(){
   AroundEdges(epp3[1], case_th_bottom, 1)
     EdgeProfile();
@@ -303,14 +569,17 @@ module Case(){ ////toplevel
        translate([0,0, -25])
          linear_extrude(height = 50)
          hull()
-         // CaseBase_rhsflip() // actually, we only care about the LH
-         CaseBase_botflip()
+         // Flip_rhs() // actually, we only care about the LH
+         Flip_bot()
          circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
       }
+
+      // hinge
+      HingePortion(hex20, hex21) HingeBaseProfile();
     }
 
     // slot for keeper
-    CaseBase_rhsflip(1)
+    Flip_rhs(1)
       translate([0, -phone_cnr_rad, 0])
       rotate([90, 0, 0])
       linear_extrude(height = phone_height + phone_cnr_rad * 2)
@@ -321,11 +590,7 @@ module Case(){ ////toplevel
       }
 
     // front camera
-    CaseBase_rhsflip([1])
-      mirror([0, 0, 1])
-      linear_extrude(height = 20)
-      mirror([0, 1, 0])
-      rectfromto(camera_pos_tl, camera_pos_br);
+    RearCameraAperture();
 
     // struts (invisible, because they're buried in the case)
     Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
@@ -333,14 +598,44 @@ module Case(){ ////toplevel
     Buttons(){
       mirror([1,0,0])
        rotate([90,0,90]) {
-         translate([0,0,-10])
-           linear_extrude(height= 20)
-           ButtonPlan($button_l, 0,1);
+         intersection(){
+           translate([0,0,-10])
+             linear_extrude(height= 20)
+             ButtonPlan($button_l, 0,1);
+           if ($button_leg_only)
+             rotate([-90,90,0])
+               translate([phone_width/2, -400, kppe[1]])
+               mirror([$rhsflip,0,0]) cube([400, 800, 50]);
+         }
          translate([0,0, -bppR[0]])
            linear_extrude(height= 20)
            ButtonPlan($button_l, 1,1);
         }
     }
+
+    // apertures along top edge
+    CaseAperture(jack_pos, jack_dia, 8);
+    Flip_rhs(1)
+      CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
+
+    OrdinaryRearApertures();
+
+    MicroUSB();
+
+    // 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
+    HingeScrews();
+
+    // catch striker
+    CatchPortion(catch_width + catch_side_gap*2)
+      CatchCutProfile();
   }
 }
 
@@ -363,16 +658,62 @@ module Lid(){ ////toplevel
            ButtonCoverProfile();
        }
       }
+
+      // hinge arms
+      HingePortion(hex20, hex21) HingeLidProfile();
+
+      // catch
+      CatchPortion(catch_width)
+       CatchCatchProfile();
     }
     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
+
+    // screw holes in the hinge arms
+    HingeScrews();
+  }
+}
+
+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
+    HingeScrews();
+
+    // space for the charging cable
+    MicroUSB();
+    Flip_hinge() MicroUSB();
   }
 }
 
+module HingeLeverPrint(){ ////toplevel
+  rotate([90,0,0])
+    HingeLever();
+}
+
+module TestSelectLength(){
+  translate([-30, -200, -20])
+    cube([30 + 15, 250, 40]);
+}
+
 module TestLength(){ ////toplevel
   intersection(){
     Case();
-    translate([-30, -200, -20])
-    cube([30 + 15, 250, 40]);
+    TestSelectLength();
+  }
+}
+
+module TestLengthRight(){ ////toplevel
+  intersection(){
+    Case();
+    Flip_rhs(1)
+      TestSelectLength();
   }
 }
 
@@ -390,16 +731,31 @@ module TestWidth(){ ////toplevel
 }
 
 module TestLidWidthPrint(){ ////toplevel
-  rotate([0,180.0]) TestLidWidth();
+  rotate([0,180.0]) intersection(){
+    Lid();
+    TestSelectWidth();
+  }
+}
+
+module TestSelectRearAperture(){
+  minkowski(){
+    union() children();
+    translate([20, 0,0])
+      cube([42, 2, 1], center=true);
+  }
 }
 
 module TestSelectCamera(){
-  CaseBase_rhsflip(1)
-    translate([0,0,-25])
-    linear_extrude(height = 50)
-    mirror([0, 1, 0])
-    rectfromto([-20, -20],
-              camera_pos_br + [ 5, 5 ]);
+  minkowski(){
+    TestSelectRearAperture()
+      RearCameraAperture();
+    cube([0.1, 50, 0.1]);
+  }
+}
+
+module TestSelectOrdinaryRearApertures(){
+  TestSelectRearAperture()
+    OrdinaryRearApertures();
 }
 
 module TestCamera(){ ////toplevel
@@ -437,8 +793,42 @@ module OneKeeperPrint(){ ////toplevel
     OneKeeper();
 }
 
+module LidPrint(){ ////toplevel
+  rotate([0,180,0])
+    Lid();
+}
+
+module TestSelectFrame(){
+  include = [1,-1] * (epp2i[0] + 4);
+
+  difference(){
+    cube(1000, center=true);
+    translate([0,0, -100])
+      linear_extrude(height=200)
+      rectfromto(include,  inside_br - include);
+  }
+}
+
+module TestFrameCase(){ ////toplevel
+  intersection(){
+    Case();
+    union(){
+      TestSelectFrame();
+      TestSelectCamera();
+      TestSelectOrdinaryRearApertures();
+    }
+  }
+}
+
+module TestFrameLidPrint(){ ////toplevel
+  rotate([0,180,0]) intersection(){
+    Lid();
+    TestSelectFrame();
+  }
+}
+
 module Keeper(){ ////toplevel
-  CaseBase_rhsflip()
+  Flip_rhs()
     OneKeeper();
 }
 
@@ -447,6 +837,47 @@ module ButtonPlanForDemo(z, deep, cut){
     ButtonPlan(8, deep, cut);
 }
 
+module HingeScrews(){
+  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") HingeScrews();
+  %HingeLever();
+}
+
+module DemoHingedFrame(){ ///toplevel
+  color("red") TestFrameCase();
+  translate([0,0, -2*hp_k])
+  color("blue") intersection(){ Lid(); TestSelectFrame(); }
+
+  Flip_hinge(){
+    color("orange") HingeLever();
+    color("black") HingeScrews();
+  }
+}
+
+module DemoHinge(){ ////toplevel
+  DemoFrame();
+  translate([0,0, -hp_k*3])
+    DemoHingedFrame();
+}
+
 module DemoProfiles(){ ////toplevel
   LidEdgeProfile();
   %EdgeProfile();
@@ -471,6 +902,23 @@ module DemoProfiles(){ ////toplevel
     color("red" )  ButtonPlanForDemo(-4, 1,1);
     color("blue")  ButtonPlanForDemo(-6, 1,0);
   }
+
+  translate([0, -30]) {
+    %LidEdgeProfile();
+    %EdgeProfile();
+    color("blue") HingeLidProfile();
+    color("red")  HingeBaseProfile();
+    color("black") translate([0,0,-2]) HingeLeverOuterProfile();
+    color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
+  }
+
+  translate([20,-30]) {
+    %EdgeProfile();
+    %LidEdgeProfile();
+    //translate([0,0,1]) CatchCutProfile();
+    color("blue") CatchCatchProfile();
+    color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
+  }
 }
 
 //EdgeProfile();