chiark / gitweb /
fairphone-case: fix hex22 (from v11)
[reprap-play.git] / fairphone-case.scad
index ea8207e..64fe13d 100644 (file)
@@ -26,11 +26,15 @@ 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 = [ 14, 17 ];
+fingerpushhole_dias = [ 15, 18 ];
 
-rearspeaker_pos_bl = [ 14.92, 18.72 ];
+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;
 case_th_side = 2;
@@ -58,6 +62,8 @@ 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;
 
@@ -66,6 +72,7 @@ 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;
 
@@ -75,6 +82,8 @@ $fs = 0.1;
 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;
@@ -84,6 +93,16 @@ 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_width =  (phone + bumper*2)[0];
@@ -140,9 +159,12 @@ bppJ = [ bppN[0], bppL[1] ];
 
 // hinge plan
 hp_rn = hingescrew_nut_dia/2;
-hp_r2 = hp_rn + lever_cover_th;
+hp_r2_min = hp_rn + lever_cover_th;
 hp_rs = hingescrew_shaft_dia/2;
-hp_r1 = hp_rs + hingemount_th;
+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;
@@ -150,8 +172,12 @@ 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 + 0.5 * [0,+1] * hp_k;
-hppB = hppM + 0.5 * [0,-1] * hp_k;
+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
 
@@ -162,9 +188,32 @@ 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;
+hex22 = hex21 + hinge_x_gap;
 hex23 = hex22 + hingescrew_portion_len;
-hex24 = hex23 + hinge_x_postscrew_gap;
+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 ----------
 
@@ -259,6 +308,31 @@ module ButtonPlan(l, deep, cut){
   }
 }
 
+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])
@@ -378,6 +452,17 @@ module OrdinaryRearAperture(rhs,bot, pos){
     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)
@@ -415,6 +500,7 @@ module HingeBaseProfile(){
   difference(){
     hull(){
       circleat(hppB, hp_r1);
+      circleat(hppE, hp_r1);
       circleat(epp2o, case_th_bottom);
       circleat(hppB + [10,0], hp_r1);
     }
@@ -439,6 +525,14 @@ module HingeLeverInnerProfile(){
   }
 }
 
+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])
@@ -448,6 +542,13 @@ module HingePortion(x0,x1){
     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();
@@ -519,6 +620,8 @@ module Case(){ ////toplevel
 
     OrdinaryRearApertures();
 
+    MicroUSB();
+
     // gaps for the lid's hinge arms
     HingePortion(hex20 - hinge_x_arms_gap,
                 hex21 + hinge_x_arms_gap)
@@ -526,6 +629,13 @@ module Case(){ ////toplevel
         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();
   }
 }
 
@@ -551,11 +661,42 @@ module Lid(){ ////toplevel
 
       // 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]);
@@ -680,7 +821,7 @@ module TestFrameCase(){ ////toplevel
 }
 
 module TestFrameLidPrint(){ ////toplevel
-  rotate([0,0,180]) intersection(){
+  rotate([0,180,0]) intersection(){
     Lid();
     TestSelectFrame();
   }
@@ -696,9 +837,45 @@ 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
@@ -734,6 +911,14 @@ module DemoProfiles(){ ////toplevel
     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();