ksafe-base: toplevels

[reprap-play.git] / ksafe-base.scad

diff --git a/ksafe-base.scad b/ksafe-base.scad
index 0f881c33401085b87af74c4688793ad09890abdf..d6daa8f91bf3b0e5eb0be822a9a02d8d529edd95 100644 (file)
--- a/ksafe-base.scad
+++ b/ksafe-base.scad
@@ -1,13 +1,13 @@
 // -*- C -*-
 
-// xxx from actual ksafe
-bolt_above = 4;
-wall_thick = 4;
-bolthole_height = 4;
-bolthole_width = 10;
-main_sz = 30;
-cnr_rad = 10;
-lidinner_thick_allow = 20;
+// from actual ksafe
+bolt_above = 8.50 - 0.50;
+bolthole_height = 4.24 + 1.00;
+wall_thick = 4.50;
+bolthole_width = 16.62 + 2.00;
+main_sz = 150.56 + 0.75;
+cnr_rad = 13.5; // approx
+lidinner_thick_allow = 20.78 + 0.50;
 
 // other parameters
 web_thick = 4;
@@ -15,20 +15,36 @@ web_height = 20; // excluding wall and base thick
 bolthole_rhs = 20;
 bolthole_lhs = 20;
 boltreinf_thick = 6;
-anchor_wall_space = 45;
+anchor_wall_space = 25;
 base_thick = 4;
 space = 25;
 anchor_thick = 4;
 anchor_rad = 4;
-bevel = 15;
+bevel = 8;
+string_slot = 3.0;
+string_depth = 6.0;
 
 // ----- calculated -----
 
+hsz = main_sz/2;
+
 gppA = [0,0];
 gppB = gppA - [ wall_thick, 0 ];
 
 gppL = [ gppB[0], -(lidinner_thick_allow + space + base_thick) ];
 
+yw1 = -web_thick/2;
+yw2 = yw1 - bolthole_rhs;
+yw3 = yw2 - anchor_thick;
+yw4 = yw3 - anchor_wall_space;
+yw5 = yw4 - wall_thick;
+yw6 = -(hsz - cnr_rad + 0.1);
+
+yw10 = web_thick/2;
+yw11 = yw2 + anchor_wall_space;
+yw12 = yw11 + wall_thick;
+yw13 = -yw6;
+
 // anchor
 
 anchor_b = anchor_thick + anchor_rad;
@@ -60,7 +76,8 @@ module upp_app_Profile(){
            $xppF,
            $xppF + [1,0],
            $xppI + [1,0],
-           $xppJ ]);
+           $xppJ ],
+         convexity=10);
 }
 
 
@@ -82,7 +99,8 @@ module AnchorProfile(){
        polygon([ $xppE,
                  $xppF,
                  $xppF + [0,1],
-                 $xppE + [1,0] ]);
+                 $xppE + [1,0] ],
+         convexity=10);
        translate(appM) circle(r= anchor_b);
       }
       translate(appM) circle(r= anchor_rad);
@@ -99,7 +117,8 @@ module AnchorWallProfile(){
        polygon([ $xppE,
                  $xppF,
                  $xppI,
-                 $xppJ ]);
+                 $xppJ ],
+         convexity=10);
       }
     }
   }
@@ -116,18 +135,110 @@ module WebProfile(){
                $xppE,
                $xppF,
                $gppS,
-               $gppR ]);
+               $gppR ],
+         convexity=10);
     } else {
       polygon([ $gppP,
                $xppE,
                $xppF,
                $gppS,
-               $gppP + web_height * [1,0] ]);
+               $gppP + web_height * [1,0] ],
+         convexity=10);
     }
     polygon([ $gppS,
              $xppF,
              $xppF + [1,0],
-             $gppS + [1,0] ]);
+             $gppS + [1,0] ],
+         convexity=10);
+  }
+}
+
+module SomeBaseProfile(I, F){
+  polygon([ I,
+           F,
+           [ hsz+1, F[1] ],
+           [ hsz+1, I[1] ] ]);
+}
+
+module BaseProfile(){
+  SomeBaseProfile($xppI, $xppF);
+}
+
+module SWalls(ymin, ymax, t_bevel) {
+  upp_app_Vars(t_bevel) {
+    translate([0,ymin,0])
+      mirror([0,1,0])
+      rotate([90,0,0])
+      linear_extrude(height= ymax-ymin, convexity=10)
+      for (xm=[0,1])
+       mirror([xm,0])
+         translate([-hsz, 0])
+           children();
+  }
+}
+
+module AtTwoCorners(){
+  for (xm=[0,1]) {
+    mirror([xm,0,0]) 
+    translate((hsz - cnr_rad) * [1,1])
+    intersection(){
+      rotate_extrude(convexity=10)
+       translate([-cnr_rad,0])
+       children();
+      translate([0,0,-250])
+       cube([50,50,500]);
+    }
+  }
+}
+
+module Box(){
+  /// corners, and front and back of base
+  for (ym=[0,1]) mirror([0,ym,0]) {
+    AtTwoCorners(){
+      UsualProfile();
+    }
+    hull() AtTwoCorners(){
+      upp_app_Vars(bevel){
+       polygon([ $xppI,
+                 $xppF,
+                 $xppF + [0.1, 0],
+                 $xppI + [0.1, 0]
+                 ]);
+      }
+    }
+  }
+
+  // side walls and base
+  SWalls(yw6 , yw4 , bevel  ) { UsualProfile();      BaseProfile(); }
+  SWalls(yw5 , yw4 , a_bevel) { AnchorWallProfile(); BaseProfile(); }
+  SWalls(yw5 , yw12, a_bevel) { NearAnchorProfile(); BaseProfile(); }
+  SWalls(yw3 , yw2 , a_bevel) { AnchorProfile();     BaseProfile(); }
+  SWalls(yw11, yw12, a_bevel) { AnchorWallProfile(); BaseProfile(); }
+  SWalls(yw11, yw13, bevel  ) { UsualProfile();      BaseProfile(); }
+  SWalls(yw1,  yw10, a_bevel) { WebProfile(); SomeBaseProfile($gppS, $xppF); }
+
+  // front and rear walls
+  rotate([0,0,90]) SWalls(yw6, yw13, bevel) UsualProfile();
+}
+
+module KsafeBase(){ ////toplevel
+  cut = main_sz + 20;
+
+  difference(){
+    Box();
+
+    // bolt holes
+    translate([0,0, -bolt_above -0.5 * bolthole_height])
+      cube(center=true, [ cut, bolthole_width, bolthole_height ]);
+
+    // string slot
+    translate([ -cut,
+               -(bolthole_width/2 + bolthole_rhs),
+               1 ])
+      mirror([0,1,0]) mirror([0,0,1])
+      cube([ cut*2,
+            string_slot,
+            lidinner_thick_allow + string_depth + 1 ]);
   }
 }
 
@@ -139,4 +250,7 @@ module DemoProfiles(){
   translate([0,0,-4]) color("pink") WebProfile();
 }
 
-DemoProfiles();
+//DemoProfiles();
+//Box();
+//KsafeBase();
+//RimTest();