sleepphone-cable-box: new button height

[reprap-play.git] / sleepphone-cable-box.scad

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index fe801f0bde70b4307df9e8ec1b0838cb51ba7e3a..321146affcb377aec58f1ca9dfd4e4f5d03db064 100644 (file)
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -1,28 +1,58 @@
 // -*- C -*-
 
+include <funcs.scad>
+
 wall = 0.75 * [1,1,1];
-phone = [ 76.40, 30.96, 6.26 ];
+phone = [ 76.40, 30.96, 6.00 ]; // includes socket
 phone_button_z = 6.58;
-minwall = 0.25;
+minwall = 0.50;
+
+button_dz = 1.35;
 
 button_dy_outer = 28.42;
 button_dy_inner = 19.05;
 button_dy_centre = 5.65;
 
-phone_slop = [1,1,1] * 0.5;
+phone_slop = 0.5 * [1,1,0]
+           + 0.5 * [0,0,1];
 
 led = [25.9, 9.44]; // y is from edge
 led_dia = 4.4;
 
+// next values include slop
+plug_maxw = 10.95 + 0.35;
+plug_minw=   6.53 + 0.35;
+plug_sllen=  6.50;
+plug_totlen = 84.90; // to maxw, including phone
+
+plug_h = 6.5;
+plug_tooth_h = 0.5;
+plug_tooth_dy = 0.5;
+
+keeper_prong = 2;
+keeper_stalk_basewidth = 4;
+keeper_stalk_len = 70;
+keeper_stalk_gap = 2;
+
 // calculated
 
 top_z = max( phone[2] + wall[2],
             phone_button_z + minwall )
   + phone_slop[2];
 
+plugkeeper_x_maxw = phone[0] - plug_totlen;
+
+plugkeeper_p_max = [ 0, plug_maxw/2 ];
+plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
+plugkeeper_d_u = unitvector2d(
+                 clockwise2d(
+                 vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
+                            )
+                            );
+
 module MainProfileInnerHalf(){
   p = phone + phone_slop;
-  pb = phone_button_z + phone_slop[2];
+  pb = p[2] + button_dz;
   polygon([[ -2,                 0    ],
           [ p[1]/2,             0    ],
           [ p[1]/2,             p[2] ],
@@ -37,13 +67,17 @@ module MainProfileInnerHalf(){
 
 module MainProfile(){
   p = phone + phone_slop;
-  for (m=[0,1]) mirror([m,0]) {
-      difference(){
-       translate([-1, -wall[2] ])
-         square([ p[1]/2 + wall[1] + 1, top_z + wall[2] ]);
+  difference(){
+    for (m=[0,1]) mirror([m,0]) {
+       minkowski(){
+         square(2 * [wall[1], wall[2]], center=true);
+         MainProfileInnerHalf();
+       }
+      }
+    for (m=[0,1]) mirror([m,0]) {
        MainProfileInnerHalf();
       }
-    }
+  }
 }
 
 module BoxMain(){
@@ -56,14 +90,61 @@ module BoxMain(){
   }
 }
 
+module PlugKeeperProfileHalf(){
+  p_max = plugkeeper_p_max;
+  p_min = plugkeeper_p_min;
+  d = plugkeeper_d_u * keeper_prong;
+  
+  translate([ plugkeeper_x_maxw, 0 ]) {
+    polygon([ p_min,
+             p_max,
+             p_max + d,
+             p_min + d ]);
+  }
+}
+
+module PlugKeeperStalkProfile(){
+  hull(){
+    for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
+    translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
+      square([ 0.1, keeper_stalk_basewidth/2 ], center=true);
+  }
+}
+
+module PlugKeeper(){
+  for (m=[0,1]) mirror([0,m,0]) {
+      translate([0,0, -wall[2]])
+       linear_extrude(height=plug_h + wall[2])
+       PlugKeeperProfileHalf();
+
+      translate([0, 0, plug_h - plug_tooth_h])
+       linear_extrude(height= plug_tooth_h)
+       translate(plugkeeper_d_u * -plug_tooth_dy)
+       PlugKeeperProfileHalf();
+
+    }
+
+  translate([0,0, -wall[2]])
+    linear_extrude(height = wall[2])
+    PlugKeeperStalkProfile();
+}
+
 module Box(){
   difference(){
     BoxMain();
 
     translate([ led[0], phone[1]/2 - led[1], 1 ])
       cylinder(r = led_dia/2, h= phone[2]*2, $fn=20);
+
+    for (ys=[-1,+1])
+      translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
+       linear_extrude(height = wall[2]*3)
+       PlugKeeperStalkProfile();
   }
+
+  PlugKeeper();
 }
 
 //MainProfileInner();
 Box();
+