sleepphone-cable-box: another attempt at cutout

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

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index d422420967b9656e160dcba37bfe55456f047416..54645e037e2f66011b7ba5330f0fd756be42a930 100644 (file)
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -3,9 +3,16 @@
 include <funcs.scad>
 
 wall = 0.75 * [1,1,1];
-phone = [ 76.40, 30.96, 6.26 ]; // includes socket
+wall_bot = 1.0;
+
+phone = [ 76.40, 30.96, 6.00 ]; // includes socket
 phone_button_z = 6.58;
-minwall = 0.25;
+minwall = 0.50;
+
+cutout_dia = 7;
+cutout_between = 5;
+
+button_dz = 1.35;
 
 button_dy_outer = 28.42;
 button_dy_inner = 19.05;
@@ -21,13 +28,17 @@ led_dia = 4.4;
 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_totlen = 84.90 - 1.5; // 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;
+keeper_stalk_thick = wall_bot;
 
 // calculated
 
@@ -47,7 +58,7 @@ plugkeeper_d_u = unitvector2d(
 
 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] ],
@@ -62,13 +73,18 @@ 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(){
+         translate([ -wall[1], -wall_bot ])
+           square([ wall[1]*2, wall_bot + wall[2] ]);
+         MainProfileInnerHalf();
+       }
+      }
+    for (m=[0,1]) mirror([m,0]) {
        MainProfileInnerHalf();
       }
-    }
+  }
 }
 
 module BoxMain(){
@@ -94,30 +110,64 @@ module PlugKeeperProfileHalf(){
   }
 }
 
+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 ], center=true);
+  }
+}
+
 module PlugKeeper(){
   for (m=[0,1]) mirror([0,m,0]) {
-      translate([0,0, -wall[2]])
-       linear_extrude(height=plug_h + wall[2])
+      translate([0,0, -keeper_stalk_thick])
+       linear_extrude(height=plug_h + keeper_stalk_thick)
        PlugKeeperProfileHalf();
 
       translate([0, 0, plug_h - plug_tooth_h])
        linear_extrude(height= plug_tooth_h)
        translate(plugkeeper_d_u * -plug_tooth_dy)
        PlugKeeperProfileHalf();
+
     }
 }
 
+module KeeperProjection(){
+  projection()
+    rotate([0,90,0])
+    linear_extrude(height= 20)
+    projection()
+    PlugKeeper();
+}
+
 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();
+
+      translate([ phone[0] + wall[0],
+                 ys * (cutout_between/2 + cutout_dia/2),
+                 -10 ])
+       cylinder( r= cutout_dia/2, h = 50, $fn = 20 );
+    }
   }
 
   PlugKeeper();
+
+  translate([0,0, -keeper_stalk_thick])
+    linear_extrude(height = keeper_stalk_thick)
+    PlugKeeperStalkProfile();
 }
 
-//MainProfileInner();
+//MainProfileInnerHalf();
+//MainProfile();
+//KeeperProjection();
 Box();