sleepphone-cable-box: adjust expose (from v3)

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

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index a0260de469e2f9b04204c464e0d778cb03943b63..77ee2148b5ea850398426afafd38e432693e1d9a 100644 (file)
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -9,10 +9,14 @@ phone = [ 76.40, 30.96, 6.00 ]; // includes socket
 phone_button_z = 6.58;
 minwall = 0.50;
 
+expose = 4.00;
+
 cutout_dia = 7;
 cutout_between = 5;
 
 button_dz = 1.35;
+button_dz_centre = 1.35;
+button_dz_outer  = 1.35;
 
 button_dy_outer = 28.42;
 button_dy_inner = 19.05;
@@ -28,7 +32,7 @@ led_dia = 4.4;
 plug_maxw = 10.95 + 0.35;
 plug_minw=   6.53 + 0.35;
 plug_sllen=  6.50;
-plug_totlen = 84.90 - 1.5; // to maxw, including phone
+plug_totlen = 84.90 + 1.5; // to maxw, including phone
 
 plug_h = 6.5;
 plug_tooth_h = 0.5;
@@ -40,6 +44,9 @@ keeper_stalk_len = 70;
 keeper_stalk_gap = 1;
 keeper_stalk_thick = wall_bot;
 
+keeper_stalk_base_reinforce_len = 5;
+keeper_stalk_base_reinforce_thick = 2.0;
+
 // calculated
 
 top_z = max( phone[2] + wall[2],
@@ -58,17 +65,18 @@ plugkeeper_d_u = unitvector2d(
 
 module MainProfileInnerHalf(){
   p = phone + phone_slop;
-  pb = p[2] + button_dz;
+  pbc = p[2] + button_dz_centre;
+  pbo = p[2] + button_dz_outer;
   polygon([[ -2,                 0    ],
           [ p[1]/2,             0    ],
           [ p[1]/2,             p[2] ],
           [ button_dy_outer/2,  p[2] ],
-          [ button_dy_outer/2,  pb   ],
-          [ button_dy_inner/2,  pb   ],
+          [ button_dy_outer/2,  pbo  ],
+          [ button_dy_inner/2,  pbo  ],
           [ button_dy_inner/2,  p[2] ],
           [ button_dy_centre/2, p[2] ],
-          [ button_dy_centre/2, pb   ],
-          [ -2,                 pb   ]]);
+          [ button_dy_centre/2, pbc  ],
+          [ -2,                 pbc  ]]);
 }
 
 module MainProfile(){
@@ -89,7 +97,8 @@ module MainProfile(){
 
 module BoxMain(){
   rotate([0,0,90]) rotate([90,0,0]) {
-    linear_extrude(height = phone[0] + wall[0], convexity=20)
+    translate([0,0, expose])
+      linear_extrude(height = phone[0] + wall[0] - expose, convexity=20)
       MainProfile();
     translate([0,0, phone[0]])
       linear_extrude(height = wall[0], convexity=20)
@@ -133,6 +142,8 @@ module PlugKeeper(){
 }
 
 module Box(){
+  sidewall_cutout_z = phone[2] + phone_slop[2] + button_dz_outer;
+
   difference(){
     BoxMain();
 
@@ -149,6 +160,11 @@ module Box(){
                  ys * (cutout_between/2 + cutout_dia/2),
                  -10 ])
        cylinder( r= cutout_dia/2, h = 50, $fn = 20 );
+
+      translate([expose, ys*phone[1]/2, sidewall_cutout_z/2])
+       rotate([90,0,0])
+       translate([0,0,-3])
+       cylinder( r= sidewall_cutout_z/2 - 0.1, h=6 , $fn=20 );
     }
   }
 
@@ -157,12 +173,22 @@ module Box(){
   translate([0,0, -keeper_stalk_thick])
     linear_extrude(height = keeper_stalk_thick)
     PlugKeeperStalkProfile();
+
+  translate([ plugkeeper_x_maxw + keeper_stalk_len +
+              -keeper_stalk_base_reinforce_len/2,
+              -keeper_stalk_basewidth/2,
+              0 ])
+    mirror([0,0,1])
+    cube([ keeper_stalk_base_reinforce_len,
+          keeper_stalk_basewidth,
+          keeper_stalk_base_reinforce_thick ]);
 }
 
 module BoxPrint(){
   // This makes' Cura's support more optimal: specifically,
   // it then doesn't seem to touch the back (bottom) wall
-  rotate([0,90,0])
+  translate([0,0,phone[0]])
+    rotate([0,90,0])
     Box();
 }