poster-tube-lid: catch: Colourise CatchDemo

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

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index 54645e037e2f66011b7ba5330f0fd756be42a930..836f07d925da0734a71d62972d11af27b8397376 100644 (file)
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -9,15 +9,21 @@ 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 + 0.75;
+button_dz_outer  = 1.35;
 
 button_dy_outer = 28.42;
 button_dy_inner = 19.05;
 button_dy_centre = 5.65;
 
+nrbutton_brace_x = 37.5;
+
 phone_slop = 0.5 * [1,1,0]
            + 0.5 * [0,0,1];
 
@@ -28,18 +34,21 @@ 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 - 2.0; // 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_basewidth = 12;
 keeper_stalk_len = 70;
-keeper_stalk_gap = 2;
+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 +67,18 @@ 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(){
@@ -87,9 +97,52 @@ module MainProfile(){
   }
 }
 
+module BraceProfileInitial(){
+  p = phone + phone_slop;
+  pbo = p[2] + button_dz_outer;
+  pbc = p[2] + button_dz_centre;
+  polygon([[ button_dy_outer/2 + 0.2,  p[2]           ],
+          [ button_dy_outer/2 + 0.2,  pbo  + wall[2] ],
+          [ button_dy_outer/2      ,  pbo  + wall[2] ],
+          [ button_dy_outer/2      ,  p[2]           ],
+          ]);
+}  
+
+module BraceProfileFinal(){
+  p = phone + phone_slop;
+  pbo = p[2] + button_dz_outer;
+  pbc = p[2] + button_dz_centre;
+  polygon([[ -1,                       p[2]           ],
+          [ -1,                       pbc  + wall[2] ],
+          [ 0,                        pbc  + wall[2] ],
+          [ 0,                        p[2]           ]
+          ]);
+}  
+
+module Brace(){
+  for (m=[0,1]) mirror([0,m,0]) {
+      hull(){
+       for (e=[0,1]) {
+         translate([ nrbutton_brace_x + e * phone[1]/2,
+                     0, 0 ]){
+           rotate([ 90,0,90 ]){
+             linear_extrude(height= (e==0 ? wall[0] : 0.1)){
+               hull(){
+                 BraceProfileInitial();
+                 if (e==0) BraceProfileFinal();
+             }
+             }
+           }
+         }
+       }
+      }
+    }
+}
+
 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)
@@ -132,20 +185,18 @@ module PlugKeeper(){
     }
 }
 
-module KeeperProjection(){
-  projection()
-    rotate([0,90,0])
-    linear_extrude(height= 20)
-    projection()
-    PlugKeeper();
-}
-
 module Box(){
+  sidewall_cutout_z = phone[2] + phone_slop[2] + button_dz_outer;
+
   difference(){
-    BoxMain();
+    union(){
+      BoxMain();
+      Brace();
+    }
 
     translate([ led[0], phone[1]/2 - led[1], 1 ])
-      cylinder(r = led_dia/2, h= phone[2]*2, $fn=20);
+      rotate([0,0, 360/8/2])
+      cylinder(r = led_dia/2 / cos(360/8/2), h= phone[2]*2, $fn=8);
 
     for (ys=[-1,+1]) {
       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
@@ -156,6 +207,11 @@ 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 );
     }
   }
 
@@ -164,10 +220,29 @@ 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
+  translate([0,0,phone[0]])
+    rotate([0,90,0])
+    Box();
 }
 
 //MainProfileInnerHalf();
 //MainProfile();
-//KeeperProjection();
-Box();
-
+//translate([0,0,1]) color("black") BraceProfileInitial();
+//translate([0,0,1]) color("black") BraceProfileFinal();
+//Brace();
+//Box();
+BoxPrint();