X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=crossbar-computer-led-mount.scad;h=4bc474a38aaed7b2bd82fe25b3866e30c7217432;hp=71a449e20c324439bb80515a84b207f0f7854db7;hb=4f92d46640259aabd3e3d1f8b404256e20511e49;hpb=8788d8e8b01d1fffdaaa0f520c233a1fbe566db2

diff --git a/crossbar-computer-led-mount.scad b/crossbar-computer-led-mount.scad
index 71a449e..4bc474a 100644
--- a/crossbar-computer-led-mount.scad
+++ b/crossbar-computer-led-mount.scad
@@ -3,19 +3,56 @@
 led_dia = 5 + 0.6;
 led_depth = 5;
 
-test_width = 15;
-test_height = 12;
+led_tip_height_above_crossbar = 70;
+led_angle = -60;
+crossbar_dia = 25; // fixme
 
-thicks = [1,2,4,6];
+vert_space_inside = 8;
+backfront_space_inside = 12;
+width_space_inside = 10;
 
-module Tests(){
-  for (thicki=[0:len(thicks)-1]) {
-    translate([thicki*test_width-0.1, 0, 0]) {
+backfront_mate_size = 25;
+tower_frontheight = 20;
+tower_slot_width = 3;
+
+cableclamp_ctie_width = 3 + 0.5;
+cableclamp_ctie_thick = 2 + 0.5;
+
+lidclamp_ctie_width = 4.0 + 0.5;
+lidclamp_ctie_thick = 2.5 + 0.5;
+
+base_ctie_width = 4.0 + 0.5;
+base_ctie_thick = 2.5 + 0.5;
+
+tube_ctie_width = 5 + 0.5;
+tube_ctie_thick = 3 + 0.5;
+
+// tuning
+
+tower_over_angle = 45;
+tower_wall_thick = 1.6;
+tower_base_height = 10;
+tower_forehead_angle = 30;
+lid_wall_thick = 1.6;
+lid_slop = 0.75;
+base_ctie_anchor = 5;
+tube_ctie_anchor = 5;
+
+//--- tests ---
+
+test_width = 24;
+test_height = 24;
+
+test_thicks = [9,14,21];
+
+module Tests(){ ////toplevel
+  for (thicki=[0:len(test_thicks)-1]) {
+    translate([thicki*test_width-0.5, 0, 0]) {
       difference(){
 	cube([test_width,
-	      thicks[thicki] + led_depth,
+	      test_thicks[thicki] + led_depth,
 	      test_height]);
-	%translate([test_width/2, -1, test_height/2])
+	translate([test_width/2, -1, test_height/2])
 	  rotate([-90,0,0])
 	  cylinder(r=led_dia/2, h=led_depth+1, $fn=30);
       }
@@ -23,4 +60,213 @@ module Tests(){
   }
 }
 
-Tests();
+//Tests();
+
+//--- real thing ---
+
+// calculated
+
+tower_overhang = led_dia * 2.5;
+tower_width = width_space_inside + tower_wall_thick*2;
+
+tower_over_max_y = tower_overhang * sin(tower_over_angle);
+tower_over_max_z = tower_frontheight + tower_overhang * cos(tower_over_angle);
+tower_total_max_z = tower_over_max_z + vert_space_inside + led_depth;
+tower_rearwall_y = -(backfront_space_inside + tower_wall_thick);
+led_head_y = tower_over_max_y/2;
+led_head_z = tower_frontheight + tower_overhang*sin(tower_over_angle)/2;
+backfront_mate_extra = (backfront_mate_size - (-tower_rearwall_y));
+
+tower_height_contribution = led_head_z + tower_base_height;
+
+base_ctie_anchor_eff = base_ctie_anchor+base_ctie_thick/2;
+tube_ctie_anchor_eff = tube_ctie_anchor+tube_ctie_thick/2;
+
+base_width = 0.7 * crossbar_dia;
+base_backfront = backfront_mate_extra - tower_rearwall_y;
+base_height = led_tip_height_above_crossbar - tower_height_contribution;
+
+echo(tower_height_contribution, base_height);
+
+module TowerWallCrossSection(){
+  // generates a 2D shape - a polygon
+  // x is what is going to be -y
+  // y is what is going to be z
+  polygon([[0,                  0],
+	   [0,                  tower_frontheight],
+	   [-tower_over_max_y,  tower_over_max_z],
+	   [-tower_over_max_y
+	    + tan(tower_forehead_angle) * (vert_space_inside + led_depth),
+	    tower_total_max_z],
+	   [-tower_rearwall_y,  tower_total_max_z],
+	   [-tower_rearwall_y,  0],
+	   [-tower_rearwall_y, -tower_base_height],
+	   [-backfront_mate_extra, -tower_base_height]],
+	  convexity=5);
+}
+
+module TowerWallSomeEdge(front){
+  minkowski(){
+    difference(){
+      TowerWallCrossSection();
+      translate([front ? 0.10 : -0.10, 0])
+	TowerWallCrossSection();
+    }
+    circle(r=tower_wall_thick, $fn=8);
+  }
+}
+
+module TowerBulkCrossSection(){
+  intersection(){
+    TowerWallCrossSection();
+    union(){
+      translate([-led_head_y, led_head_z])
+	circle(r = led_depth);
+      TowerWallSomeEdge(true);
+      translate([-50, -50])
+	square([100, 50]);
+    }
+  }
+}
+
+module TowerRearWallCrossSection(){
+  intersection(){
+    TowerWallCrossSection();
+    union(){
+      intersection(){
+	translate([0,-10]) square([100, 10+led_head_z]);
+	TowerWallSomeEdge(false);
+      }
+      TowerBulkCrossSection();
+    }
+  }
+}
+
+
+module TowerCrossSectionDemo(){
+  %TowerWallCrossSection();
+  //TowerBulkCrossSection();
+  TowerRearWallCrossSection();
+}
+
+module TowerMain(){
+  for (mir=[0,1])
+    mirror([mir,0,0]) rotate([90,0,-90]) {
+      translate([0,0, tower_width/2-tower_wall_thick])
+	linear_extrude(height=tower_wall_thick) {
+	TowerWallCrossSection();
+      }
+      translate([0,0,-1])
+	linear_extrude(height=tower_width/2+0.9)
+	union(){
+	  TowerBulkCrossSection();
+	  hull(){
+	    intersection(){
+	      TowerWallCrossSection();
+	      translate([-30, -30])
+		square([30 + 0.1, 30 + tower_frontheight]);
+	    }
+	  }
+        }
+      translate([0,0, tower_slot_width/2])
+	linear_extrude(height=(tower_width - tower_slot_width)/2 - 0.2)
+	TowerRearWallCrossSection();
+    }
+}
+
+module LedHole(){
+  translate([0, led_head_y, led_head_z])
+    rotate([90 + led_angle])
+    translate([0,0,-10])
+    cylinder(r=led_dia/2, h=led_depth+0.1+10, $fn=30);
+}
+
+module Tower(){ ////toplevel
+  difference(){
+    TowerMain();
+    LedHole();
+    // passages for cable ties
+    translate([0,
+	       tower_rearwall_y/2,
+	       tower_frontheight/2
+	       + cableclamp_ctie_width/2 + lidclamp_ctie_thick/2])
+      cube([50, lidclamp_ctie_width, lidclamp_ctie_thick], center=true);
+    translate([0,
+		(backfront_mate_extra+tower_rearwall_y)/2,
+		-tower_base_height/2])
+      cube([50, base_ctie_width, base_ctie_thick], center=true);
+    for (mir=[0,1])
+      mirror([mir,0,0]) {
+	translate([tower_width/4, 20, tower_frontheight/2])
+	  cube([cableclamp_ctie_thick,
+		tower_wall_thick*2+1+40,
+		cableclamp_ctie_width],
+	       center=true);
+      }
+  }
+}
+
+module TowerMainHull(){
+  hull(){ TowerMain(); }
+}
+
+module Lid(){
+  intersection(){
+    difference(){
+      minkowski(){
+	TowerMainHull();
+	sphere(r=lid_wall_thick+lid_slop, $fn=4);
+      }
+      minkowski(){
+	TowerMainHull();
+	sphere(r=lid_slop, $fn=4);
+      }
+    }
+    translate([-50,-50,led_head_z]) cube([100,100,100]);
+  }
+}
+
+module LidT(){ ////toplevel
+  rotate([180,0,0]) Lid();
+}
+
+module Base(){ ////toplevel
+  difference(){
+    mirror([0,0,1]){
+      hull(){
+	translate([-tower_width/2, 0, 0])
+	  cube([tower_width, base_backfront, 0.1]);
+	translate([-base_width/2, 0, base_height])
+	  cube([base_width, base_backfront, crossbar_dia/2]);
+      }
+    }
+    translate([-50, base_backfront/2, -base_ctie_anchor_eff])
+      cube([100, base_ctie_width, base_ctie_thick], center=true);
+    translate([-50, base_backfront/2, -base_height + tube_ctie_anchor_eff])
+      cube([100, tube_ctie_width, tube_ctie_thick], center=true);
+    translate([0, -1, -(base_height + crossbar_dia/2)])
+      rotate([-90,0,0])
+      cylinder(r=crossbar_dia/2, h=101);
+  }
+}
+
+module BaseT(){ ////toplevel
+  rotate([90,0,0]) Base();
+}
+
+module Demo(){
+  Tower();
+  translate([0,0, 25]) Lid();
+  translate([0, tower_rearwall_y, -(tower_base_height+5)]) Base();
+}
+
+//TowerCrossSectionDemo();
+//TowerWallSomeEdge(false);
+//TowerWallFrontEdge();
+//TowerMainHull();
+//LidT();
+//Tower();
+//Lid();
+//Base();
+//BaseT();
+Demo();