X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=04c4d61b93c93c6c11f5717a98d86a11bedca2a1;hp=01796a134896a9d53289f51b7f635abdb286555b;hb=85db45c1dd57ad34e781f8d108368fa1124a2e47;hpb=69979e27b4ba8a0faf9b15fa8366baebffd70006

diff --git a/fairphone-case.scad b/fairphone-case.scad
index 01796a1..04c4d61 100644
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -4,17 +4,9 @@ include <utils.scad>
 
 phone = [ 75.0, 145.0 ];
 
-prop_lid_posns = [ 70 ]; // measured from bottom of phone
+prop_buildout_less = 3;
 
-prop_lengths = [ 80, 50 ];
-
-prop_angle_specs = [
-  // angle    prop length index     prop lid posn index
-  [   15,          1,                    0 ],
-  [   30,          1,                    0 ],
-  [   45,          0,                    0 ],
-  [   60,          0,                    0 ],
-  ];
+prop_angles = [ 15, 30, 45, 60 ];
 
 bumper = [ 0.250, -0.025 ];
 // ^ One side.  Overall size is increased by twice this.
@@ -34,7 +26,7 @@ phone_backside_slope_outer = 1.0; // larger means shallower
 camera_pos_tl = [  6.450, 12.750 ]; // measured from tl corner
 camera_pos_br = [ 22.300, 37.600 ]; // tl/br as seen from back
 
-jack_pos = [ 14.38, 7.96 ];
+jack_pos = [ 13.83, 8.485 ];
 jack_dia = 10.64 + .5; // some jack I had lying around
 
 noisecancelmic_pos = [ 19.54, 7.37 ];   // from rhs
@@ -120,20 +112,18 @@ catch_height = 0.35;
 catch_finger_height = 1.5;
 catch_finger_depth = 2.5;
 
-prop_main_width = 3;
-prop_wing_len = 3;
-prop_nose_slope = 1.5; // bigger means pointier
-prop_side_gap = 0.75; // each side
-prop_fin_height = 1.5;
-prop_fin_width = 0.75;
-prop_max_angle = 45; // bigger means at worse angle
-prop_recess_under = 0.30;
-prop_backfwd_gap = 1.0; // total
-
-prop_recess_slop = 0.125; // each side
+prop_recess_under = 0.50;
+prop_recess_slop = 0.200; // each side
 prop_end_dia = 0.5;
 prop_main_th = 3;
 prop_taper_len = 6;
+prop_main_width = 4;
+prop_side_gap = 0.75; // each side
+prop_lidrecess_behind = 0.75;
+prop_caserecess_behind = 0.75;
+prop_caserecess_taper = 0.45; // one side only
+prop_prop_gap = 0.5;
+prop_prong_heel_slope = 0.5;
 
 // ---------- calculated ----------
 
@@ -142,6 +132,8 @@ phone_height = (phone + bumper*2)[1];
 
 inside_br = [phone_width, -phone_height];
 
+prop_prong_h = prop_main_th;
+
 //echo(camera_pos_tl + bumper,
 //     camera_pos_br + bumper);
 
@@ -151,10 +143,12 @@ lid_buttoncover_overlap = case_th_lip + keeper_gap_z_top;
 
 phone_backside_slope_thick = phone_total_thick - phone_edge_thick;
 
-prop_nose_len = case_th_lid - prop_recess_under;
-prop_recess_slope = tan(prop_max_angle); // bigger means steeper
-prop_recess_depth = case_th_lid - prop_recess_under;
-prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
+//prop_lidrecess_depth = case_th_lid - prop_recess_under;
+
+//prop_nose_len = case_th_lid - prop_recess_under;
+//prop_recess_slope = tan(prop_max_angle); // bigger means steeper
+//prop_recess_width = prop_main_th / cos(prop_max_angle) + prop_backfwd_gap;
+
 
 //lid_lip_overlap_width xxx bad name = ;
 //lid_lip_inner_slope = [ 5, 5 ]; // xxx
@@ -182,6 +176,8 @@ lp_r12 = case_th_lid - (lpp11[1] - lpp10[1]);
 lpp12 = [ epp4[0] + lp_r12,    lpp11[1] ];
 lpp13 = [ lpp12[0],            lpp12[1] + lp_r12 ];
 
+case_bottom_z = epp2o[1] - case_th_bottom;
+
 // button profile
 bppM = epp4 + [0,5];
 bppN = [ 0.5 * (epp0[0] + epp4[0]), bppM[1] ];
@@ -193,6 +189,9 @@ bppO = [ bppN[0], bppP[1] ];
 bppL = lpp10 + [5,0];
 bppK = [ bppL[0], bppN[1] ];
 bppJ = [ bppN[0], bppL[1] ];
+bppU = [ bppJ[0], lpp12[1] ];
+bppV = lpp11;
+bppW = lpp10;
 
 // hinge plan
 hp_rn = hingescrew_nut_dia/2;
@@ -253,18 +252,38 @@ cppQ = [ cppR[0],
 	 cppV[1] - (catch_finger_height - cp_rQ) ];
 cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
 
-// prop recess
+// prop recess in case
+
+prop_x_pos = phone_width/2;
 
-prp1 = [0,0]; // by definition
-prp2 = prp1 + [ -prop_recess_slope, -1 ] * prop_recess_depth;
-prp4 = prp1 + [1,0] * prop_recess_width;
-prp3 = [ prp4[0], prp2[1] ];
-prp5 = prp4 + [1,0] * prop_recess_depth;
+prop_recess_hw = 0.5 * prop_main_width + prop_side_gap;
+
+prc_r1 = prop_end_dia/2;
+prc_r3 = prc_r1 + prop_recess_slop;
+
+prcp2 = [ epp4[0] + prop_buildout_less,
+	  case_bottom_z ];
+
+prop_caserecess_buildout_r = -1; // prcp2[0] - epp2o[0];
+
+prcp1 = [ epp2o[0] + prc_r3 + prop_caserecess_behind,
+	  epp2i[1] - prc_r3 - prop_recess_under];
 
 // prop recess in lid
 
-prlp1 = [ lpp10[0] + prop_recess_slop + prop_end_dia/2,
-	  lpp10[1] + prop_recess_slop + prop_end_dia/2 ];
+prl_r10 = prop_end_dia/2;
+prl_r10o = prl_r10 + prop_recess_slop;
+
+prlp10 = lpp10 + [1,1] * prl_r10o
+  + [1,0] * prop_lidrecess_behind
+  + [0,1] * prop_recess_under;
+
+// prop
+
+$prpp10 = [0,0];
+$prpp11 = [0, prop_taper_len];
+
+$prp_r10 = prl_r10;
 
 // ---------- modules ----------
 
@@ -305,7 +324,9 @@ module LidEdgeProfile(){
 
 module ButtonCoverProfile(){
   intersection(){
-    polygon([ bppM, bppP, bppO, bppJ, bppL, bppK ]);
+    polygon(concat([ bppM, bppP, bppO, bppJ ],
+		   (enable_support ? [ bppU, bppV, bppW ] : []),
+		   [ bppL, bppK ]));
     hull(){
       EdgeProfile();
       LidEdgeProfile();
@@ -568,12 +589,15 @@ module HingeLeverOuterProfile(){
 }
 
 module HingeLeverInnerProfile(){
-  for (c = [hppT, hppB]) {
-    hull()
+  for (s = [-1,+1]) {
+    c = s > 0 ? hppT : hppB;
+    translate(c)
+      mirror([0,0,s>0])
+      hull()
       for (x=[-20,20])
-	for (y=[0, c[1] - hppM[1]])
+	for (y=[0, s * 10])
 	  translate([x,y])
-	    circleat(c, hp_rn);
+	    circle(hp_rn);
   }
 }
 
@@ -601,68 +625,105 @@ module CatchPortion(width){
     children(0);
 }
 
-module PropRecess(){
-  // origin is nonstandard
-  hwd345 = 0.5*prop_main_width + prop_side_gap;
-  hwd35  = 0.5*prop_fin_width + prop_side_gap;
-  rotate([90,0,90]){
-    linextr(-hwd345, +hwd345)
-      polygon([ prp1,
-		prp2,
-		prp3,
-		prp4,
-		prp4 + [0,10],
-		prp1 + [0,10],
-		]);
-    linextr(-hwd35, +hwd35)
-      polygon([ prp1,
-		prp3,
-		prp5,
-		prp5 + [0,10],
-		prp1 + [0,10],
-		]);
-  }
+module CaseBase(){
+  AroundEdges(epp3[1], case_th_bottom, 1)
+    EdgeProfile();
 }
 
-module SomePropProfile(gamma){
-// prop-internal
-  pip1 = [0,0];
-  pip2 = [ 0.5 * (prop_main_th - prop_end_dia),
-	   prop_taper_len ];
-  
-  translate(prlp1) {
-    circleat([0,0], prop_end_dia/2);
-    cirecleat(pip2, prop_main_th);
-    
-  }
+function prop_x(gamma) = hp_k / (2 * sin(gamma/2)) - hppT[0];
+
+module PropProfileAssignments(gamma){
+  // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_the_included_angle_given_(SAS)
+  x = prop_x(gamma);
+  p = phone_height + prlp10[0] - hppB[0];
+  b = p + x;
+
+  q = phone_height - hppT[0] - prcp1[0]; // $prpp7[0] is 0 by definition
+  a = q + x;
+  c = sqrt(a*a + b*b - 2*a*b*cos(gamma));
+  $prp_alpha = acos( (b*b + c*c - a*a) / (2*b*c) );
+
+  $prp_theta = 90 - $prp_alpha;
+  beta = 180 - $prp_alpha - gamma;
+  psi = 90 - beta;
+
+  //echo("abc", a,b,c);
+
+  v1 = [ [ cos(psi), -sin(psi) ],    // x
+	 [ sin(psi),  cos(psi) ] ];  // y
+
+  $prpp7 = [0, c + (lpp13[1] - $prpp10[1] - hp_k) ];
+
+  $prp_r1 = prc_r1;
+  $prp_r11 = prop_main_th/2;
+
+  $prpp1 = $prpp7 + [1,0] *
+    // this is approximate, but will do
+    (prop_main_th/2 + prop_prop_gap + prcp1[0] - cppA[0]);
+  $prpp3 = $prpp1 +
+    v1[0] * -$prp_r1 +
+    v1[1] * ((prcp2[1] - prcp1[1]) - prop_prop_gap);
+  $prpp12 = $prpp3 + v1[0] *
+    (prop_end_dia + prop_caserecess_taper * ($prpp1[1] - $prpp3[1]));
+  $prp_r8 = prop_main_th;
+  $prpp4 = [ prop_main_th/2, $prpp3[1] ];
+  $prp_r5 = $prp_r8;
+  $prpp5 = [ $prpp12[0] - $prp_r5,
+	    $prpp3[1] - prop_prong_h + $prp_r5 ];
+  $prpp6 = $prpp4 + [0,-1] * (prop_prong_h +
+         prop_prong_heel_slope * ($prpp5[0] - $prpp4[0]));
+  $prpp8 = $prpp4 + [0,-1] * $prp_r8;
+  $prpp9 = $prpp8 + [-1,0] * $prp_r8;
+
+  children();
 }
 
-module CasePropRecess(pas) {
-  // destructure entry in prop_angle_specs
-  beta =                 pas[0];
-  b    = prop_lengths  [ pas[1] ];
-  p    = prop_lid_posns[ pas[2]] ;
+module PropProfile(gamma, cut=0, rot=0){ ////toplevel
+  PropProfileAssignments(gamma){
 
-  k = hp_k;
-  x = k / (2 * sin(beta/2)) - hppT[0];
-  c = p + x;
+    //#circleat($prpp3,1);
+    //#circleat($prpp12,1);
 
-  // https://en.wikipedia.org/wiki/Solution_of_triangles#Two_sides_and_non-included_angle_given_(SSA) [25.1.18]
-  // we always want the positive solution because it has a closer to c
-  a = c * cos(beta) + sqrt( b*b - pow(c * sin(beta),2) );
-  q = a - x;
-
-  echo(beta, a, b, c);
+    if (!cut) {
+      hull(){
+	translate($prpp8)
+	  intersection(){
+	    circle($prp_r8);
+	    polygon([[-20,-0], [20,20], [0,0]]);
+	  }
+	rectfromto($prpp6, $prpp9);
+	translate($prpp5) intersection(){
+	  circle($prp_r5);
+	  polygon([[-10,-10], [0,0], [10,0]]);
+	}
+	rectfromto($prpp12 + [0,-0.1], $prpp3);
+      }
+      hull(){
+	circleat($prpp1, $prp_r1);
+	rectfromto($prpp12 + [0,-0.1], $prpp3);
+      }
+    }
+    // main shaft
+    rotate([0,0, rot*-$prp_theta]){
+      hull(){
+	extra = cut ? prop_recess_slop : 0;
+	rectfromto($prpp6, $prpp9);
+	circleat($prpp11, $prp_r11 + extra);
+	circleat($prpp10, $prp_r10 + extra);
+      }
+    }
+  }
+}
 
-  Flip_bot(1)
-    translate([ phone_width/2, -q, epp2o[1]-case_th_bottom ])
-    rotate([0,180,0])
-    PropRecess();
+module PropAggregateProfile(){
+  for (angle = prop_angles)
+    PropProfile(angle, 0,0);
 }
 
-module CaseBase(){
-  AroundEdges(epp3[1], case_th_bottom, 1)
-    EdgeProfile();
+module Prop(){ ////toplevel
+  hw = prop_main_width/2;
+  linextr(-hw, +hw)
+    PropAggregateProfile();
 }
 
 module Case(){ ////toplevel
@@ -686,6 +747,16 @@ module Case(){ ////toplevel
 
       // hinge
       HingePortion(hex20, hex21) HingeBaseProfile();
+
+      // buildout for prop recess
+      if (prop_caserecess_buildout_r > 0) Flip_rhs(1)
+	linextr(case_bottom_z, epp2i[1])
+	hull() {
+  	  for (dxs = [-1,+1])
+	    circleat([ prop_x_pos + dxs * prop_caserecess_buildout_r,
+		       -epp2o[0] ],
+		     r = epp2o[0] - prcp2[0]);
+        }
     }
 
     // slot for keeper
@@ -728,6 +799,7 @@ module Case(){ ////toplevel
 	    linear_extrude(height= 20)
 	    ButtonPlan($button_l, 1,1);
         }
+      
     }
 
     // apertures along top edge
@@ -754,9 +826,17 @@ module Case(){ ////toplevel
     CatchPortion(catch_width + catch_side_gap*2)
       CatchCutProfile();
 
-    // prop recesses
-    #for (pas = prop_angle_specs)
-      CasePropRecess(pas);
+    // prop recess
+    Flip_rhs(1)
+      translate([prop_x_pos,0,0])
+      mirror([0,1,0])
+      rotate([90,0,90])
+      linextr(-prop_recess_hw, +prop_recess_hw)
+      hull(){
+        for (d=[ [0,0], [0,-1], [+1,-1/prop_caserecess_taper] ])
+	  circleat(prcp1 + 20*d,
+		   prc_r3);
+      }
   }
 }
 
@@ -792,11 +872,14 @@ module Lid(){ ////toplevel
     // screw holes in the hinge arms
     HingeScrews();
 
-    // prop recesses
-    Flip_bot(1)
-      for (y = prop_lid_posns)
-	translate([ phone_width/2, -y, lpp13[1] ])
-	  PropRecess();
+    // prop recess
+    translate([prop_x_pos, -prlp10[0], prlp10[1]])
+      mirror([0,1,0])
+      rotate([90,0,90])
+      linextr(-prop_recess_hw, +prop_recess_hw)
+      hull()
+      for (pa = prop_angles)
+	PropProfile(pa, 1,1);
   }
 }
 
@@ -925,19 +1008,6 @@ module LidPrint(){ ////toplevel
     Lid();
 }
 
-module TestSelectPropRecesses(posns){
-  linextr(-100,100){
-    translate([phone_width/2, -phone_height]){
-      square([ 3, 500 ], center=true);
-      for (y=posns)
-	hull()
-	  for (dy=[ -prp5[0], -prp2[0] ])
-	    translate([0,y+dy])
-	      square([prop_main_width+5, 5], center=true);
-    }
-  }
-}
-
 module TestSelectFrame(){
   include = [1,-1] * (epp2i[0] + 4);
 
@@ -951,7 +1021,6 @@ module TestSelectFrame(){
 
 module TestSelectLidFrame(){
   TestSelectFrame();
-  TestSelectPropRecesses(prop_lid_posns);
 }
 
 module TestFrameCase(){ ////toplevel
@@ -965,6 +1034,15 @@ module TestFrameCase(){ ////toplevel
   }
 }
 
+module TestTopApertures(){ ////toplevel
+  intersection(){
+    Case();
+    TestSelectFrame();
+    translate([-100, -35, -100])
+      cube([400, 100, 200]);
+  }
+}
+
 module TestFrameLidPrint(){ ////toplevel
   rotate([0,180,0]) intersection(){
     Lid();
@@ -994,6 +1072,48 @@ module HingeScrews(){
   }
 }
 
+module DemoPropAngleSelect(c){
+  color(c) difference(){
+    union(){ children(); }
+    translate([ prop_x_pos, -400, -200 ])
+      cube([ 400,800,400 ]);
+  }
+}
+
+module DemoPropAngle(ang){
+  hL = [0, -(phone_height - hppT[0]), hppT[1] - hp_k*2];
+  hC = [0, -(phone_height - hppB[0]), hppB[1]];
+
+  translate(hL)
+    rotate([ang/2,0,0])
+    translate(-hL)
+    translate(hC)
+    rotate([ang/2,0,0])
+    translate(-hC) {
+      DemoPropAngleSelect("red") Case();
+
+      color("orange")
+	translate([prop_x_pos, -prcp1[0], prcp1[1]])
+	PropProfileAssignments(ang) {
+          echo($prpp1);
+	  rotate([-$prp_theta, 0, 0])
+	  translate([0, $prpp1[0], -$prpp1[1]])
+	  rotate([90,0,-90])
+	  Prop();
+        }
+    }
+
+  translate([0,0, -hp_k*2])
+    DemoPropAngleSelect("blue")
+    Lid();
+}
+
+module DemoPropAngles(){ ////toplevel
+  for (i=[0 : len(prop_angles)-1])
+    translate(i * [0, -100, 100])
+    DemoPropAngle(prop_angles[i]);
+}
+
 module DemoFrame(){ ////toplevel
   color("red") TestFrameCase();
   color("blue") intersection(){ Lid(); TestSelectLidFrame(); }
@@ -1059,6 +1179,19 @@ module DemoProfiles(){ ////toplevel
     color("blue") CatchCatchProfile();
     color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
   }
+
+  translate([40,-30]) {
+    difference(){
+      LidEdgeProfile();
+      translate(prlp10)
+	PropProfile(10, 1, 0);
+    }
+    translate(prlp10)
+      PropProfile(15, 0);
+  }
+  translate([60,-30]) {
+    PropAggregateProfile();
+  }
 }
 
 //EdgeProfile();