X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=fairphone-case.scad;h=64fe13d8e308f6b13ff4ee8eb74ec15ff56713b0;hp=59dd894fcbad25d60300a7c8a5513d56b0192cb0;hb=3280426eef100da072284693787efb97ca2fe848;hpb=d7aca80e53472fca75c92aa8d07221e9e79c5963;ds=sidebyside

diff --git a/fairphone-case.scad b/fairphone-case.scad
index 59dd894..64fe13d 100644
--- a/fairphone-case.scad
+++ b/fairphone-case.scad
@@ -1,8 +1,10 @@
 // -*- C -*-
 
+include <utils.scad>
+
 phone = [ 75.0, 145.0 ];
 
-bumper = [ 0.250, 0.250 ];
+bumper = [ 0.250, -0.025 ];
 // ^ One side.  Overall size is increased by twice this.
 // If no bumpers, is the gap around the phone.
 
@@ -24,9 +26,15 @@ jack_dia = 9.1 + .5; // some jack I had lying around
 noisecancelmic_pos = [ 19.54, 7.37 ];   // from rhs
 noisecancelmic_dia = 1.75;
 
-rearspeaker_pos_bl = [ 14.92, 18.72 ];
+fingerpushhole_dias = [ 15, 18 ];
+
+rearspeaker_pos_bl = [ 12.64, 18.72 ];
 rearspeaker_size   = [  3.76,  7.36 ];
 
+microusb_above = 3.27 - 0.25;
+microusb_below = 0.0;
+microusb_width = 16.12 + 0.25;
+
 case_th_bottom = 2.5;
 case_th_lid = 2.5;
 case_th_side = 2;
@@ -54,16 +62,47 @@ lid_gap_x = 0.25;
 lid_gap_z = 0.25;
 lid_lip = 1.75;
 
+catch_slop = 0.25;
+
+foldover_gap = 0.50;
+foldover_lever_gap = 0.50;
+
+hingescrew_shaft_dia = 2.0 + 0.25; // M2 x 12mm machine screw
+hingescrew_shaft_len = 12;
+hingescrew_nut_thick = 1.93 + 0.20; // incl. washer
+hingescrew_nut_dia = 4.72 + 0.50; // washer, actually
+hingescrew_head_th = 1.38 + 0.75;
+hingescrew_head_dia = 3.92;
+lever_cover_th = 0.75;
+hingemount_th = 2.5;
+
 $fa = 5;
 $fs = 0.1;
 
 button_l_fudge = 4.4;
 buttonishleg_default_l_is_fudge = 10;
 
+hinge_base_slope = 1.5; // bigger is steeper
+
 strut_min_at_end = 1.5;
 
+hinge_x_gap = 0.125;
+hinge_x_postscrew_gap = 0.75;
+hinge_x_arms_gap = 0.35;
+hinge_r_arms_gap = 0.55;
+
 rearspeaker_gap    = [ 1.0, 1.0 ]; // each side
 
+catch_len = 7.5;
+catch_width = 15;
+catch_thickness = 1.0;
+catch_side_gap = 0.75; // each side
+
+catch_depth = 1.25;
+catch_height = 0.35;
+catch_finger_height = 1.5;
+catch_finger_depth = 2.5;
+
 // ---------- calculated ----------
 
 phone_width =  (phone + bumper*2)[0];
@@ -118,17 +157,65 @@ bppL = lpp10 + [5,0];
 bppK = [ bppL[0], bppN[1] ];
 bppJ = [ bppN[0], bppL[1] ];
 
-module rectfromto(a,b) {
-  ab = b - a;
-  translate([min(a[0], b[0]), min(a[1], b[1])])
-    square([abs(ab[0]), abs(ab[1])]);
-}
-module circleat(c,r) { translate(c) circle(r); }
-module linextr(z0,z1) {
-  translate([0,0,z0])
-    linear_extrude(height=z1-z0)
-    children();
-}
+// hinge plan
+hp_rn = hingescrew_nut_dia/2;
+hp_r2_min = hp_rn + lever_cover_th;
+hp_rs = hingescrew_shaft_dia/2;
+hp_r1_min = hp_rs + hingemount_th;
+
+hp_r1 = max(hp_r1_min, hp_r2_min);
+hp_r2 = hp_r1;
+
+hppU = lpp13;
+hppS = epp2o + [0,-1] * case_th_bottom;
+hp_k = 0.5 * (hppU[1] - hppS[1] + foldover_gap);
+
+hppM = [ epp4[0] - foldover_lever_gap - hp_r2,
+	 0.5 * (hppU + hppS)[1] ];
+hppT = [ hppM[0], hppU[1] - hp_r1 ];
+hppB = hppT + [0,-1] * hp_k;
+
+hppE_y = epp2o[1] - case_th_bottom + hp_r1;
+hppE_x = hppB[0] + (hppB[1] - hppE_y) * hinge_base_slope;
+hppE = [ hppE_x, hppE_y ];
+
+// hinge elevation x coords
+
+hingescrew_portion_len =
+  0.5* (hingescrew_shaft_len - hingescrew_nut_thick - hinge_x_gap);
+
+hex20 = max(epp2o[0],
+	    phone_cnr_rad,
+	    kppd[0] + hingescrew_head_th + keeper_gap_x_holes);
+hex21 = hex20 + hingescrew_portion_len;
+hex22 = hex21 + hinge_x_gap;
+hex23 = hex22 + hingescrew_portion_len;
+hex24 = hex20 + hingescrew_shaft_len + hinge_x_postscrew_gap;
+echo(hex20, hex21, hex22, hex23, hex24);
+echo(hingescrew_portion_len);
+
+// catch
+
+cppJ = [ epp4[0] + catch_thickness, lpp10[1] ];
+cppA = cppJ + [lid_gap_x, -lid_gap_z];
+cppB = [ epp0[0], cppA[1] ];
+cppP = [ epp4[0], cppJ[1] ];
+
+cppS = cppJ + [0,-1] * catch_len;
+cppD = [ cppA[0], cppS[1] + catch_slop ];
+cppC = [ cppB[0], cppD[1] ];
+cppT = cppS + [1,0] * catch_depth;
+cppU = cppT + [0,-1] * catch_height;
+cppV = [ cppS[0], cppU[1] - catch_depth ];
+
+cppR = 0.5*(cppP + cppJ);
+
+cp_rQ = 0.5 * (cppJ[0] - cppP[0]);
+cppQ = [ cppR[0],
+	 cppV[1] - (catch_finger_height - cp_rQ) ];
+cppF = [ cppV[0] + catch_finger_depth, cppC[1] ];
+
+// ---------- modules ----------
 
 module KeeperProfile(slant=0){
   use_e = kppe + [0,-1] * slant * keeper_inner_width / keeper_slant_slope;
@@ -221,7 +308,32 @@ module ButtonPlan(l, deep, cut){
   }
 }
 
-module CaseBase_rhsflip(yn=[0,1]) {
+module CatchCatchProfile(){
+  hull(){
+    for (c=[ cppR, cppQ ])
+      circleat(c, cp_rQ);
+  }
+  hull(){
+    circleat(lpp12, lp_r12);
+    circleat(lpp12 + [5,0], lp_r12);
+    rectfromto(cppP, cppP + [5,0.1]);
+  }
+  polygon([cppJ, cppS, cppT, cppU, cppV, cppQ, cppR]);
+}
+
+module CatchCutProfile(){
+  polygon([ cppB,
+	    cppA,
+	    cppD,
+	    cppF,
+	    cppF + [0,-10],
+	    cppF + [-10,-10],
+	    lpp12 + [-10,0],
+	    lpp12 + [10,0]
+	    ]);
+}
+
+module Flip_rhs(yn=[0,1]) {
   for ($rhsflip=yn) {
     translate([phone_width/2, 0, 0])
       mirror([$rhsflip,0,0])
@@ -230,7 +342,7 @@ module CaseBase_rhsflip(yn=[0,1]) {
   }
 }
 
-module CaseBase_botflip(yn=[0,1]) {
+module Flip_bot(yn=[0,1]) {
   for ($botflip=yn) {
     translate([0, -phone_height/2, 0])
       mirror([0, $botflip, 0])
@@ -241,14 +353,14 @@ module CaseBase_botflip(yn=[0,1]) {
 
 module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
   // sides
-  CaseBase_rhsflip(){
+  Flip_rhs(){
     translate([0, -phone_cnr_rad, 0])
       rotate([90,0,0])
       linear_extrude(height = phone_height - phone_cnr_rad*2)
       children(0);
   }
   // corners
-  CaseBase_rhsflip() CaseBase_botflip() {
+  Flip_rhs() Flip_bot() {
     translate([+1,-1] * phone_cnr_rad)
       intersection(){
 	rotate_extrude()
@@ -263,7 +375,7 @@ module AroundEdges(fill_zstart, fill_th, fill_downwards=0){
       }
   }
   // top and bottom
-  CaseBase_botflip(){
+  Flip_bot(){
     translate([ phone_width - phone_cnr_rad, 0,0 ])
       rotate([90,0,-90])
       linear_extrude(height = phone_width - phone_cnr_rad*2)
@@ -296,7 +408,7 @@ module SideButton(y, y_ref_sign, l){
   eff_y = y_ref_sign > 0 ?         -bumper [1] -y -l/2 :
 	  y_ref_sign < 0 ? (-phone -bumper)[1] +y +l/2 :
 	  y;
-  echo(eff_y);
+  //echo(eff_y);
   translate([0, eff_y, 0])
     children();
 }
@@ -307,11 +419,11 @@ module LidButtonishLeg(y, y_ref_sign, l=buttonishleg_default_l_is_fudge) {
 }
 
 module Buttons(){
-  CaseBase_rhsflip([1]) SideButton(15.580, +1, 8.9) children(); // power
-  CaseBase_rhsflip([1]) SideButton(48.700, -1, 8.920) children(); // camera
-  CaseBase_rhsflip([0]) SideButton(30.800, +1, 21.96) children(); // volume
-  CaseBase_rhsflip(   ) LidButtonishLeg(20, -1) children();
-//  CaseBase_rhsflip([0]) LidButtonishLeg(20, +1, 20) children();
+  Flip_rhs(1) SideButton(15.580, +1, 8.9) children(); // power
+  Flip_rhs(1) SideButton(48.700, -1, 8.920) children(); // camera
+  Flip_rhs(0) SideButton(30.800, +1, 21.96) children(); // volume
+  Flip_rhs(   ) LidButtonishLeg(20, -1) children();
+//  Flip_rhs(0) LidButtonishLeg(20, +1, 20) children();
 }
 
 module Struts(x_start, z_min, th){
@@ -332,6 +444,111 @@ module Struts(x_start, z_min, th){
   }
 }
 
+module OrdinaryRearAperture(rhs,bot, pos){
+  Flip_rhs(rhs) Flip_bot(bot)
+    linextr(-20, 20)
+    mirror([0,1])
+    translate(pos + bumper)
+    children();
+}
+
+module MicroUSB(){
+  Flip_bot(1){
+    rotate([90,0,0])
+      mirror([0,0,1])
+      linextr(-epp2i[0], 60)
+      translate([0.5 * phone_width, 0, 0])
+      rectfromto([-microusb_width/2, epp2i[1] + microusb_below],
+		 [+microusb_width/2, epp0[1] + -microusb_above]);
+  }
+}
+
+module OrdinaryRearApertures(){
+  // rear speaker
+  OrdinaryRearAperture(1,1, rearspeaker_pos_bl)
+    rectfromto(-rearspeaker_gap,
+	       rearspeaker_size + rearspeaker_gap);
+
+  // finger hole to remove phone
+  OrdinaryRearAperture(1,0, [ fingerpushhole_dias[0]/2 + epp2i[0],
+			      phone[1]/2 ])
+    scale(fingerpushhole_dias)
+    circle(r= 0.5 );
+}
+
+module RearCameraAperture(){
+  Flip_rhs(1)
+    mirror([0, 0, 1])
+    linear_extrude(height = 20)
+    mirror([0, 1, 0])
+    translate(bumper)
+    rectfromto(camera_pos_tl, camera_pos_br);
+}
+
+module HingeLidProfile(){
+  hull(){
+    circleat(hppT, hp_r1);
+    circleat(lpp12, lp_r12);
+    polygon([lpp10,
+	     lpp13 + [2,0],
+	     lpp12,
+	     hppT]);
+  }
+}
+
+module HingeBaseProfile(){
+  difference(){
+    hull(){
+      circleat(hppB, hp_r1);
+      circleat(hppE, hp_r1);
+      circleat(epp2o, case_th_bottom);
+      circleat(hppB + [10,0], hp_r1);
+    }
+    polygon([epp5, epp1, epp2i, epp3, bppL]);
+  }
+}
+
+module HingeLeverOuterProfile(){
+  hull(){
+    circleat(hppT, hp_r2);
+    circleat(hppB, hp_r2);
+  }
+}
+
+module HingeLeverInnerProfile(){
+  for (c = [hppT, hppB]) {
+    hull()
+      for (x=[0,20])
+	translate([x,0])
+	  circleat(c, hp_rn);
+	circleat(hppB, hp_rn);
+  }
+}
+
+module Flip_hinge(){
+  hinge_origin = [0, -(phone_height - hppB[0]), hppB[1]];
+  translate(hinge_origin)
+    rotate([180,0,0])
+    translate(-hinge_origin)
+    children();
+}
+
+module HingePortion(x0,x1){
+  Flip_rhs() Flip_bot(1)
+    translate([x0,0,0])
+    mirror([1,0,0])
+    rotate([90,0,-90])
+    linear_extrude(height=x1-x0)
+    children(0);
+}
+
+module CatchPortion(width){
+  translate([phone_width/2, 0,0])
+    rotate([90,0,-90])
+    linextr(-width/2, width/2)
+    children(0);
+}
+
 module CaseBase(){
   AroundEdges(epp3[1], case_th_bottom, 1)
     EdgeProfile();
@@ -352,14 +569,17 @@ module Case(){ ////toplevel
 	translate([0,0, -25])
 	  linear_extrude(height = 50)
 	  hull()
-	  // CaseBase_rhsflip() // actually, we only care about the LH
-	  CaseBase_botflip()
+	  // Flip_rhs() // actually, we only care about the LH
+	  Flip_bot()
 	  circleat([+1,-1] * phone_cnr_rad, phone_cnr_rad + case_th_side/2);
       }
+
+      // hinge
+      HingePortion(hex20, hex21) HingeBaseProfile();
     }
 
     // slot for keeper
-    CaseBase_rhsflip(1)
+    Flip_rhs(1)
       translate([0, -phone_cnr_rad, 0])
       rotate([90, 0, 0])
       linear_extrude(height = phone_height + phone_cnr_rad * 2)
@@ -370,12 +590,7 @@ module Case(){ ////toplevel
       }
 
     // front camera
-    CaseBase_rhsflip([1])
-      mirror([0, 0, 1])
-      linear_extrude(height = 20)
-      mirror([0, 1, 0])
-      translate(bumper)
-      rectfromto(camera_pos_tl, camera_pos_br);
+    RearCameraAperture();
 
     // struts (invisible, because they're buried in the case)
     Struts(epp2i[0], epp2i[1] - case_th_bottom, case_th_bottom);
@@ -400,16 +615,27 @@ module Case(){ ////toplevel
 
     // apertures along top edge
     CaseAperture(jack_pos, jack_dia, 8);
-    CaseBase_rhsflip([1])
+    Flip_rhs(1)
       CaseAperture(noisecancelmic_pos, noisecancelmic_dia, 20);
 
-    // rear speaker
-    CaseBase_rhsflip([1]) CaseBase_botflip([1])
-      linextr(-20, 20)
-      mirror([0,1])
-      translate(rearspeaker_pos_bl + bumper)
-      rectfromto(-rearspeaker_gap,
-		 rearspeaker_size + rearspeaker_gap);
+    OrdinaryRearApertures();
+
+    MicroUSB();
+
+    // gaps for the lid's hinge arms
+    HingePortion(hex20 - hinge_x_arms_gap,
+		 hex21 + hinge_x_arms_gap)
+      minkowski(){
+        HingeLidProfile();
+	circle(r= hinge_r_arms_gap, $fn= 8);
+      }
+
+    // screw holes in the hinge arms
+    HingeScrews();
+
+    // catch striker
+    CatchPortion(catch_width + catch_side_gap*2)
+      CatchCutProfile();
   }
 }
 
@@ -432,16 +658,62 @@ module Lid(){ ////toplevel
 	    ButtonCoverProfile();
 	}
       }
+
+      // hinge arms
+      HingePortion(hex20, hex21) HingeLidProfile();
+
+      // catch
+      CatchPortion(catch_width)
+	CatchCatchProfile();
     }
     Struts(lpp10[0] + strut_min_at_end, lpp13[1], -case_th_lid);
+
+    // screw holes in the hinge arms
+    HingeScrews();
   }
 }
 
+module HingeLever(){ ////toplevel
+  difference() {
+    // outer body, positive
+    HingePortion(hex22, hex22 + phone_width/2)
+      HingeLeverOuterProfile();
+
+    // space for the screws
+    HingePortion(hex23, hex24)
+      HingeLeverInnerProfile();
+
+    // bores for the screws
+    HingeScrews();
+
+    // space for the charging cable
+    MicroUSB();
+    Flip_hinge() MicroUSB();
+  }
+}
+
+module HingeLeverPrint(){ ////toplevel
+  rotate([90,0,0])
+    HingeLever();
+}
+
+module TestSelectLength(){
+  translate([-30, -200, -20])
+    cube([30 + 15, 250, 40]);
+}
+
 module TestLength(){ ////toplevel
   intersection(){
     Case();
-    translate([-30, -200, -20])
-    cube([30 + 15, 250, 40]);
+    TestSelectLength();
+  }
+}
+
+module TestLengthRight(){ ////toplevel
+  intersection(){
+    Case();
+    Flip_rhs(1)
+      TestSelectLength();
   }
 }
 
@@ -465,22 +737,25 @@ module TestLidWidthPrint(){ ////toplevel
   }
 }
 
+module TestSelectRearAperture(){
+  minkowski(){
+    union() children();
+    translate([20, 0,0])
+      cube([42, 2, 1], center=true);
+  }
+}
+
 module TestSelectCamera(){
-  CaseBase_rhsflip(1)
-    translate([0,0,-25])
-    linear_extrude(height = 50)
-    mirror([0, 1, 0])
-    rectfromto([-20, -20],
-	       camera_pos_br + bumper + [ 5, 5 ]);
+  minkowski(){
+    TestSelectRearAperture()
+      RearCameraAperture();
+    cube([0.1, 50, 0.1]);
+  }
 }
 
-module TestSelectRearSpeaker(){
-  CaseBase_rhsflip(1) CaseBase_botflip([1])
-    linextr(-20,20)
-    mirror([0,1,0])
-    translate(rearspeaker_pos_bl + bumper)
-    rectfromto(-(rearspeaker_gap + [40,2]),
-	       rearspeaker_size + rearspeaker_gap + [2,2]);
+module TestSelectOrdinaryRearApertures(){
+  TestSelectRearAperture()
+    OrdinaryRearApertures();
 }
 
 module TestCamera(){ ////toplevel
@@ -540,20 +815,20 @@ module TestFrameCase(){ ////toplevel
     union(){
       TestSelectFrame();
       TestSelectCamera();
-      TestSelectRearSpeaker();
+      TestSelectOrdinaryRearApertures();
     }
   }
 }
 
 module TestFrameLidPrint(){ ////toplevel
-  rotate([0,0,180]) intersection(){
+  rotate([0,180,0]) intersection(){
     Lid();
     TestSelectFrame();
   }
 }
 
 module Keeper(){ ////toplevel
-  CaseBase_rhsflip()
+  Flip_rhs()
     OneKeeper();
 }
 
@@ -562,6 +837,47 @@ module ButtonPlanForDemo(z, deep, cut){
     ButtonPlan(8, deep, cut);
 }
 
+module HingeScrews(){
+  Flip_rhs() Flip_bot(1){
+    for (c= [ hppT, hppB ])
+      translate([ hex20,
+		  -c[0],
+		  c[1] ]){
+	rotate([0,90,0])
+	  translate([0,0,-.2])
+	  cylinder( r= hingescrew_shaft_dia/2,
+		    h = hingescrew_shaft_len+0.2 );
+	rotate([0,-90,0])
+	  translate([0,0,+.1])
+	  cylinder( r= hingescrew_head_dia/2, h = hingescrew_head_th );
+      }
+  }
+}
+
+module DemoFrame(){ ////toplevel
+  color("red") TestFrameCase();
+  color("blue") intersection(){ Lid(); TestSelectFrame(); }
+  color("black") HingeScrews();
+  %HingeLever();
+}
+
+module DemoHingedFrame(){ ///toplevel
+  color("red") TestFrameCase();
+  translate([0,0, -2*hp_k])
+  color("blue") intersection(){ Lid(); TestSelectFrame(); }
+
+  Flip_hinge(){
+    color("orange") HingeLever();
+    color("black") HingeScrews();
+  }
+}
+
+module DemoHinge(){ ////toplevel
+  DemoFrame();
+  translate([0,0, -hp_k*3])
+    DemoHingedFrame();
+}
+
 module DemoProfiles(){ ////toplevel
   LidEdgeProfile();
   %EdgeProfile();
@@ -586,6 +902,23 @@ module DemoProfiles(){ ////toplevel
     color("red" )  ButtonPlanForDemo(-4, 1,1);
     color("blue")  ButtonPlanForDemo(-6, 1,0);
   }
+
+  translate([0, -30]) {
+    %LidEdgeProfile();
+    %EdgeProfile();
+    color("blue") HingeLidProfile();
+    color("red")  HingeBaseProfile();
+    color("black") translate([0,0,-2]) HingeLeverOuterProfile();
+    color("orange") translate([0,0,-1]) HingeLeverInnerProfile();
+  }
+
+  translate([20,-30]) {
+    %EdgeProfile();
+    %LidEdgeProfile();
+    //translate([0,0,1]) CatchCutProfile();
+    color("blue") CatchCatchProfile();
+    color("red") difference(){ EdgeProfile(); CatchCutProfile(); }
+  }
 }
 
 //EdgeProfile();