X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=sleepphone-cable-box.scad;h=836f07d925da0734a71d62972d11af27b8397376;hp=7a678b7cd90660fa3a202876fc9c7c9d1824a30b;hb=80a9b9a4a16c60541ff0698ca9527aec0e966951;hpb=b9294866b775e2e1cf938a52d9af54091b860b11

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index 7a678b7..836f07d 100644
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -3,18 +3,27 @@
 include <funcs.scad>
 
 wall = 0.75 * [1,1,1];
-wall_bot = 0.75;
+wall_bot = 1.0;
 
 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];
 
@@ -25,16 +34,20 @@ 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
 
@@ -54,17 +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(){
@@ -83,9 +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)
@@ -116,8 +173,8 @@ module PlugKeeperStalkProfile(){
 
 module PlugKeeper(){
   for (m=[0,1]) mirror([0,m,0]) {
-      translate([0,0, -wall[2]])
-	linear_extrude(height=plug_h + wall[2])
+      translate([0,0, -keeper_stalk_thick])
+	linear_extrude(height=plug_h + keeper_stalk_thick)
 	PlugKeeperProfileHalf();
 
       translate([0, 0, plug_h - plug_tooth_h])
@@ -126,29 +183,66 @@ module PlugKeeper(){
 	PlugKeeperProfileHalf();
 
     }
-
-  translate([0,0, -wall[2]])
-    linear_extrude(height = wall[2])
-    PlugKeeperStalkProfile();
 }
 
 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])
+    for (ys=[-1,+1]) {
       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
 	linear_extrude(height = wall[2]*3)
 	PlugKeeperStalkProfile();
+
+      translate([ phone[0] + wall[0],
+		  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 );
+    }
   }
 
   PlugKeeper();
+
+  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();
-Box();
-
+//translate([0,0,1]) color("black") BraceProfileInitial();
+//translate([0,0,1]) color("black") BraceProfileFinal();
+//Brace();
+//Box();
+BoxPrint();