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=a5a28dbbd65b3cff29bd947a5f42999ee957b2db;hb=f1824fce4c0b4420e0ba377d8d8a4e43e42e4a7d;hpb=2ba18bd8353cd97755aa5c83d9036dfde2722fa2

diff --git a/sleepphone-cable-box.scad b/sleepphone-cable-box.scad
index a5a28db..836f07d 100644
--- a/sleepphone-cable-box.scad
+++ b/sleepphone-cable-box.scad
@@ -1,15 +1,53 @@
 // -*- C -*-
 
+include <funcs.scad>
+
 wall = 0.75 * [1,1,1];
-phone = [ 76.40, 30.96, 6.26 ];
+wall_bot = 1.0;
+
+phone = [ 76.40, 30.96, 6.00 ]; // includes socket
 phone_button_z = 6.58;
-minwall = 0.25;
+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;
 
-phone_slop = [1,1,1] * 0.5;
+nrbutton_brace_x = 37.5;
+
+phone_slop = 0.5 * [1,1,0]
+           + 0.5 * [0,0,1];
+
+led = [25.9, 9.44]; // y is from edge
+led_dia = 4.4;
+
+// next values include slop
+plug_maxw = 10.95 + 0.35;
+plug_minw=   6.53 + 0.35;
+plug_sllen=  6.50;
+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 = 12;
+keeper_stalk_len = 70;
+keeper_stalk_gap = 1;
+keeper_stalk_thick = wall_bot;
+
+keeper_stalk_base_reinforce_len = 5;
+keeper_stalk_base_reinforce_thick = 2.0;
 
 // calculated
 
@@ -17,41 +55,194 @@ top_z = max( phone[2] + wall[2],
 	     phone_button_z + minwall )
   + phone_slop[2];
 
+plugkeeper_x_maxw = phone[0] - plug_totlen;
+
+plugkeeper_p_max = [ 0, plug_maxw/2 ];
+plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
+plugkeeper_d_u = unitvector2d(
+                 clockwise2d(
+                 vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
+			     )
+			     );
+
 module MainProfileInnerHalf(){
   p = phone + phone_slop;
-  pb = phone_button_z + phone_slop[2];
+  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(){
   p = phone + phone_slop;
-  for (m=[0,1]) mirror([m,0]) {
-      difference(){
-	translate([-1, -wall[2] ])
-	  square([ p[1]/2 + wall[1] + 1, top_z + wall[2] ]);
+  difference(){
+    for (m=[0,1]) mirror([m,0]) {
+	minkowski(){
+	  translate([ -wall[1], -wall_bot ])
+	    square([ wall[1]*2, wall_bot + wall[2] ]);
+	  MainProfileInnerHalf();
+	}
+      }
+    for (m=[0,1]) mirror([m,0]) {
 	MainProfileInnerHalf();
       }
+  }
+}
+
+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 Box(){
-  mirror([0,1,0]) rotate([90,0,0]) {
-    linear_extrude(height = phone[0] + wall[0])
+module BoxMain(){
+  rotate([0,0,90]) rotate([90,0,0]) {
+    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])
+      linear_extrude(height = wall[0], convexity=20)
       hull() MainProfile();
   }
 }
 
-//MainProfileInner();
-Box();
+module PlugKeeperProfileHalf(){
+  p_max = plugkeeper_p_max;
+  p_min = plugkeeper_p_min;
+  d = plugkeeper_d_u * keeper_prong;
+  
+  translate([ plugkeeper_x_maxw, 0 ]) {
+    polygon([ p_min,
+	      p_max,
+	      p_max + d,
+	      p_min + d ]);
+  }
+}
+
+module PlugKeeperStalkProfile(){
+  hull(){
+    for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
+    translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
+      square([ 0.1, keeper_stalk_basewidth ], center=true);
+  }
+}
+
+module PlugKeeper(){
+  for (m=[0,1]) mirror([0,m,0]) {
+      translate([0,0, -keeper_stalk_thick])
+	linear_extrude(height=plug_h + keeper_stalk_thick)
+	PlugKeeperProfileHalf();
+
+      translate([0, 0, plug_h - plug_tooth_h])
+	linear_extrude(height= plug_tooth_h)
+	translate(plugkeeper_d_u * -plug_tooth_dy)
+	PlugKeeperProfileHalf();
+
+    }
+}
+
+module Box(){
+  sidewall_cutout_z = phone[2] + phone_slop[2] + button_dz_outer;
+
+  difference(){
+    union(){
+      BoxMain();
+      Brace();
+    }
+
+    translate([ led[0], phone[1]/2 - led[1], 1 ])
+      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])
+	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();
+//translate([0,0,1]) color("black") BraceProfileInitial();
+//translate([0,0,1]) color("black") BraceProfileFinal();
+//Brace();
+//Box();
+BoxPrint();