powerbank-bike-clamp.scad

   1 // -*- C -*-
   2
   3 // Print one of each:
   4 //    Main
   5 //    TubeClampRight
   6
   7 include <utils.scad>
   8
   9 tube_dia = 22.4;
  10
  11 hinge_around = 2.5;
  12 hinge_pin = 1.8 + 0.75;
  13 main_th = 3;
  14 minor_wall_min = 1;
  15
  16 screw = 5.0 + 0.75;
  17 screw_head = 8.7 + 1.2;
  18 screw_nut_across = 7.9 + 0.75;
  19 screw_nut_th = 3.9 + 0.75;
  20
  21 knob_behind_across = 12.2 + 0.75;
  22 behind_knob_th = 5;
  23 knob_standout_h = 2;
  24
  25 clamp_min_width = 20;
  26
  27 clamp_gap = 2;
  28
  29 lower_th = 1;
  30
  31 overlap_l = 0.1;
  32
  33 bridge_slop = 1.2;
  34
  35 hinge_lobe_per = 10;
  36 hinge_gap_z = 0.75;
  37 hinge_gap_xy = 0.75;
  38
  39 $fs = 0.1;
  40 $fa = 5;
  41
  42 bank_eps_bbox_x = [149, 598];
  43 bank_eps_bbox_y = [274, 1452];
  44
  45 bank_y_sz = 102.25 + 0.50 + 3.2;
  46 bank_x_sz = (26.0 + 0.5);
  47 bank_recess_y = 5;
  48
  49 strap_th = 3;
  50 strap_w = 5;
  51 strap_above = 2.5;
  52
  53 strap_around_over = 1.0;
  54 strap_around_attach = 2.0;
  55
  56 retainer_walls = [18, 30];
  57
  58 bank_profile_scale_bodge = 1.0;
  59
  60 bank_output_ctr = [ 12.5, 11.5 ]; // from nearest corner
  61 bank_output_sz  = [ 11.0, 10.5 ];
  62
  63 mounted_pos_y_offset_lim = -100;
  64
  65 liner_th = 0.8;
  66
  67 brace_r = 5;
  68 brace_len = 50;
  69
  70 // calculated
  71
  72 straps_y = [ -bank_y_sz * 0.25, // these entries are special and used
  73              +bank_y_sz * 0.25, //  for the brace struts
  74              0 ];
  75
  76 screw_head_behind = main_th;
  77 endwall_th = main_th;
  78
  79 bank_recess_dx = minor_wall_min;
  80
  81 pspt_to_mm = 25.4 / 72;
  82
  83 main_r = tube_dia/2 + main_th;
  84
  85 screw_max_y_lhs = -main_r -screw_nut_across/2;
  86 screw_max_y_rhs = -main_r -knob_behind_across/2;
  87
  88 screw_y = min(screw_max_y_lhs,
  89               screw_max_y_rhs);
  90
  91 bot_y = screw_y -max( screw_nut_across/2, knob_behind_across/2 )
  92   -minor_wall_min;
  93
  94 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  95 bank_bot_y = strap_above + strap_th;
  96 strap_r = strap_th;
  97
  98 brace_total_len = brace_len + main_th;
  99 brace_ctrs_y = [ straps_y[0] - (brace_r + strap_w/2),
 100                  straps_y[1] + (brace_r + strap_w/2) ];
 101
 102 clamp_width_actual = max(clamp_min_width, holder_x_sz);
 103
 104 hinge_lobes = floor(clamp_width_actual / hinge_lobe_per);
 105 hinge_stride = (clamp_width_actual + hinge_gap_z) / hinge_lobes;
 106
 107 hinge_outer_r = hinge_around + hinge_pin/2;
 108 hinge_y = tube_dia/2 + hinge_outer_r;
 109
 110 top_cnr_r = min(endwall_th, main_th);
 111
 112 mounted_pos_y_offset = max(mounted_pos_y_offset_lim,
 113                            bot_y - (-(bank_y_sz/2 + endwall_th)));
 114
 115
 116 module TubePlan(){ circle(r = tube_dia/2); }
 117 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
 118 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
 119
 120 module TubeClampLeftPlan(){
 121   difference(){
 122     union(){
 123       polygon([[ 0,                      hinge_y + hinge_outer_r ],
 124                [ -(main_r + overlap_l),  hinge_y + hinge_outer_r ],
 125                [ -(main_r + overlap_l),  bot_y                   ],
 126                [ -clamp_gap/2,           bot_y                   ],
 127                [ -clamp_gap/2,           0,                      ],
 128                [ 0,                      0,                      ],
 129                ]);
 130       HingeBodyPlan();
 131     }
 132     TubePlan();
 133     HingePinPlan();
 134   }
 135 }
 136
 137 module TubeClampLeft() { ////toplevel
 138   linextr(-clamp_width_actual/2, clamp_width_actual/2)
 139     TubeClampLeftPlan();
 140 }
 141
 142 module TubeClampRightPlan(){
 143   difference(){
 144     union(){
 145       rectfromto([ clamp_gap/2,                   bot_y ],
 146                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 147       intersection(){
 148         circle(r= main_r);
 149         union(){
 150           rectfromto([0,0],
 151                       main_r *  [5,5]);
 152           rectfromto([ clamp_gap/2, main_r*5 ],
 153                       main_r * [2,-5]);
 154         }
 155       }
 156       HingeBodyPlan();
 157     }
 158     TubePlan();
 159     HingePinPlan();
 160   }
 161 }
 162
 163 module Screws(){
 164   linextr_x_yz(-main_r*5, main_r*5)
 165     translate([screw_y, 0])
 166     circle(r= screw/2);
 167
 168   translate([0, screw_y, 0]) {
 169     linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 170       square([screw_nut_across,
 171               screw_nut_across / cos(30) + bridge_slop*2],
 172              center=true);
 173
 174     linextr_x_yz(-200,
 175                  -(clamp_gap/2 + screw_nut_th + screw_head_behind))
 176       square([screw_head, screw_head + bridge_slop*2],
 177              center=true);
 178   }
 179 }
 180
 181 module SomeClamp(hinge_alt=false){
 182   difference(){
 183     linextr(-clamp_width_actual/2, clamp_width_actual/2)
 184       children(0);
 185
 186     Screws();
 187
 188     for (i=[0 : hinge_lobes-1]) {
 189       translate([0,
 190                  hinge_y,
 191                  -clamp_width_actual/2 + i * hinge_stride
 192                  + (hinge_alt ? hinge_stride/2 : 0)
 193                  ])
 194         linextr(-hinge_gap_z, hinge_stride/2)
 195         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 196     }
 197   }
 198 }
 199
 200 module PowerBankItselfSidePlan(){
 201   translate([0, bank_bot_y]){
 202     minkowski(){
 203       circle($fn=8, r=liner_th);
 204       scale( bank_profile_scale_bodge *
 205              bank_x_sz / ( (
 206                             bank_eps_bbox_x[1] -
 207                             bank_eps_bbox_x[0]
 208                             ) * pspt_to_mm ))
 209         translate(pspt_to_mm *
 210                   [-0.5 * (bank_eps_bbox_x[0] +
 211                            bank_eps_bbox_x[1]),
 212                    -bank_eps_bbox_y[0]])
 213         import("powerbank-anker-10000.dxf", convexity=5);
 214     }
 215   }
 216 }
 217
 218 module PowerBankItself(){ ////toplevel
 219   rotate([0,90,0])
 220     linextr_y_xz(-bank_y_sz/2,
 221                  +bank_y_sz/2)
 222     PowerBankItselfSidePlan();
 223 }
 224
 225 module PowerBankSidePlan(){ ////toplevel
 226   render() difference(){
 227     rectfromto([ -holder_x_sz/2,  0 ],
 228                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 229
 230     PowerBankItselfSidePlan();
 231   }
 232 }
 233
 234 module PowerBankStrapCut(){ ////toplevel
 235   difference(){
 236     rectfromto([ -holder_x_sz, -0.05 ],
 237                [ +holder_x_sz, strap_th + strap_r ]);
 238     hull(){
 239       for (sx=[-1,+1]) {
 240         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 241                    strap_th + strap_r])
 242           circle(strap_r);
 243       }
 244     }
 245   }
 246 }
 247
 248 module PowerBankHolderTest(){ ////toplevel
 249   difference(){
 250     linextr(-1,5) PowerBankSidePlan();
 251     linextr(0, strap_w) PowerBankStrapCut();
 252   }
 253 }
 254
 255 module EndRetainer(depth){ ////toplevel
 256   translate([0, -bank_y_sz/2, 0]) {
 257     linextr_y_xz(-endwall_th, 0)
 258     rectfromto([ 0,         -holder_x_sz/2 ],
 259                [ -depth,    +holder_x_sz/2 ]);
 260
 261     for (m=[0,1]) {
 262       mirror([0,0,m]) {
 263         linextr(-holder_x_sz/2, -bank_x_sz/2){
 264           hull(){
 265             rectfromto([ 0, -endwall_th ],
 266                        [ depth, 0 ]);
 267             rectfromto([ 0, 0 ],
 268                        [ 0.1, depth-0.1 ]);
 269           }
 270         }
 271       }
 272     }
 273   }
 274 }
 275
 276 module BraceTubePlan(){
 277   intersection(){
 278     circle(r= brace_r);
 279     rectfromto(brace_r * [-2,  0],
 280                brace_r * [+2, +2]);
 281   }
 282 }
 283
 284 module PowerBankHolder(){ ////toplevel
 285   difference(){
 286     union(){
 287       rotate([0,90,0])
 288         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 289                      +(bank_y_sz/2 + 0.1))
 290         PowerBankSidePlan();
 291
 292       EndRetainer(retainer_walls[0]);
 293       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 294
 295       translate([0,0, bank_x_sz/2]){
 296         for (y = brace_ctrs_y) {
 297           translate([0,y,0]) {
 298             linextr_x_yz(0, brace_total_len)
 299               BraceTubePlan();
 300           }
 301         }
 302         translate([brace_total_len, 0,0])
 303           linextr_y_xz(brace_ctrs_y[0] - brace_r,
 304                        brace_ctrs_y[1] + brace_r)
 305           BraceTubePlan();
 306       }
 307
 308       for (strap_y = straps_y) {
 309         translate([0, strap_y, 0]) {
 310           linextr(-holder_x_sz/2,
 311                   +holder_x_sz/2){
 312             hull(){
 313               for (dy = [-1,+1] *
 314                      (strap_w/2 + strap_around_attach - strap_around_over)) {
 315                 translate([0, dy, 0])
 316                   circle(r=strap_around_over);
 317               }
 318             }
 319           }
 320         }
 321       }
 322     }
 323
 324     for (strap_y = straps_y)
 325       translate([0, strap_y, 0])
 326         rotate([0,0,-90])
 327         rotate([0,90,0])
 328         linextr(-strap_w/2,
 329                 +strap_w/2)
 330         PowerBankStrapCut();
 331
 332     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
 333       linextr_y_xz(-50,50)
 334        rotate([0,0,90])
 335        translate(bank_output_ctr)
 336        square(center=true, bank_output_sz);
 337
 338     translate([0, -(bank_y_sz/2 + endwall_th), 0] + 0.01 * [-1,-1]) {
 339       linextr(-200,200){
 340         difference(){
 341           square(center=true, top_cnr_r*2);
 342           translate(top_cnr_r * [1,1])
 343             circle(r= top_cnr_r);
 344         }
 345       }
 346     }
 347   }
 348 }
 349
 350 module TubeClampLeft() { ////toplevel
 351   // We want this to print with the recess overhand to the right
 352   // where the workpiece cooling fan is
 353   rotate([0,0,180]){
 354     difference(){
 355       SomeClamp(true)
 356         TubeClampLeftPlan();
 357
 358       Screws();
 359     }
 360   }
 361 }
 362
 363 module PlacePowerBank(){
 364   translate([main_r, -mounted_pos_y_offset, 0])
 365     children(0);
 366 }
 367
 368 module Main(){ ////toplevel
 369   TubeClampLeft();
 370   difference(){
 371     PlacePowerBank()
 372       PowerBankHolder();
 373     rotate([0,0,180])
 374       Screws();
 375   }
 376 }
 377
 378 module TubeClampRight() { ////toplevel
 379   rotate([0,0,180]) {
 380     rotate([180,0,0]) {
 381       difference(){
 382         union(){
 383           SomeClamp()
 384             TubeClampRightPlan();
 385
 386           translate([clamp_gap/2 + behind_knob_th, screw_y, 0]) {
 387             hull(){
 388               linextr_x_yz(-0.1, 0)
 389                 square(center=true,
 390                        [knob_behind_across,
 391                         knob_behind_across + knob_standout_h*2]);
 392               linextr_x_yz(0, knob_standout_h)
 393                 square(center=true,
 394                        knob_behind_across);
 395             }
 396           }
 397         }
 398         Screws();
 399       }
 400     }
 401   }
 402 }
 403
 404 module TubeClampDemo() { ////toplevel
 405   TubeClampLeft();
 406   rotate([180,0,0])
 407     TubeClampRight();
 408 }
 409
 410 module Demo() { ////toplevel
 411   Main();
 412   rotate([180,0,0])
 413     TubeClampRight();
 414   PlacePowerBank()
 415     %PowerBankItself();
 416 }