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
  24 clamp_min_width = 20;
  25
  26 clamp_gap = 2;
  27
  28 lower_th = 1;
  29
  30 overlap_l = 0.1;
  31
  32 bridge_slop = 1.2;
  33
  34 hinge_lobe_per = 10;
  35 hinge_gap_z = 0.75;
  36 hinge_gap_xy = 0.75;
  37
  38 $fs = 0.1;
  39 $fa = 5;
  40
  41 bank_eps_bbox_x = [149, 598];
  42 bank_eps_bbox_y = [274, 1452];
  43
  44 bank_y_sz = 102.25 + 0.50 + 3.2;
  45 bank_x_sz = (26.0 + 0.5);
  46 bank_recess_y = 5;
  47
  48 strap_th = 3;
  49 strap_above = 2.5;
  50
  51 retainer_walls = [18, 30];
  52
  53 bank_profile_scale_bodge = 1.0;
  54
  55 bank_input_ctr = [ 12.5, 11.5 ]; // from nearest corner
  56 bank_input_sz  = [ 8.5, 10.5 ];
  57
  58 mounted_pos_y_offset = 20;
  59
  60 liner_th = 0.8;
  61
  62 brace_r = 5;
  63 brace_len = 50;
  64
  65 // calculated
  66
  67 straps_y = [ -bank_y_sz * 0.25,
  68              +bank_y_sz * 0.25 ];
  69
  70 screw_head_behind = main_th;
  71 endwall_th = main_th;
  72
  73 bank_recess_dx = minor_wall_min;
  74
  75 pspt_to_mm = 25.4 / 72;
  76
  77 main_r = tube_dia/2 + main_th;
  78
  79 screw_max_y_lhs = -main_r -screw_nut_across/2;
  80 screw_max_y_rhs = -main_r -knob_behind_across/2;
  81
  82 screw_y = min(screw_max_y_lhs,
  83               screw_max_y_rhs);
  84
  85 bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
  86   -minor_wall_min;
  87
  88 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  89 bank_bot_y = strap_above + strap_th;
  90 strap_r = strap_th;
  91
  92 brace_total_len = brace_len + main_th;
  93 brace_ctrs_y = [ straps_y[0] - (brace_r + strap_r/2),
  94                  straps_y[1] + (brace_r + strap_r/2) ];
  95
  96 clamp_width_actual = max(clamp_min_width, holder_x_sz);
  97
  98 hinge_lobes = floor(clamp_width_actual / hinge_lobe_per);
  99 hinge_stride = (clamp_width_actual + hinge_gap_z) / hinge_lobes;
 100
 101 hinge_outer_r = hinge_around + hinge_pin/2;
 102 hinge_y = tube_dia/2 + hinge_outer_r;
 103
 104 echo(bot_y);
 105
 106 module TubePlan(){ circle(r = tube_dia/2); }
 107 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
 108 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
 109
 110 module TubeClampLeftPlan(){
 111   difference(){
 112     union(){
 113       polygon([[ 0,                      hinge_y + hinge_outer_r ],
 114                [ -(main_r + overlap_l),  hinge_y + hinge_outer_r ],
 115                [ -(main_r + overlap_l),  bot_y                   ],
 116                [ -clamp_gap/2,           bot_y                   ],
 117                [ -clamp_gap/2,           0,                      ],
 118                [ 0,                      0,                      ],
 119                ]);
 120       HingeBodyPlan();
 121     }
 122     TubePlan();
 123     HingePinPlan();
 124   }
 125 }
 126
 127 module TubeClampLeft() { ////toplevel
 128   linextr(-clamp_width_actual/2, clamp_width_actual/2)
 129     TubeClampLeftPlan();
 130 }
 131
 132 module TubeClampRightPlan(){
 133   difference(){
 134     union(){
 135       rectfromto([ clamp_gap/2,                   bot_y ],
 136                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 137       intersection(){
 138         circle(r= main_r);
 139         union(){
 140           rectfromto([0,0],
 141                       main_r *  [5,5]);
 142           rectfromto([ clamp_gap/2, main_r*5 ],
 143                       main_r * [2,-5]);
 144         }
 145       }
 146       HingeBodyPlan();
 147     }
 148     TubePlan();
 149     HingePinPlan();
 150   }
 151 }
 152
 153 module Screws(){
 154   linextr_x_yz(-main_r*5, main_r*5)
 155     translate([screw_y, 0])
 156     circle(r= screw/2);
 157
 158   translate([0, screw_y, 0]) {
 159     linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 160       square([screw_nut_across,
 161               screw_nut_across / cos(30) + bridge_slop*2],
 162              center=true);
 163
 164     linextr_x_yz(-200,
 165                  -(clamp_gap/2 + screw_nut_th + screw_head_behind))
 166       square([screw_head, screw_head + bridge_slop*2],
 167              center=true);
 168   }
 169 }
 170
 171 module SomeClamp(hinge_alt=false){
 172   difference(){
 173     linextr(-clamp_width_actual/2, clamp_width_actual/2)
 174       children(0);
 175
 176     Screws();
 177
 178     for (i=[0 : hinge_lobes-1]) {
 179       translate([0,
 180                  hinge_y,
 181                  -clamp_width_actual/2 + i * hinge_stride
 182                  + (hinge_alt ? hinge_stride/2 : 0)
 183                  ])
 184         linextr(-hinge_gap_z, hinge_stride/2)
 185         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 186     }
 187   }
 188 }
 189
 190 module PowerBankItselfSidePlan(){
 191   translate([0, bank_bot_y]){
 192     minkowski(){
 193       circle($fn=8, r=liner_th);
 194       scale( bank_profile_scale_bodge *
 195              bank_x_sz / ( (
 196                             bank_eps_bbox_x[1] -
 197                             bank_eps_bbox_x[0]
 198                             ) * pspt_to_mm ))
 199         translate(pspt_to_mm *
 200                   [-0.5 * (bank_eps_bbox_x[0] +
 201                            bank_eps_bbox_x[1]),
 202                    -bank_eps_bbox_y[0]])
 203         import("powerbank-anker-10000.dxf", convexity=5);
 204     }
 205   }
 206 }
 207
 208 module PowerBankItself(){ ////toplevel
 209   rotate([0,90,0])
 210     linextr_y_xz(-bank_y_sz/2,
 211                  +bank_y_sz/2)
 212     PowerBankItselfSidePlan();
 213 }
 214
 215 module PowerBankSidePlan(){ ////toplevel
 216   render() difference(){
 217     rectfromto([ -holder_x_sz/2,  0 ],
 218                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 219
 220     PowerBankItselfSidePlan();
 221   }
 222 }
 223
 224 module PowerBankStrapCut(){ ////toplevel
 225   difference(){
 226     rectfromto([ -holder_x_sz, -0.05 ],
 227                [ +holder_x_sz, strap_th + strap_r ]);
 228     hull(){
 229       for (sx=[-1,+1]) {
 230         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 231                    strap_th + strap_r])
 232           circle(strap_r);
 233       }
 234     }
 235   }
 236 }
 237
 238 module PowerBankHolderTest(){ ////toplevel
 239   difference(){
 240     linextr(-1,5) PowerBankSidePlan();
 241     linextr(0, strap_th) PowerBankStrapCut();
 242   }
 243 }
 244
 245 module EndRetainer(depth){ ////toplevel
 246   translate([0, -bank_y_sz/2, 0]) {
 247     linextr_y_xz(-endwall_th, 0)
 248     rectfromto([ 0,         -holder_x_sz/2 ],
 249                [ -depth,    +holder_x_sz/2 ]);
 250
 251     for (m=[0,1]) {
 252       mirror([0,0,m]) {
 253         linextr(-holder_x_sz/2, -bank_x_sz/2){
 254           hull(){
 255             rectfromto([ 0, -endwall_th ],
 256                        [ depth, 0 ]);
 257             rectfromto([ 0, 0 ],
 258                        [ 0.1, depth-0.1 ]);
 259           }
 260         }
 261       }
 262     }
 263   }
 264 }
 265
 266 module BraceTubePlan(){
 267   intersection(){
 268     circle(r= brace_r);
 269     rectfromto(brace_r * [-2,  0],
 270                brace_r * [+2, +2]);
 271   }
 272 }
 273
 274 module PowerBankHolder(){ ////toplevel
 275   difference(){
 276     union(){
 277       rotate([0,90,0])
 278         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 279                      +(bank_y_sz/2 + 0.1))
 280         PowerBankSidePlan();
 281
 282       EndRetainer(retainer_walls[0]);
 283       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 284     }
 285
 286     for (strap_y = straps_y)
 287       translate([0, strap_y, 0])
 288         rotate([0,0,-90])
 289         rotate([0,90,0])
 290         linextr(-strap_th/2,
 291                 +strap_th/2)
 292         PowerBankStrapCut();
 293
 294     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
 295       linextr_y_xz(-50,50)
 296        rotate([0,0,90])
 297        translate(bank_input_ctr)
 298        square(center=true, bank_input_sz);
 299   }
 300
 301   translate([0,0, bank_x_sz/2]){
 302     for (y = brace_ctrs_y) {
 303       translate([0,y,0]) {
 304         linextr_x_yz(0, brace_total_len)
 305           BraceTubePlan();
 306       }
 307     }
 308     translate([brace_total_len, 0,0])
 309       linextr_y_xz(brace_ctrs_y[0] - brace_r,
 310                    brace_ctrs_y[1] + brace_r)
 311       BraceTubePlan();
 312   }
 313 }
 314
 315 module TubeClampLeft() { ////toplevel
 316   // We want this to print with the recess overhand to the right
 317   // where the workpiece cooling fan is
 318   rotate([0,0,180]){
 319     difference(){
 320       SomeClamp(true)
 321         TubeClampLeftPlan();
 322
 323       Screws();
 324     }
 325   }
 326 }
 327
 328 module PlacePowerBank(){
 329   translate([main_r, -mounted_pos_y_offset, 0])
 330     children(0);
 331 }
 332
 333 module Main(){ ////toplevel
 334   TubeClampLeft();
 335   difference(){
 336     PlacePowerBank()
 337       PowerBankHolder();
 338     rotate([0,0,180])
 339       Screws();
 340   }
 341 }
 342
 343 module TubeClampRight() { ////toplevel
 344   rotate([0,0,180])
 345     rotate([180,0,0])
 346     SomeClamp()
 347     TubeClampRightPlan();
 348 }
 349
 350 module TubeClampDemo() { ////toplevel
 351   TubeClampLeft();
 352   rotate([180,0,0])
 353     TubeClampRight();
 354 }
 355
 356 module Demo() { ////toplevel
 357   Main();
 358   rotate([180,0,0])
 359     TubeClampRight();
 360   PlacePowerBank()
 361     %PowerBankItself();
 362 }