powerbank-bike-clamp: fix to reduce size below bolt

[reprap-play.git] / powerbank-bike-clamp.scad

diff --git a/powerbank-bike-clamp.scad b/powerbank-bike-clamp.scad
index 7c92ae3870c2b193887a692e1e6a91fe66d45c58..01b5ebef502ed12fe7ee34c93a713acb6bb57e21 100644 (file)
--- a/powerbank-bike-clamp.scad
+++ b/powerbank-bike-clamp.scad
@@ -1,5 +1,9 @@
 // -*- C -*-
 
+// Print one of each:
+//    Main
+//    TubeClampRight
+
 include <utils.scad>
 
 tube_dia = 22.4;
@@ -13,12 +17,11 @@ screw = 5.0 + 0.75;
 screw_head = 8.7 + 1.2;
 screw_nut_across = 7.9 + 0.75;
 screw_nut_th = 3.9 + 0.75;
-screw_head_h = 3.6 + 0.75;
 
 knob_behind_across = 12.2 + 0.75;
 behind_knob_th = 5;
 
-clamp_width = 20;
+clamp_min_width = 20;
 
 clamp_gap = 2;
 
@@ -28,7 +31,7 @@ overlap_l = 0.1;
 
 bridge_slop = 1.2;
 
-hinge_lobes = 2;
+hinge_lobe_per = 10;
 hinge_gap_z = 0.75;
 hinge_gap_xy = 0.75;
 
@@ -38,11 +41,12 @@ $fa = 5;
 bank_eps_bbox_x = [149, 598];
 bank_eps_bbox_y = [274, 1452];
 
-bank_y_sz = 102.25 + 0.50;
+bank_y_sz = 102.25 + 0.50 + 3.2;
 bank_x_sz = (26.0 + 0.5);
 bank_recess_y = 5;
 
 strap_th = 3;
+strap_w = 5;
 strap_above = 2.5;
 
 retainer_walls = [18, 30];
@@ -64,26 +68,22 @@ brace_len = 50;
 straps_y = [ -bank_y_sz * 0.25,
             +bank_y_sz * 0.25 ];
 
+screw_head_behind = main_th;
 endwall_th = main_th;
 
 bank_recess_dx = minor_wall_min;
 
 pspt_to_mm = 25.4 / 72;
 
-hinge_stride = (clamp_width + hinge_gap_z) / hinge_lobes;
-
 main_r = tube_dia/2 + main_th;
 
-hinge_outer_r = hinge_around + hinge_pin/2;
-hinge_y = tube_dia/2 + hinge_outer_r;
-
 screw_max_y_lhs = -main_r -screw_nut_across/2;
 screw_max_y_rhs = -main_r -knob_behind_across/2;
 
 screw_y = min(screw_max_y_lhs,
              screw_max_y_rhs);
 
-bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
+bot_y = screw_y -max( screw_nut_across/2, knob_behind_across/2 )
   -minor_wall_min;
 
 holder_x_sz = bank_x_sz + bank_recess_dx*2;
@@ -91,8 +91,18 @@ bank_bot_y = strap_above + strap_th;
 strap_r = strap_th;
 
 brace_total_len = brace_len + main_th;
-brace_ctrs_y = [ straps_y[0] - (brace_r + strap_r/2),
-                straps_y[1] + (brace_r + strap_r/2) ];
+brace_ctrs_y = [ straps_y[0] - (brace_r + strap_w/2),
+                straps_y[1] + (brace_r + strap_w/2) ];
+
+clamp_width_actual = max(clamp_min_width, holder_x_sz);
+
+hinge_lobes = floor(clamp_width_actual / hinge_lobe_per);
+hinge_stride = (clamp_width_actual + hinge_gap_z) / hinge_lobes;
+
+hinge_outer_r = hinge_around + hinge_pin/2;
+hinge_y = tube_dia/2 + hinge_outer_r;
+
+top_cnr_r = min(endwall_th, main_th);
 
 echo(bot_y);
 
@@ -118,7 +128,7 @@ module TubeClampLeftPlan(){
 }
 
 module TubeClampLeft() { ////toplevel
-  linextr(-clamp_width/2, clamp_width/2)
+  linextr(-clamp_width_actual/2, clamp_width_actual/2)
     TubeClampLeftPlan();
 }
 
@@ -154,7 +164,8 @@ module Screws(){
              screw_nut_across / cos(30) + bridge_slop*2],
             center=true);
 
-    linextr_x_yz(-200, -main_r + screw_head_h)
+    linextr_x_yz(-200,
+                -(clamp_gap/2 + screw_nut_th + screw_head_behind))
       square([screw_head, screw_head + bridge_slop*2],
             center=true);
   }
@@ -162,7 +173,7 @@ module Screws(){
 
 module SomeClamp(hinge_alt=false){
   difference(){
-    linextr(-clamp_width/2, clamp_width/2)
+    linextr(-clamp_width_actual/2, clamp_width_actual/2)
       children(0);
 
     Screws();
@@ -170,7 +181,7 @@ module SomeClamp(hinge_alt=false){
     for (i=[0 : hinge_lobes-1]) {
       translate([0,
                 hinge_y,
-                -clamp_width/2 + i * hinge_stride
+                -clamp_width_actual/2 + i * hinge_stride
                 + (hinge_alt ? hinge_stride/2 : 0)
                 ])
        linextr(-hinge_gap_z, hinge_stride/2)
@@ -230,7 +241,7 @@ module PowerBankStrapCut(){ ////toplevel
 module PowerBankHolderTest(){ ////toplevel
   difference(){
     linextr(-1,5) PowerBankSidePlan();
-    linextr(0, strap_th) PowerBankStrapCut();
+    linextr(0, strap_w) PowerBankStrapCut();
   }
 }
 
@@ -273,14 +284,27 @@ module PowerBankHolder(){ ////toplevel
 
       EndRetainer(retainer_walls[0]);
       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
+
+      translate([0,0, bank_x_sz/2]){
+       for (y = brace_ctrs_y) {
+         translate([0,y,0]) {
+           linextr_x_yz(0, brace_total_len)
+             BraceTubePlan();
+         }
+       }
+       translate([brace_total_len, 0,0])
+         linextr_y_xz(brace_ctrs_y[0] - brace_r,
+                      brace_ctrs_y[1] + brace_r)
+         BraceTubePlan();
+      }
     }
 
     for (strap_y = straps_y)
       translate([0, strap_y, 0])
        rotate([0,0,-90])
        rotate([0,90,0])
-       linextr(-strap_th/2,
-               +strap_th/2)
+       linextr(-strap_w/2,
+               +strap_w/2)
        PowerBankStrapCut();
 
     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
@@ -288,19 +312,16 @@ module PowerBankHolder(){ ////toplevel
        rotate([0,0,90])
        translate(bank_input_ctr)
        square(center=true, bank_input_sz);
-  }
 
-  translate([0,0, bank_x_sz/2]){
-    for (y = brace_ctrs_y) {
-      translate([0,y,0]) {
-       linextr_x_yz(0, brace_total_len)
-         BraceTubePlan();
+    translate([0, -(bank_y_sz/2 + endwall_th), 0] + 0.01 * [-1,-1]) {
+      linextr(-200,200){
+       difference(){
+         square(center=true, top_cnr_r*2);
+         translate(top_cnr_r * [1,1])
+           circle(r= top_cnr_r);
+       }
       }
     }
-    translate([brace_total_len, 0,0])
-      linextr_y_xz(brace_ctrs_y[0] - brace_r,
-                  brace_ctrs_y[1] + brace_r)
-      BraceTubePlan();
   }
 }
 
@@ -317,10 +338,15 @@ module TubeClampLeft() { ////toplevel
   }
 }
 
+module PlacePowerBank(){
+  translate([main_r, -mounted_pos_y_offset, 0])
+    children(0);
+}
+
 module Main(){ ////toplevel
   TubeClampLeft();
   difference(){
-    translate([main_r, -mounted_pos_y_offset, 0])
+    PlacePowerBank()
       PowerBankHolder();
     rotate([0,0,180])
       Screws();
@@ -339,3 +365,11 @@ module TubeClampDemo() { ////toplevel
   rotate([180,0,0])
     TubeClampRight();
 }
+
+module Demo() { ////toplevel
+  Main();
+  rotate([180,0,0])
+    TubeClampRight();
+  PlacePowerBank()
+    %PowerBankItself();
+}