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