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