powerbank-bike-clamp.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 tube_dia = 22.4;
   6
   7 hinge_around = 2.5;
   8 hinge_pin = 1.8 + 0.75;
   9 main_th = 3;
  10 minor_wall_min = 1;
  11
  12 screw = 5.0 + 0.75;
  13 screw_head = 8.7 + 1.2;
  14 screw_nut_across = 7.9 + 0.75;
  15 screw_nut_th = 3.9 + 0.75;
  16 screw_head_h = 3.6 + 0.75;
  17
  18 knob_behind_across = 12.2 + 0.75;
  19 behind_knob_th = 5;
  20
  21 clamp_width = 20;
  22
  23 clamp_gap = 2;
  24
  25 lower_th = 1;
  26
  27 overlap_l = 0.1;
  28
  29 bridge_slop = 1.2;
  30
  31 hinge_lobes = 2;
  32 hinge_gap_z = 0.75;
  33 hinge_gap_xy = 0.75;
  34
  35 $fs = 0.1;
  36 $fa = 5;
  37
  38 bank_eps_bbox_x = [149, 598];
  39 bank_eps_bbox_y = [274, 1452];
  40
  41 bank_y_sz = 102.25 + 0.50;
  42 bank_x_sz = (26.0 + 0.5);
  43 bank_recess_y = 5;
  44
  45 strap_th = 3;
  46 strap_above = 2.5;
  47
  48 retainer_walls = [18, 30];
  49
  50 bank_profile_scale_bodge = 1.0;
  51
  52 bank_input_ctr = [ 12.5, 11.5 ]; // from nearest corner
  53 bank_input_sz  = [ 8.5, 10.5 ];
  54
  55 mounted_pos_y_offset = 20;
  56
  57 liner_th = 0.8;
  58
  59 brace_r = 5;
  60 brace_len = 50;
  61
  62 // calculated
  63
  64 straps_y = [ -bank_y_sz * 0.25,
  65              +bank_y_sz * 0.25 ];
  66
  67 endwall_th = main_th;
  68
  69 bank_recess_dx = minor_wall_min;
  70
  71 pspt_to_mm = 25.4 / 72;
  72
  73 hinge_stride = (clamp_width + hinge_gap_z) / hinge_lobes;
  74
  75 main_r = tube_dia/2 + main_th;
  76
  77 hinge_outer_r = hinge_around + hinge_pin/2;
  78 hinge_y = tube_dia/2 + hinge_outer_r;
  79
  80 screw_max_y_lhs = -main_r -screw_nut_across/2;
  81 screw_max_y_rhs = -main_r -knob_behind_across/2;
  82
  83 screw_y = min(screw_max_y_lhs,
  84               screw_max_y_rhs);
  85
  86 bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
  87   -minor_wall_min;
  88
  89 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  90 bank_bot_y = strap_above + strap_th;
  91 strap_r = strap_th;
  92
  93 brace_total_len = brace_len + main_th;
  94 brace_ctrs_y = [ straps_y[0] - (brace_r + strap_r/2),
  95                  straps_y[1] + (brace_r + strap_r/2) ];
  96
  97 echo(bot_y);
  98
  99 module TubePlan(){ circle(r = tube_dia/2); }
 100 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
 101 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
 102
 103 module TubeClampLeftPlan(){
 104   difference(){
 105     union(){
 106       polygon([[ 0,                      hinge_y + hinge_outer_r ],
 107                [ -(main_r + overlap_l),  hinge_y + hinge_outer_r ],
 108                [ -(main_r + overlap_l),  bot_y                   ],
 109                [ -clamp_gap/2,           bot_y                   ],
 110                [ -clamp_gap/2,           0,                      ],
 111                [ 0,                      0,                      ],
 112                ]);
 113       HingeBodyPlan();
 114     }
 115     TubePlan();
 116     HingePinPlan();
 117   }
 118 }
 119
 120 module TubeClampLeft() { ////toplevel
 121   linextr(-clamp_width/2, clamp_width/2)
 122     TubeClampLeftPlan();
 123 }
 124
 125 module TubeClampRightPlan(){
 126   difference(){
 127     union(){
 128       rectfromto([ clamp_gap/2,                   bot_y ],
 129                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 130       intersection(){
 131         circle(r= main_r);
 132         union(){
 133           rectfromto([0,0],
 134                       main_r *  [5,5]);
 135           rectfromto([ clamp_gap/2, main_r*5 ],
 136                       main_r * [2,-5]);
 137         }
 138       }
 139       HingeBodyPlan();
 140     }
 141     TubePlan();
 142     HingePinPlan();
 143   }
 144 }
 145
 146 module Screws(){
 147   linextr_x_yz(-main_r*5, main_r*5)
 148     translate([screw_y, 0])
 149     circle(r= screw/2);
 150
 151   translate([0, screw_y, 0]) {
 152     linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 153       square([screw_nut_across,
 154               screw_nut_across / cos(30) + bridge_slop*2],
 155              center=true);
 156
 157     linextr_x_yz(-200, -main_r + screw_head_h)
 158       square([screw_head, screw_head + bridge_slop*2],
 159              center=true);
 160   }
 161 }
 162
 163 module SomeClamp(hinge_alt=false){
 164   difference(){
 165     linextr(-clamp_width/2, clamp_width/2)
 166       children(0);
 167
 168     Screws();
 169
 170     for (i=[0 : hinge_lobes-1]) {
 171       translate([0,
 172                  hinge_y,
 173                  -clamp_width/2 + i * hinge_stride
 174                  + (hinge_alt ? hinge_stride/2 : 0)
 175                  ])
 176         linextr(-hinge_gap_z, hinge_stride/2)
 177         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 178     }
 179   }
 180 }
 181
 182 module PowerBankItselfSidePlan(){
 183   translate([0, bank_bot_y]){
 184     minkowski(){
 185       circle($fn=8, r=liner_th);
 186       scale( bank_profile_scale_bodge *
 187              bank_x_sz / ( (
 188                             bank_eps_bbox_x[1] -
 189                             bank_eps_bbox_x[0]
 190                             ) * pspt_to_mm ))
 191         translate(pspt_to_mm *
 192                   [-0.5 * (bank_eps_bbox_x[0] +
 193                            bank_eps_bbox_x[1]),
 194                    -bank_eps_bbox_y[0]])
 195         import("powerbank-anker-10000.dxf", convexity=5);
 196     }
 197   }
 198 }
 199
 200 module PowerBankItself(){ ////toplevel
 201   rotate([0,90,0])
 202     linextr_y_xz(-bank_y_sz/2,
 203                  +bank_y_sz/2)
 204     PowerBankItselfSidePlan();
 205 }
 206
 207 module PowerBankSidePlan(){ ////toplevel
 208   render() difference(){
 209     rectfromto([ -holder_x_sz/2,  0 ],
 210                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 211
 212     PowerBankItselfSidePlan();
 213   }
 214 }
 215
 216 module PowerBankStrapCut(){ ////toplevel
 217   difference(){
 218     rectfromto([ -holder_x_sz, -0.05 ],
 219                [ +holder_x_sz, strap_th + strap_r ]);
 220     hull(){
 221       for (sx=[-1,+1]) {
 222         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 223                    strap_th + strap_r])
 224           circle(strap_r);
 225       }
 226     }
 227   }
 228 }
 229
 230 module PowerBankHolderTest(){ ////toplevel
 231   difference(){
 232     linextr(-1,5) PowerBankSidePlan();
 233     linextr(0, strap_th) PowerBankStrapCut();
 234   }
 235 }
 236
 237 module EndRetainer(depth){ ////toplevel
 238   translate([0, -bank_y_sz/2, 0]) {
 239     linextr_y_xz(-endwall_th, 0)
 240     rectfromto([ 0,         -holder_x_sz/2 ],
 241                [ -depth,    +holder_x_sz/2 ]);
 242
 243     for (m=[0,1]) {
 244       mirror([0,0,m]) {
 245         linextr(-holder_x_sz/2, -bank_x_sz/2){
 246           hull(){
 247             rectfromto([ 0, -endwall_th ],
 248                        [ depth, 0 ]);
 249             rectfromto([ 0, 0 ],
 250                        [ 0.1, depth-0.1 ]);
 251           }
 252         }
 253       }
 254     }
 255   }
 256 }
 257
 258 module BraceTubePlan(){
 259   intersection(){
 260     circle(r= brace_r);
 261     rectfromto(brace_r * [-2,  0],
 262                brace_r * [+2, +2]);
 263   }
 264 }
 265
 266 module PowerBankHolder(){ ////toplevel
 267   difference(){
 268     union(){
 269       rotate([0,90,0])
 270         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 271                      +(bank_y_sz/2 + 0.1))
 272         PowerBankSidePlan();
 273
 274       EndRetainer(retainer_walls[0]);
 275       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 276     }
 277
 278     for (strap_y = straps_y)
 279       translate([0, strap_y, 0])
 280         rotate([0,0,-90])
 281         rotate([0,90,0])
 282         linextr(-strap_th/2,
 283                 +strap_th/2)
 284         PowerBankStrapCut();
 285
 286     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
 287       linextr_y_xz(-50,50)
 288        rotate([0,0,90])
 289        translate(bank_input_ctr)
 290        square(center=true, bank_input_sz);
 291   }
 292
 293   translate([0,0, bank_x_sz/2]){
 294     for (y = brace_ctrs_y) {
 295       translate([0,y,0]) {
 296         linextr_x_yz(0, brace_total_len)
 297           BraceTubePlan();
 298       }
 299     }
 300     translate([brace_total_len, 0,0])
 301       linextr_y_xz(brace_ctrs_y[0] - brace_r,
 302                    brace_ctrs_y[1] + brace_r)
 303       BraceTubePlan();
 304   }
 305 }
 306
 307 module TubeClampLeft() { ////toplevel
 308   // We want this to print with the recess overhand to the right
 309   // where the workpiece cooling fan is
 310   rotate([0,0,180]){
 311     difference(){
 312       SomeClamp(true)
 313         TubeClampLeftPlan();
 314
 315       Screws();
 316     }
 317   }
 318 }
 319
 320 module Main(){ ////toplevel
 321   TubeClampLeft();
 322   difference(){
 323     translate([main_r, -mounted_pos_y_offset, 0])
 324       PowerBankHolder();
 325     rotate([0,0,180])
 326       Screws();
 327   }
 328 }
 329
 330 module TubeClampRight() { ////toplevel
 331   rotate([0,0,180])
 332     rotate([180,0,0])
 333     SomeClamp()
 334     TubeClampRightPlan();
 335 }
 336
 337 module TubeClampDemo() { ////toplevel
 338   TubeClampLeft();
 339   rotate([180,0,0])
 340     TubeClampRight();
 341 }