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 // calculated
  58
  59 straps_y = [ -bank_y_sz * 0.25,
  60              +bank_y_sz * 0.25 ];
  61
  62 endwall_th = main_th;
  63
  64 bank_recess_dx = minor_wall_min;
  65
  66 pspt_to_mm = 25.4 / 72;
  67
  68 hinge_stride = (clamp_width + hinge_gap_z) / hinge_lobes;
  69
  70 main_r = tube_dia/2 + main_th;
  71
  72 hinge_outer_r = hinge_around + hinge_pin/2;
  73 hinge_y = tube_dia/2 + hinge_outer_r;
  74
  75 screw_max_y_lhs = -main_r -screw_nut_across/2;
  76 screw_max_y_rhs = -main_r -knob_behind_across/2;
  77
  78 screw_y = min(screw_max_y_lhs,
  79               screw_max_y_rhs);
  80
  81 bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
  82   -minor_wall_min;
  83
  84 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  85 bank_bot_y = strap_above + strap_th;
  86 strap_r = strap_th;
  87
  88 echo(bot_y);
  89
  90 module TubePlan(){ circle(r = tube_dia/2); }
  91 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
  92 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
  93
  94 module TubeClampLeftPlan(){
  95   difference(){
  96     union(){
  97       polygon([[ 0,                      hinge_y + hinge_outer_r ],
  98                [ -(main_r + overlap_l),  hinge_y + hinge_outer_r ],
  99                [ -(main_r + overlap_l),  bot_y                   ],
 100                [ -clamp_gap/2,           bot_y                   ],
 101                [ -clamp_gap/2,           0,                      ],
 102                [ 0,                      0,                      ],
 103                ]);
 104       HingeBodyPlan();
 105     }
 106     TubePlan();
 107     HingePinPlan();
 108   }
 109 }
 110
 111 module TubeClampLeft() { ////toplevel
 112   linextr(-clamp_width/2, clamp_width/2)
 113     TubeClampLeftPlan();
 114 }
 115
 116 module TubeClampRightPlan(){
 117   difference(){
 118     union(){
 119       rectfromto([ clamp_gap/2,                   bot_y ],
 120                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 121       intersection(){
 122         circle(r= main_r);
 123         union(){
 124           rectfromto([0,0],
 125                       main_r *  [5,5]);
 126           rectfromto([ clamp_gap/2, main_r*5 ],
 127                       main_r * [2,-5]);
 128         }
 129       }
 130       HingeBodyPlan();
 131     }
 132     TubePlan();
 133     HingePinPlan();
 134   }
 135 }
 136
 137 module Screws(){
 138   linextr_x_yz(-main_r*5, main_r*5)
 139     translate([screw_y, 0])
 140     circle(r= screw/2);
 141
 142   translate([0, screw_y, 0]) {
 143     linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 144       square([screw_nut_across,
 145               screw_nut_across / cos(30) + bridge_slop*2],
 146              center=true);
 147
 148     linextr_x_yz(-200, -main_r + screw_head_h)
 149       square([screw_head, screw_head + bridge_slop*2],
 150              center=true);
 151   }
 152 }
 153
 154 module SomeClamp(hinge_alt=false){
 155   difference(){
 156     linextr(-clamp_width/2, clamp_width/2)
 157       children(0);
 158
 159     Screws();
 160
 161     for (i=[0 : hinge_lobes-1]) {
 162       translate([0,
 163                  hinge_y,
 164                  -clamp_width/2 + i * hinge_stride
 165                  + (hinge_alt ? hinge_stride/2 : 0)
 166                  ])
 167         linextr(-hinge_gap_z, hinge_stride/2)
 168         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 169     }
 170   }
 171 }
 172
 173 module PowerBankItselfSidePlan(){
 174   translate([0, bank_bot_y])
 175     scale( bank_profile_scale_bodge *
 176            bank_x_sz / ( (
 177                           bank_eps_bbox_x[1] -
 178                           bank_eps_bbox_x[0]
 179                           ) * pspt_to_mm ))
 180     translate(pspt_to_mm *
 181               [-0.5 * (bank_eps_bbox_x[0] +
 182                        bank_eps_bbox_x[1]),
 183                -bank_eps_bbox_y[0]])
 184     import("powerbank-anker-10000.dxf", convexity=5);
 185 }
 186
 187 module PowerBankItself(){ ////toplevel
 188   rotate([0,90,0])
 189     linextr_y_xz(-bank_y_sz/2,
 190                  +bank_y_sz/2)
 191     PowerBankItselfSidePlan();
 192 }
 193
 194 module PowerBankSidePlan(){ ////toplevel
 195   render() difference(){
 196     rectfromto([ -holder_x_sz/2,  0 ],
 197                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 198
 199     PowerBankItselfSidePlan();
 200   }
 201 }
 202
 203 module PowerBankStrapCut(){ ////toplevel
 204   difference(){
 205     rectfromto([ -holder_x_sz, -0.05 ],
 206                [ +holder_x_sz, strap_th + strap_r ]);
 207     hull(){
 208       for (sx=[-1,+1]) {
 209         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 210                    strap_th + strap_r])
 211           circle(strap_r);
 212       }
 213     }
 214   }
 215 }
 216
 217 module PowerBankHolderTest(){ ////toplevel
 218   difference(){
 219     linextr(-1,5) PowerBankSidePlan();
 220     linextr(0, strap_th) PowerBankStrapCut();
 221   }
 222 }
 223
 224 module EndRetainer(depth){ ////toplevel
 225   translate([0, -bank_y_sz/2, 0]) {
 226     linextr_y_xz(-endwall_th, 0)
 227     rectfromto([ 0,         -holder_x_sz/2 ],
 228                [ -depth,    +holder_x_sz/2 ]);
 229
 230     for (m=[0,1]) {
 231       mirror([0,0,m]) {
 232         linextr(-holder_x_sz/2, -bank_x_sz/2){
 233           hull(){
 234             rectfromto([ 0, -endwall_th ],
 235                        [ depth, 0 ]);
 236             rectfromto([ 0, 0 ],
 237                        [ 0.1, depth-0.1 ]);
 238           }
 239         }
 240       }
 241     }
 242   }
 243 }
 244
 245 module PowerBankHolder(){ ////toplevel
 246   difference(){
 247     union(){
 248       rotate([0,90,0])
 249         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 250                      +(bank_y_sz/2 + 0.1))
 251         PowerBankSidePlan();
 252
 253       EndRetainer(retainer_walls[0]);
 254       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 255     }
 256
 257     for (strap_y = straps_y)
 258       translate([0, strap_y, 0])
 259         rotate([0,0,-90])
 260         rotate([0,90,0])
 261         linextr(-strap_th/2,
 262                 +strap_th/2)
 263         PowerBankStrapCut();
 264
 265     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
 266       linextr_y_xz(-50,50)
 267        rotate([0,0,90])
 268        translate(bank_input_ctr)
 269        square(center=true, bank_input_sz);
 270   }
 271 }
 272
 273 module TubeClampLeft() { ////toplevel
 274   // We want this to print with the recess overhand to the right
 275   // where the workpiece cooling fan is
 276   rotate([0,0,180]){
 277     difference(){
 278       SomeClamp(true)
 279         TubeClampLeftPlan();
 280
 281       Screws();
 282     }
 283   }
 284 }
 285
 286 module Main(){ ////toplevel
 287   TubeClampLeft();
 288   translate([main_r, -mounted_pos_y_offset, 0])
 289     PowerBankHolder();
 290 }
 291
 292 module TubeClampRight() { ////toplevel
 293   rotate([0,0,180])
 294     rotate([180,0,0])
 295     SomeClamp()
 296     TubeClampRightPlan();
 297 }
 298
 299 module TubeClampDemo() { ////toplevel
 300   TubeClampLeft();
 301   rotate([180,0,0])
 302     TubeClampRight();
 303 }