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 // calculated
  56
  57 straps_y = [ -bank_y_sz * 0.25,
  58              +bank_y_sz * 0.25 ];
  59
  60 endwall_th = main_th;
  61
  62 bank_recess_dx = minor_wall_min;
  63
  64 pspt_to_mm = 25.4 / 72;
  65
  66 hinge_stride = (clamp_width + hinge_gap_z) / hinge_lobes;
  67
  68 main_r = tube_dia/2 + main_th;
  69
  70 hinge_outer_r = hinge_around + hinge_pin/2;
  71 hinge_y = tube_dia/2 + hinge_outer_r;
  72
  73 screw_max_y_lhs = -main_r -screw_nut_across/2;
  74 screw_max_y_rhs = -main_r -knob_behind_across/2;
  75
  76 screw_y = min(screw_max_y_lhs,
  77               screw_max_y_rhs);
  78
  79 bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
  80   -minor_wall_min;
  81
  82 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  83 bank_bot_y = strap_above + strap_th;
  84 strap_r = strap_th;
  85
  86 echo(bot_y);
  87
  88 module TubePlan(){ circle(r = tube_dia/2); }
  89 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
  90 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
  91
  92 module TubeClampLeftPlan(){
  93   difference(){
  94     union(){
  95       polygon([[ 0,                      hinge_y + hinge_outer_r ],
  96                [ -(main_r + overlap_l),  hinge_y + hinge_outer_r ],
  97                [ -(main_r + overlap_l),  bot_y                   ],
  98                [ -clamp_gap/2,           bot_y                   ],
  99                [ -clamp_gap/2,           0,                      ],
 100                [ 0,                      0,                      ],
 101                ]);
 102       HingeBodyPlan();
 103     }
 104     TubePlan();
 105     HingePinPlan();
 106   }
 107 }
 108
 109 module TubeClampLeft() { ////toplevel
 110   linextr(-clamp_width/2, clamp_width/2)
 111     TubeClampLeftPlan();
 112 }
 113
 114 module TubeClampRightPlan(){
 115   difference(){
 116     union(){
 117       rectfromto([ clamp_gap/2,                   bot_y ],
 118                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 119       intersection(){
 120         circle(r= main_r);
 121         union(){
 122           rectfromto([0,0],
 123                       main_r *  [5,5]);
 124           rectfromto([ clamp_gap/2, main_r*5 ],
 125                       main_r * [2,-5]);
 126         }
 127       }
 128       HingeBodyPlan();
 129     }
 130     TubePlan();
 131     HingePinPlan();
 132   }
 133 }
 134
 135 module SomeClamp(hinge_alt=false){
 136   difference(){
 137     linextr(-clamp_width/2, clamp_width/2)
 138       children(0);
 139
 140     linextr_x_yz(-main_r*5, main_r*5)
 141       translate([screw_y, 0])
 142       circle(r= screw/2);
 143
 144     for (i=[0 : hinge_lobes-1]) {
 145       translate([0,
 146                  hinge_y,
 147                  -clamp_width/2 + i * hinge_stride
 148                  + (hinge_alt ? hinge_stride/2 : 0)
 149                  ])
 150         linextr(-hinge_gap_z, hinge_stride/2)
 151         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 152     }
 153   }
 154 }
 155
 156 module PowerBankItselfSidePlan(){
 157   translate([0, bank_bot_y])
 158     scale( bank_profile_scale_bodge *
 159            bank_x_sz / ( (
 160                           bank_eps_bbox_x[1] -
 161                           bank_eps_bbox_x[0]
 162                           ) * pspt_to_mm ))
 163     translate(pspt_to_mm *
 164               [-0.5 * (bank_eps_bbox_x[0] +
 165                        bank_eps_bbox_x[1]),
 166                -bank_eps_bbox_y[0]])
 167     import("powerbank-anker-10000.dxf", convexity=5);
 168 }
 169
 170 module PowerBankItself(){ ////toplevel
 171   rotate([0,90,0])
 172     linextr_y_xz(-bank_y_sz/2,
 173                  +bank_y_sz/2)
 174     PowerBankItselfSidePlan();
 175 }
 176
 177 module PowerBankSidePlan(){ ////toplevel
 178   render() difference(){
 179     rectfromto([ -holder_x_sz/2,  0 ],
 180                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 181
 182     PowerBankItselfSidePlan();
 183   }
 184 }
 185
 186 module PowerBankStrapCut(){ ////toplevel
 187   difference(){
 188     rectfromto([ -holder_x_sz, -0.05 ],
 189                [ +holder_x_sz, strap_th + strap_r ]);
 190     hull(){
 191       for (sx=[-1,+1]) {
 192         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 193                    strap_th + strap_r])
 194           circle(strap_r);
 195       }
 196     }
 197   }
 198 }
 199
 200 module PowerBankHolderTest(){ ////toplevel
 201   difference(){
 202     linextr(-1,5) PowerBankSidePlan();
 203     linextr(0, strap_th) PowerBankStrapCut();
 204   }
 205 }
 206
 207 module EndRetainer(depth){ ////toplevel
 208   translate([0, -bank_y_sz/2, 0]) {
 209     linextr_y_xz(-endwall_th, 0)
 210     rectfromto([ 0,         -holder_x_sz/2 ],
 211                [ -depth,    +holder_x_sz/2 ]);
 212
 213     for (m=[0,1]) {
 214       mirror([0,0,m]) {
 215         linextr(-holder_x_sz/2, -bank_x_sz/2){
 216           hull(){
 217             rectfromto([ 0, -endwall_th ],
 218                        [ depth, 0 ]);
 219             rectfromto([ 0, 0 ],
 220                        [ 0.1, depth-0.1 ]);
 221           }
 222         }
 223       }
 224     }
 225   }
 226 }
 227
 228 module PowerBankHolder(){ ////toplevel
 229   difference(){
 230     union(){
 231       rotate([0,90,0])
 232         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 233                      +(bank_y_sz/2 + 0.1))
 234         PowerBankSidePlan();
 235
 236       EndRetainer(retainer_walls[0]);
 237       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 238     }
 239
 240     for (strap_y = straps_y)
 241       translate([0, strap_y, 0])
 242         rotate([0,0,-90])
 243         rotate([0,90,0])
 244         linextr(-strap_th/2,
 245                 +strap_th/2)
 246         PowerBankStrapCut();
 247
 248     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
 249       linextr_y_xz(-50,50)
 250        rotate([0,0,90])
 251        translate(bank_input_ctr)
 252        square(center=true, bank_input_sz);
 253   }
 254 }
 255
 256 module TubeClampLeft() { ////toplevel
 257   // We want this to print with the recess overhand to the right
 258   // where the workpiece cooling fan is
 259   rotate([0,0,180]){
 260     difference(){
 261       SomeClamp(true)
 262         TubeClampLeftPlan();
 263
 264       translate([0, screw_y, 0]) {
 265         linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 266           square([screw_nut_across,
 267                   screw_nut_across / cos(30) + bridge_slop*2],
 268                  center=true);
 269
 270         linextr_x_yz(-main_r, -main_r + screw_head_h)
 271           square([screw_head, screw_head + bridge_slop*2],
 272                  center=true);
 273       }
 274     }
 275   }
 276 }
 277
 278 module Main(){ ////toplevel
 279   translate([-main_r, 0,0])
 280     TubeClampLeft();
 281   PowerBankHolder();
 282 }
 283
 284 module TubeClampRight() { ////toplevel
 285   rotate([0,0,180])
 286     rotate([180,0,0])
 287     SomeClamp()
 288     TubeClampRightPlan();
 289 }
 290
 291 module TubeClampDemo() { ////toplevel
 292   TubeClampLeft();
 293   rotate([180,0,0])
 294     TubeClampRight();
 295 }