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_space = 12.2 + 0.75;
  22 behind_knob_th = 5;
  23
  24 clamp_min_width = 20;
  25
  26 clamp_gap = 2;
  27
  28 lower_th = 1;
  29
  30 overlap_l = 0.1;
  31
  32 bridge_slop = 1.2;
  33
  34 hinge_lobe_per = 10;
  35 hinge_gap_z = 0.75;
  36 hinge_gap_xy = 0.75;
  37
  38 $fs = 0.1;
  39 $fa = 5;
  40
  41 bank_eps_bbox_x = [149, 598];
  42 bank_eps_bbox_y = [274, 1452];
  43
  44 bank_y_sz = 102.25 + 0.50 + 3.2;
  45 bank_x_sz = (26.0 + 0.5);
  46 bank_recess_y = 5;
  47
  48 strap_th = 3;
  49 strap_w = 5;
  50 strap_above = 2.5;
  51
  52 retainer_walls = [18, 30];
  53
  54 bank_profile_scale_bodge = 1.0;
  55
  56 bank_input_ctr = [ 12.5, 11.5 ]; // from nearest corner
  57 bank_input_sz  = [ 8.5, 10.5 ];
  58
  59 mounted_pos_y_offset = 20;
  60
  61 liner_th = 0.8;
  62
  63 brace_r = 5;
  64 brace_len = 50;
  65
  66 // calculated
  67
  68 straps_y = [ -bank_y_sz * 0.25,
  69              +bank_y_sz * 0.25 ];
  70
  71 screw_head_behind = main_th;
  72 endwall_th = main_th;
  73
  74 bank_recess_dx = minor_wall_min;
  75
  76 pspt_to_mm = 25.4 / 72;
  77
  78 main_r = tube_dia/2 + main_th;
  79
  80 screw_max_y_lhs = -main_r -screw_nut_across/2;
  81 screw_max_y_rhs = -main_r -knob_behind_across_space/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_space/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_w/2),
  95                  straps_y[1] + (brace_r + strap_w/2) ];
  96
  97 clamp_width_actual = max(clamp_min_width, holder_x_sz);
  98
  99 hinge_lobes = floor(clamp_width_actual / hinge_lobe_per);
 100 hinge_stride = (clamp_width_actual + hinge_gap_z) / hinge_lobes;
 101
 102 hinge_outer_r = hinge_around + hinge_pin/2;
 103 hinge_y = tube_dia/2 + hinge_outer_r;
 104
 105 top_cnr_r = min(endwall_th, main_th);
 106
 107 echo(bot_y);
 108
 109 module TubePlan(){ circle(r = tube_dia/2); }
 110 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
 111 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
 112
 113 module TubeClampLeftPlan(){
 114   difference(){
 115     union(){
 116       polygon([[ 0,                      hinge_y + hinge_outer_r ],
 117                [ -(main_r + overlap_l),  hinge_y + hinge_outer_r ],
 118                [ -(main_r + overlap_l),  bot_y                   ],
 119                [ -clamp_gap/2,           bot_y                   ],
 120                [ -clamp_gap/2,           0,                      ],
 121                [ 0,                      0,                      ],
 122                ]);
 123       HingeBodyPlan();
 124     }
 125     TubePlan();
 126     HingePinPlan();
 127   }
 128 }
 129
 130 module TubeClampLeft() { ////toplevel
 131   linextr(-clamp_width_actual/2, clamp_width_actual/2)
 132     TubeClampLeftPlan();
 133 }
 134
 135 module TubeClampRightPlan(){
 136   difference(){
 137     union(){
 138       rectfromto([ clamp_gap/2,                   bot_y ],
 139                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 140       intersection(){
 141         circle(r= main_r);
 142         union(){
 143           rectfromto([0,0],
 144                       main_r *  [5,5]);
 145           rectfromto([ clamp_gap/2, main_r*5 ],
 146                       main_r * [2,-5]);
 147         }
 148       }
 149       HingeBodyPlan();
 150     }
 151     TubePlan();
 152     HingePinPlan();
 153   }
 154 }
 155
 156 module Screws(){
 157   linextr_x_yz(-main_r*5, main_r*5)
 158     translate([screw_y, 0])
 159     circle(r= screw/2);
 160
 161   translate([0, screw_y, 0]) {
 162     linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 163       square([screw_nut_across,
 164               screw_nut_across / cos(30) + bridge_slop*2],
 165              center=true);
 166
 167     linextr_x_yz(-200,
 168                  -(clamp_gap/2 + screw_nut_th + screw_head_behind))
 169       square([screw_head, screw_head + bridge_slop*2],
 170              center=true);
 171   }
 172 }
 173
 174 module SomeClamp(hinge_alt=false){
 175   difference(){
 176     linextr(-clamp_width_actual/2, clamp_width_actual/2)
 177       children(0);
 178
 179     Screws();
 180
 181     for (i=[0 : hinge_lobes-1]) {
 182       translate([0,
 183                  hinge_y,
 184                  -clamp_width_actual/2 + i * hinge_stride
 185                  + (hinge_alt ? hinge_stride/2 : 0)
 186                  ])
 187         linextr(-hinge_gap_z, hinge_stride/2)
 188         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 189     }
 190   }
 191 }
 192
 193 module PowerBankItselfSidePlan(){
 194   translate([0, bank_bot_y]){
 195     minkowski(){
 196       circle($fn=8, r=liner_th);
 197       scale( bank_profile_scale_bodge *
 198              bank_x_sz / ( (
 199                             bank_eps_bbox_x[1] -
 200                             bank_eps_bbox_x[0]
 201                             ) * pspt_to_mm ))
 202         translate(pspt_to_mm *
 203                   [-0.5 * (bank_eps_bbox_x[0] +
 204                            bank_eps_bbox_x[1]),
 205                    -bank_eps_bbox_y[0]])
 206         import("powerbank-anker-10000.dxf", convexity=5);
 207     }
 208   }
 209 }
 210
 211 module PowerBankItself(){ ////toplevel
 212   rotate([0,90,0])
 213     linextr_y_xz(-bank_y_sz/2,
 214                  +bank_y_sz/2)
 215     PowerBankItselfSidePlan();
 216 }
 217
 218 module PowerBankSidePlan(){ ////toplevel
 219   render() difference(){
 220     rectfromto([ -holder_x_sz/2,  0 ],
 221                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 222
 223     PowerBankItselfSidePlan();
 224   }
 225 }
 226
 227 module PowerBankStrapCut(){ ////toplevel
 228   difference(){
 229     rectfromto([ -holder_x_sz, -0.05 ],
 230                [ +holder_x_sz, strap_th + strap_r ]);
 231     hull(){
 232       for (sx=[-1,+1]) {
 233         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 234                    strap_th + strap_r])
 235           circle(strap_r);
 236       }
 237     }
 238   }
 239 }
 240
 241 module PowerBankHolderTest(){ ////toplevel
 242   difference(){
 243     linextr(-1,5) PowerBankSidePlan();
 244     linextr(0, strap_w) PowerBankStrapCut();
 245   }
 246 }
 247
 248 module EndRetainer(depth){ ////toplevel
 249   translate([0, -bank_y_sz/2, 0]) {
 250     linextr_y_xz(-endwall_th, 0)
 251     rectfromto([ 0,         -holder_x_sz/2 ],
 252                [ -depth,    +holder_x_sz/2 ]);
 253
 254     for (m=[0,1]) {
 255       mirror([0,0,m]) {
 256         linextr(-holder_x_sz/2, -bank_x_sz/2){
 257           hull(){
 258             rectfromto([ 0, -endwall_th ],
 259                        [ depth, 0 ]);
 260             rectfromto([ 0, 0 ],
 261                        [ 0.1, depth-0.1 ]);
 262           }
 263         }
 264       }
 265     }
 266   }
 267 }
 268
 269 module BraceTubePlan(){
 270   intersection(){
 271     circle(r= brace_r);
 272     rectfromto(brace_r * [-2,  0],
 273                brace_r * [+2, +2]);
 274   }
 275 }
 276
 277 module PowerBankHolder(){ ////toplevel
 278   difference(){
 279     union(){
 280       rotate([0,90,0])
 281         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 282                      +(bank_y_sz/2 + 0.1))
 283         PowerBankSidePlan();
 284
 285       EndRetainer(retainer_walls[0]);
 286       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 287
 288       translate([0,0, bank_x_sz/2]){
 289         for (y = brace_ctrs_y) {
 290           translate([0,y,0]) {
 291             linextr_x_yz(0, brace_total_len)
 292               BraceTubePlan();
 293           }
 294         }
 295         translate([brace_total_len, 0,0])
 296           linextr_y_xz(brace_ctrs_y[0] - brace_r,
 297                        brace_ctrs_y[1] + brace_r)
 298           BraceTubePlan();
 299       }
 300     }
 301
 302     for (strap_y = straps_y)
 303       translate([0, strap_y, 0])
 304         rotate([0,0,-90])
 305         rotate([0,90,0])
 306         linextr(-strap_w/2,
 307                 +strap_w/2)
 308         PowerBankStrapCut();
 309
 310     translate([ bank_bot_y, -bank_y_sz/2, -bank_x_sz/2 ])
 311       linextr_y_xz(-50,50)
 312        rotate([0,0,90])
 313        translate(bank_input_ctr)
 314        square(center=true, bank_input_sz);
 315
 316     translate([0, -(bank_y_sz/2 + endwall_th), 0] + 0.01 * [-1,-1]) {
 317       linextr(-200,200){
 318         difference(){
 319           square(center=true, top_cnr_r*2);
 320           translate(top_cnr_r * [1,1])
 321             circle(r= top_cnr_r);
 322         }
 323       }
 324     }
 325   }
 326 }
 327
 328 module TubeClampLeft() { ////toplevel
 329   // We want this to print with the recess overhand to the right
 330   // where the workpiece cooling fan is
 331   rotate([0,0,180]){
 332     difference(){
 333       SomeClamp(true)
 334         TubeClampLeftPlan();
 335
 336       Screws();
 337     }
 338   }
 339 }
 340
 341 module PlacePowerBank(){
 342   translate([main_r, -mounted_pos_y_offset, 0])
 343     children(0);
 344 }
 345
 346 module Main(){ ////toplevel
 347   TubeClampLeft();
 348   difference(){
 349     PlacePowerBank()
 350       PowerBankHolder();
 351     rotate([0,0,180])
 352       Screws();
 353   }
 354 }
 355
 356 module TubeClampRight() { ////toplevel
 357   rotate([0,0,180])
 358     rotate([180,0,0])
 359     SomeClamp()
 360     TubeClampRightPlan();
 361 }
 362
 363 module TubeClampDemo() { ////toplevel
 364   TubeClampLeft();
 365   rotate([180,0,0])
 366     TubeClampRight();
 367 }
 368
 369 module Demo() { ////toplevel
 370   Main();
 371   rotate([180,0,0])
 372     TubeClampRight();
 373   PlacePowerBank()
 374     %PowerBankItself();
 375 }