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 = (24.9 + 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 // calculated
  51
  52 endwall_th = main_th;
  53
  54 bank_recess_dx = minor_wall_min;
  55
  56 pspt_to_mm = 25.4 / 72;
  57
  58 hinge_stride = (clamp_width + hinge_gap_z) / hinge_lobes;
  59
  60 main_r = tube_dia/2 + main_th;
  61
  62 hinge_outer_r = hinge_around + hinge_pin/2;
  63 hinge_y = tube_dia/2 + hinge_outer_r;
  64
  65 screw_max_y_lhs = -main_r -screw_nut_across/2;
  66 screw_max_y_rhs = -main_r -knob_behind_across/2;
  67
  68 screw_y = min(screw_max_y_lhs,
  69               screw_max_y_rhs);
  70
  71 bot_y = screw_y -max( screw_nut_across, knob_behind_across/2 )
  72   -minor_wall_min;
  73
  74 holder_x_sz = bank_x_sz + bank_recess_dx*2;
  75 bank_bot_y = strap_above + strap_th;
  76 strap_r = strap_th;
  77
  78 echo(bot_y);
  79
  80 module TubePlan(){ circle(r = tube_dia/2); }
  81 module HingePinPlan(){ translate([0, hinge_y]) circle(r= hinge_pin/2); }
  82 module HingeBodyPlan(){ translate([0, hinge_y]) circle(r= hinge_outer_r); }
  83
  84 module TubeClampLeftPlan(){
  85   difference(){
  86     union(){
  87       polygon([[ 0,                    hinge_y + hinge_outer_r ],
  88                [ -main_r + overlap_l,  hinge_y + hinge_outer_r ],
  89                [ -main_r + overlap_l,  bot_y                   ],
  90                [ -clamp_gap/2,         bot_y                   ],
  91                [ -clamp_gap/2,         0,                      ],
  92                [ 0,                    0,                      ],
  93                ]);
  94       HingeBodyPlan();
  95     }
  96     TubePlan();
  97     HingePinPlan();
  98   }
  99 }
 100
 101 module TubeClampLeft() { ////toplevel
 102   linextr(-clamp_width/2, clamp_width/2)
 103     TubeClampLeftPlan();
 104 }
 105
 106 module TubeClampRightPlan(){
 107   difference(){
 108     union(){
 109       rectfromto([ clamp_gap/2,                   bot_y ],
 110                  [ clamp_gap/2 + behind_knob_th,  0     ]);
 111       intersection(){
 112         circle(r= main_r);
 113         union(){
 114           rectfromto([0,0],
 115                       main_r *  [5,5]);
 116           rectfromto([ clamp_gap/2, main_r*5 ],
 117                       main_r * [2,-5]);
 118         }
 119       }
 120       HingeBodyPlan();
 121     }
 122     TubePlan();
 123     HingePinPlan();
 124   }
 125 }
 126
 127 module SomeClamp(hinge_alt=false){
 128   difference(){
 129     linextr(-clamp_width/2, clamp_width/2)
 130       children(0);
 131
 132     linextr_x_yz(-main_r*5, main_r*5)
 133       translate([screw_y, 0])
 134       circle(r= screw/2);
 135
 136     for (i=[0 : hinge_lobes-1]) {
 137       translate([0,
 138                  hinge_y,
 139                  -clamp_width/2 + i * hinge_stride
 140                  + (hinge_alt ? hinge_stride/2 : 0)
 141                  ])
 142         linextr(-hinge_gap_z, hinge_stride/2)
 143         square(hinge_outer_r*2 + hinge_gap_xy, center=true);
 144     }
 145   }
 146 }
 147
 148 module PowerBankItselfSidePlan(){
 149   translate([0, bank_bot_y])
 150     scale( bank_x_sz / ( (
 151                           bank_eps_bbox_x[1] -
 152                           bank_eps_bbox_x[0]
 153                           ) * pspt_to_mm ))
 154     translate(pspt_to_mm *
 155               [-0.5 * (bank_eps_bbox_x[0] +
 156                        bank_eps_bbox_x[1]),
 157                -bank_eps_bbox_y[0]])
 158     import("powerbank-anker-10000.dxf", convexity=5);
 159 }
 160
 161 module PowerBankItself(){ ////toplevel
 162   rotate([0,90,0])
 163     linextr_y_xz(-bank_y_sz/2,
 164                  +bank_y_sz/2)
 165     PowerBankItselfSidePlan();
 166 }
 167
 168 module PowerBankSidePlan(){ ////toplevel
 169   render() difference(){
 170     rectfromto([ -holder_x_sz/2,  0 ],
 171                [ +holder_x_sz/2,  bank_recess_y + bank_bot_y ]);
 172
 173     PowerBankItselfSidePlan();
 174   }
 175 }
 176
 177 module PowerBankStrapCut(){ ////toplevel
 178   difference(){
 179     rectfromto([ -holder_x_sz, -0.05 ],
 180                [ +holder_x_sz, strap_th + strap_r ]);
 181     hull(){
 182       for (sx=[-1,+1]) {
 183         translate([sx * (holder_x_sz/2 - strap_r + 0.1),
 184                    strap_th + strap_r])
 185           circle(strap_r);
 186       }
 187     }
 188   }
 189 }
 190
 191 module PowerBankHolderTest(){ ////toplevel
 192   difference(){
 193     linextr(-20,20) PowerBankSidePlan();
 194     linextr(0, strap_th) PowerBankStrapCut();
 195   }
 196 }
 197
 198 module EndRetainer(depth){ ////toplevel
 199   translate([0, -bank_y_sz/2, 0]) {
 200     linextr_y_xz(-endwall_th, 0)
 201     rectfromto([ 0,         -holder_x_sz/2 ],
 202                [ -depth,    +holder_x_sz/2 ]);
 203
 204     for (m=[0,1]) {
 205       mirror([0,0,m]) {
 206         linextr(-holder_x_sz/2, -bank_x_sz/2){
 207           hull(){
 208             rectfromto([ 0, -endwall_th ],
 209                        [ depth, 0 ]);
 210             rectfromto([ 0, 0 ],
 211                        [ 0.1, depth-0.1 ]);
 212           }
 213         }
 214       }
 215     }
 216   }
 217 }
 218
 219 module PowerBankHolder(){ ////toplevel
 220   difference(){
 221     union(){
 222       rotate([0,90,0])
 223         linextr_y_xz(-(bank_y_sz/2 + 0.1),
 224                      +(bank_y_sz/2 + 0.1))
 225         PowerBankSidePlan();
 226
 227       EndRetainer(retainer_walls[0]);
 228       mirror([0,1,0]) EndRetainer(retainer_walls[1]);
 229     }
 230     //linextr(0, strap_th) PowerBankStrapCut();
 231   }
 232 }
 233
 234 module TubeClampLeft() { ////toplevel
 235   // We want this to print with the recess overhand to the right
 236   // where the workpiece cooling fan is
 237   rotate([0,0,180]){
 238     difference(){
 239       SomeClamp(true)
 240         TubeClampLeftPlan();
 241
 242       translate([0, screw_y, 0]) {
 243         linextr_x_yz(-(clamp_gap/2 + screw_nut_th), 0)
 244           square([screw_nut_across,
 245                   screw_nut_across / cos(30) + bridge_slop*2],
 246                  center=true);
 247
 248         linextr_x_yz(-main_r, -main_r + screw_head_h)
 249           square([screw_head, screw_head + bridge_slop*2],
 250                  center=true);
 251       }
 252     }
 253   }
 254 }
 255
 256 module TubeClampRight() { ////toplevel
 257   rotate([0,0,180])
 258     rotate([180,0,0])
 259     SomeClamp()
 260     TubeClampRightPlan();
 261 }
 262
 263 module TubeClampDemo() { ////toplevel
 264   TubeClampLeft();
 265   rotate([180,0,0])
 266     TubeClampRight();
 267 }