sleepphone-cable-box.scad

   1 // -*- C -*-
   2
   3 include <funcs.scad>
   4
   5 wall = 0.75 * [1,1,1];
   6 wall_bot = 1.0;
   7
   8 phone = [ 76.40, 30.96, 6.00 ]; // includes socket
   9 phone_button_z = 6.58;
  10 minwall = 0.50;
  11
  12 expose = 4.00;
  13
  14 cutout_dia = 7;
  15 cutout_between = 5;
  16
  17 button_dz = 1.35;
  18 button_dz_centre = 1.35 + 0.75;
  19 button_dz_outer  = 1.35;
  20
  21 button_dy_outer = 28.42;
  22 button_dy_inner = 19.05;
  23 button_dy_centre = 5.65;
  24
  25 nrbutton_brace_x = 37.5;
  26
  27 phone_slop = 0.5 * [1,1,0]
  28            + 0.5 * [0,0,1];
  29
  30 led = [25.9, 9.44]; // y is from edge
  31 led_dia = 4.4;
  32
  33 // next values include slop
  34 plug_maxw = 10.95 + 0.35;
  35 plug_minw=   6.53 + 0.35;
  36 plug_sllen=  6.50;
  37 plug_totlen = 84.90 + 1.5 - 2.0; // to maxw, including phone
  38
  39 plug_h = 6.5;
  40 plug_tooth_h = 0.5;
  41 plug_tooth_dy = 0.5;
  42
  43 keeper_prong = 2;
  44 keeper_stalk_basewidth = 12;
  45 keeper_stalk_len = 70;
  46 keeper_stalk_gap = 1;
  47 keeper_stalk_thick = wall_bot;
  48
  49 keeper_stalk_base_reinforce_len = 5;
  50 keeper_stalk_base_reinforce_thick = 2.0;
  51
  52 // calculated
  53
  54 top_z = max( phone[2] + wall[2],
  55              phone_button_z + minwall )
  56   + phone_slop[2];
  57
  58 plugkeeper_x_maxw = phone[0] - plug_totlen;
  59
  60 plugkeeper_p_max = [ 0, plug_maxw/2 ];
  61 plugkeeper_p_min = [ -plug_sllen, plug_minw/2 ];;
  62 plugkeeper_d_u = unitvector2d(
  63                  clockwise2d(
  64                  vecdiff2d( plugkeeper_p_max, plugkeeper_p_min )
  65                              )
  66                              );
  67
  68 module MainProfileInnerHalf(){
  69   p = phone + phone_slop;
  70   pbc = p[2] + button_dz_centre;
  71   pbo = p[2] + button_dz_outer;
  72   polygon([[ -2,                 0    ],
  73            [ p[1]/2,             0    ],
  74            [ p[1]/2,             p[2] ],
  75            [ button_dy_outer/2,  p[2] ],
  76            [ button_dy_outer/2,  pbo  ],
  77            [ button_dy_inner/2,  pbo  ],
  78            [ button_dy_inner/2,  p[2] ],
  79            [ button_dy_centre/2, p[2] ],
  80            [ button_dy_centre/2, pbc  ],
  81            [ -2,                 pbc  ]]);
  82 }
  83
  84 module MainProfile(){
  85   p = phone + phone_slop;
  86   difference(){
  87     for (m=[0,1]) mirror([m,0]) {
  88         minkowski(){
  89           translate([ -wall[1], -wall_bot ])
  90             square([ wall[1]*2, wall_bot + wall[2] ]);
  91           MainProfileInnerHalf();
  92         }
  93       }
  94     for (m=[0,1]) mirror([m,0]) {
  95         MainProfileInnerHalf();
  96       }
  97   }
  98 }
  99
 100 module BraceProfileInitial(){
 101   p = phone + phone_slop;
 102   pbo = p[2] + button_dz_outer;
 103   pbc = p[2] + button_dz_centre;
 104   polygon([[ button_dy_outer/2 + 0.2,  p[2]           ],
 105            [ button_dy_outer/2 + 0.2,  pbo  + wall[2] ],
 106            [ button_dy_outer/2      ,  pbo  + wall[2] ],
 107            [ button_dy_outer/2      ,  p[2]           ],
 108            ]);
 109 }
 110
 111 module BraceProfileFinal(){
 112   p = phone + phone_slop;
 113   pbo = p[2] + button_dz_outer;
 114   pbc = p[2] + button_dz_centre;
 115   polygon([[ -1,                       p[2]           ],
 116            [ -1,                       pbc  + wall[2] ],
 117            [ 0,                        pbc  + wall[2] ],
 118            [ 0,                        p[2]           ]
 119            ]);
 120 }
 121
 122 module Brace(){
 123   for (m=[0,1]) mirror([0,m,0]) {
 124       hull(){
 125         for (e=[0,1]) {
 126           translate([ nrbutton_brace_x + e * phone[1]/2,
 127                       0, 0 ]){
 128             rotate([ 90,0,90 ]){
 129               linear_extrude(height= (e==0 ? wall[0] : 0.1)){
 130                 hull(){
 131                   BraceProfileInitial();
 132                   if (e==0) BraceProfileFinal();
 133               }
 134               }
 135             }
 136           }
 137         }
 138       }
 139     }
 140 }
 141
 142 module BoxMain(){
 143   rotate([0,0,90]) rotate([90,0,0]) {
 144     translate([0,0, expose])
 145       linear_extrude(height = phone[0] + wall[0] - expose, convexity=20)
 146       MainProfile();
 147     translate([0,0, phone[0]])
 148       linear_extrude(height = wall[0], convexity=20)
 149       hull() MainProfile();
 150   }
 151 }
 152
 153 module PlugKeeperProfileHalf(){
 154   p_max = plugkeeper_p_max;
 155   p_min = plugkeeper_p_min;
 156   d = plugkeeper_d_u * keeper_prong;
 157
 158   translate([ plugkeeper_x_maxw, 0 ]) {
 159     polygon([ p_min,
 160               p_max,
 161               p_max + d,
 162               p_min + d ]);
 163   }
 164 }
 165
 166 module PlugKeeperStalkProfile(){
 167   hull(){
 168     for (m=[0,1]) mirror([0,m,0]) PlugKeeperProfileHalf();
 169     translate([ plugkeeper_x_maxw + keeper_stalk_len, 0,0 ])
 170       square([ 0.1, keeper_stalk_basewidth ], center=true);
 171   }
 172 }
 173
 174 module PlugKeeper(){
 175   for (m=[0,1]) mirror([0,m,0]) {
 176       translate([0,0, -keeper_stalk_thick])
 177         linear_extrude(height=plug_h + keeper_stalk_thick)
 178         PlugKeeperProfileHalf();
 179
 180       translate([0, 0, plug_h - plug_tooth_h])
 181         linear_extrude(height= plug_tooth_h)
 182         translate(plugkeeper_d_u * -plug_tooth_dy)
 183         PlugKeeperProfileHalf();
 184
 185     }
 186 }
 187
 188 module Box(){
 189   sidewall_cutout_z = phone[2] + phone_slop[2] + button_dz_outer;
 190
 191   difference(){
 192     union(){
 193       BoxMain();
 194       Brace();
 195     }
 196
 197     translate([ led[0], phone[1]/2 - led[1], 1 ])
 198       rotate([0,0, 360/8/2])
 199       cylinder(r = led_dia/2 / cos(360/8/2), h= phone[2]*2, $fn=8);
 200
 201     for (ys=[-1,+1]) {
 202       translate([ -0.1, ys * keeper_stalk_gap, -wall[2]*2])
 203         linear_extrude(height = wall[2]*3)
 204         PlugKeeperStalkProfile();
 205
 206       translate([ phone[0] + wall[0],
 207                   ys * (cutout_between/2 + cutout_dia/2),
 208                   -10 ])
 209         cylinder( r= cutout_dia/2, h = 50, $fn = 20 );
 210
 211       translate([expose, ys*phone[1]/2, sidewall_cutout_z/2])
 212         rotate([90,0,0])
 213         translate([0,0,-3])
 214         cylinder( r= sidewall_cutout_z/2 - 0.1, h=6 , $fn=20 );
 215     }
 216   }
 217
 218   PlugKeeper();
 219
 220   translate([0,0, -keeper_stalk_thick])
 221     linear_extrude(height = keeper_stalk_thick)
 222     PlugKeeperStalkProfile();
 223
 224   translate([ plugkeeper_x_maxw + keeper_stalk_len +
 225                -keeper_stalk_base_reinforce_len/2,
 226                -keeper_stalk_basewidth/2,
 227                0 ])
 228     mirror([0,0,1])
 229     cube([ keeper_stalk_base_reinforce_len,
 230            keeper_stalk_basewidth,
 231            keeper_stalk_base_reinforce_thick ]);
 232 }
 233
 234 module BoxPrint(){
 235   // This makes' Cura's support more optimal: specifically,
 236   // it then doesn't seem to touch the back (bottom) wall
 237   translate([0,0,phone[0]])
 238     rotate([0,90,0])
 239     Box();
 240 }
 241
 242 //MainProfileInnerHalf();
 243 //MainProfile();
 244 //translate([0,0,1]) color("black") BraceProfileInitial();
 245 //translate([0,0,1]) color("black") BraceProfileFinal();
 246 //Brace();
 247 //Box();
 248 BoxPrint();