adafruit-powerboost: reorganise layerframes

[reprap-play.git] / adafruit-powerboost-common.scad

diff --git a/adafruit-powerboost-common.scad b/adafruit-powerboost-common.scad
index 154b5f8f02854bcecc9e7a429090cfbb15565047..86241e5a0a23fc8cd7a0f8ede23fb3de8115914a 100644 (file)
--- a/adafruit-powerboost-common.scad
+++ b/adafruit-powerboost-common.scad
@@ -12,7 +12,7 @@ psu_hole_pos = [ 2.05, // from back edge of psu_sz[0]
 psu_th = 1.70 + 0.25;
 psu_th_for_clamp = 1.50;
 
-psu_hole_dia = 2.5 - 0.3;
+psu_hole_dia = 2.5 - 0.5;
 psu_connector_z = 2.9 + 0.1;
 psu_connector_z_overlap = 0.15;
 psu_connector_depth = 6.25;
@@ -51,6 +51,10 @@ psu_z_down = psu_z + 0.1;
 psu_fix_sz = NutBox_outer_size(psu_board_nutbox);
 psu_board_nutbox_y = psu_sz[1]/2 + psu_board_nutbox[0]/2;
 
+psu_mount_outer_sz_x = psu_sz[0] + psu_board_support_wall * 2; // centred
+psu_mount_outer_sz_y = psu_y + max(psu_board_support_wall, // at psu_y
+                                  psu_board_nutbox_y + psu_fix_sz/2);
+
 module PsuBoardRepresentation(){
   linear_extrude(height= psu_th)
     square(center=true, [psu_sz[0],psu_sz[1]]);
@@ -188,6 +192,15 @@ module PsuLedWindowsPlan(){
   }
 }
 
+module PsuMountWindowsNegative(ceil){
+  linextr(-10, 0.1)
+    PsuLedWindowsPlan();
+  translate([0, 0, -psu_z - ceil])
+    linextr(-1, psu_initial_layer_thick)
+    offset(delta=psu_window_ledge + psu_multicolour_gap)
+    PsuLedWindowsPlan();
+}
+
 module PsuMountDemo() { ////toplevel
   ceil = psu_test_ceil;
 
@@ -223,22 +236,31 @@ module PsuMountTest() { ////toplevel
       translate([0, psu_y, psu_z])
        PsuMountPositive();
       difference(){
-       linextr_x_yz(-(psu_sz[0]/2 + 5),
-                    +(psu_sz[0]/2 + 5)){
+
+       // rectangular box with wall
+       linextr_x_yz(-psu_mount_outer_sz_x/2,
+                    +psu_mount_outer_sz_x/2) {
          difference(){
-           rectfromto([0, -ceil], [psu_sz[1] + 10, psu_z + 10]);
+           rectfromto([0, -ceil],
+                      [psu_mount_outer_sz_y, psu_z + 10]);
            rectfromto([ceil,0], 400*[1,1]);
          }
        }
+
        translate([0, psu_y, psu_z]) {
          PsuMountNegative();
        }
+
+       translate([0, psu_y, -ceil]) {
+         linextr(-1, psu_initial_layer_thick) {
+           offset(delta=psu_multicolour_gap)
+             PsuLedLegendsPlan();
+         }
+       }
       }
     }
-    translate([0, psu_y, psu_z]) {
-      linextr(-10, 0.1)
-       PsuLedWindowsPlan();
-    }
+    translate([0, psu_y, psu_z])
+      PsuMountWindowsNegative(ceil);
   }
 }
 
@@ -247,50 +269,51 @@ psu_initial_layer_thick = 0.400;
 psu_initial_layer_width = 0.750;
 psu_window_ledge = 0.50; // each side
 
-module PsuMountTestFullLayerFrame(ix) {
-  sz = psu_sz*2 + [1,1]*psu_initial_layer_width*(3+ix);
-  translate([0, psu_y]) difference(){
-    square(center=true, sz + psu_multicolour_gap*2*[1,1]);
-    square(center=true, sz);
+psu_frame_gap = 1.0;
+
+module PsuMountLayerFrame(bl, tr, ix) {
+  gap0 = [1,1] * (psu_frame_gap + psu_initial_layer_width*(ix+0));
+  gap1 = [1,1] * (psu_frame_gap + psu_initial_layer_width*(ix+1));
+  linextr(0, psu_initial_layer_thick) {
+    difference(){
+      rectfromto(bl-gap1, tr+gap1);
+      rectfromto(bl-gap0, tr+gap0);
+    }
   }
 }
 
+module PsuMountTestFullLayerFrame(ix) {
+  PsuMountLayerFrame([-0.5 * psu_mount_outer_sz_x, 0],
+                    [+0.5 * psu_mount_outer_sz_x,
+                     psu_mount_outer_sz_y],
+                    ix);
+}
 
 module PsuMountTestFullMain() { ////toplevel
   ceil = psu_test_ceil;
 
-  linextr(0, psu_initial_layer_thick)
-    PsuMountTestFullLayerFrame(2);
+  PsuMountTestFullLayerFrame(2);
   
   difference(){
     translate([0,0, ceil])
       PsuMountTest();
-
-    translate([0, psu_y, 0]) {
-      linextr(-1, psu_initial_layer_thick) {
-       offset(delta=psu_window_ledge + psu_multicolour_gap)
-         PsuLedWindowsPlan();
-       offset(delta=psu_multicolour_gap)
-         PsuLedLegendsPlan();
-      }
-    }
   }
 }
 
 module PsuMountTestFullOneLayer(ix) {
+  PsuMountTestFullLayerFrame(ix);
   linextr(0, psu_initial_layer_thick) {
-    PsuMountTestFullLayerFrame(ix);
     translate([0, psu_y]) children();
   }
 }
 
 module PsuMountTestFullText() { ////toplevel
   PsuMountTestFullOneLayer(0)
-    offset(delta=psu_window_ledge)
     PsuLedLegendsPlan();
 }
 module PsuMountTestFullWindows() { ////toplevel
   PsuMountTestFullOneLayer(1)
+    offset(delta=psu_window_ledge)
     PsuLedWindowsPlan();
 }