adafruit-powerboost: reorganise layerframes

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

diff --git a/adafruit-powerboost-common.scad b/adafruit-powerboost-common.scad
index a98f42763b4403e47d7c591ab2faa9e35f1edd59..86241e5a0a23fc8cd7a0f8ede23fb3de8115914a 100644 (file)
--- a/adafruit-powerboost-common.scad
+++ b/adafruit-powerboost-common.scad
@@ -5,10 +5,14 @@ include <utils.scad>
 
 psu_sz  = psu_sz_nom + [ 0.11, 0.44 ] + [ 0.25, 0.25 ];
 
+psu_hole_pos = [ 2.05, // from back edge of psu_sz[0]
+                0.55 * 0.5 * 25.4, // from centreline
+                ];
+
 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;
@@ -32,10 +36,24 @@ psu_baffle_gap = 1.0 + 0.5;
 
 psu_y = +psu_sz[1]/2 + psu_usb_protr;
 
+psu_usba_v_apart = 7.0;
+psu_usba_v_from_edge = 4.86;
+psu_usba_v_space_below = 1.5;
+psu_usba_v_space_w = 1.7;
+psu_usba_v_space_l = 3.0;
+
+psu_test_ceil = 2.5;
+
 // ----- calculated -----
 
 psu_z = NutBox_h_base(psu_board_nutbox);
 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)
@@ -66,6 +84,19 @@ module PsuMountCornerExtrude(mx,my, plus_z=psu_board_support_z){
   }
 }
 
+module PsuUsbAVSpacePlan(){
+  for (x= [-1,+1] * psu_usba_v_apart/2) {
+    translate([x, -psu_usba_v_from_edge ]) {
+      hull(){
+       for (y= [-1,+1] * 0.5 * (psu_usba_v_space_l - psu_usba_v_space_w)) {
+         translate([0,y])
+           circle(r= psu_usba_v_space_w);
+       }
+      }
+    }
+  }
+}
+
 module PsuMountPositiveMain(){
   for (mx=[0,1]) {
     for (my=[0,1]) {
@@ -119,9 +150,14 @@ module PsuMountPositive(){
        circle(r= psu_hole_dia/2);
     }
   }
-  translate([0, psu_sz[1]/2 + psu_board_nutbox[0]/2, 0])
-    rotate([0,0,180])
-    NutBox(psu_board_nutbox, psu_z_down);
+  difference(){
+    translate([0, psu_board_nutbox_y, 0])
+      rotate([0,0,180])
+      NutBox(psu_board_nutbox, psu_z_down);
+    translate([0, psu_sz[1]/2, 0])
+      linextr(-psu_usba_v_space_below, +10)
+      PsuUsbAVSpacePlan();
+  }
 }
 
 module PsuClamp(){ ////toplevel
@@ -129,7 +165,7 @@ module PsuClamp(){ ////toplevel
     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
       difference(){
        hull(){
-         circle(r = fix_sz/2);
+         circle(r = psu_fix_sz/2);
          translate([ -psu_board_nutbox[0]/2, 0])
            square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
        }
@@ -141,6 +177,11 @@ module PsuClamp(){ ////toplevel
        mirror([1,0])
        translate([0,-20]) square(40);
     }
+    linextr(-10,10) {
+      rotate(-90)
+       translate([0, -psu_board_nutbox[0]/2])
+       PsuUsbAVSpacePlan();
+    }
   }
 }
 
@@ -151,12 +192,133 @@ module PsuLedWindowsPlan(){
   }
 }
 
-module PsuMountDemo(ceil = 2.5) { ////toplevel
+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;
+
   translate([0, psu_y, psu_z]) {
-    PsuMountPositive();
+    difference(){
+      PsuMountPositive();
+      linextr(-20, 0.1)
+       PsuLedWindowsPlan();
+    }
     %PsuMountNegative();
+
     color("yellow") translate([0,0, -psu_z - ceil])
       linear_extrude(height=0.4, convexity=10)
       PsuLedWindowsPlan();
+
+    color("blue") translate([0,0, -psu_z - ceil])
+      linear_extrude(height=0.4, convexity=10)
+      PsuLedLegendsPlan();
+
+    translate([0, psu_board_nutbox_y, 10])
+      rotate([180,0,0])
+      rotate([0,0,-90])
+      PsuClamp();
+  }
+}
+
+module PsuMountTest() { ////toplevel
+  ceil = psu_test_ceil;
+  $fs = 0.1;
+  $fa = 3;
+  difference(){
+    union(){
+      translate([0, psu_y, psu_z])
+       PsuMountPositive();
+      difference(){
+
+       // rectangular box with wall
+       linextr_x_yz(-psu_mount_outer_sz_x/2,
+                    +psu_mount_outer_sz_x/2) {
+         difference(){
+           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])
+      PsuMountWindowsNegative(ceil);
+  }
+}
+
+psu_multicolour_gap = 0.075;
+psu_initial_layer_thick = 0.400;
+psu_initial_layer_width = 0.750;
+psu_window_ledge = 0.50; // each side
+
+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;
+
+  PsuMountTestFullLayerFrame(2);
+  
+  difference(){
+    translate([0,0, ceil])
+      PsuMountTest();
+  }
+}
+
+module PsuMountTestFullOneLayer(ix) {
+  PsuMountTestFullLayerFrame(ix);
+  linextr(0, psu_initial_layer_thick) {
+    translate([0, psu_y]) children();
   }
 }
+
+module PsuMountTestFullText() { ////toplevel
+  PsuMountTestFullOneLayer(0)
+    PsuLedLegendsPlan();
+}
+module PsuMountTestFullWindows() { ////toplevel
+  PsuMountTestFullOneLayer(1)
+    offset(delta=psu_window_ledge)
+    PsuLedWindowsPlan();
+}
+
+module PsuMountTestFullDemo() { ////toplevel
+  color("blue") PsuMountTestFullMain();
+  color("yellow") PsuMountTestFullText();
+  %PsuMountTestFullWindows();
+}