adafruit-powerboost: reorganise layerframes

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

diff --git a/adafruit-powerboost-common.scad b/adafruit-powerboost-common.scad
index e3a67b71f3d335d76d64b5961341c2d4cac75544..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;
@@ -42,6 +42,8 @@ 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);
@@ -49,6 +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]]);
@@ -82,7 +88,7 @@ module PsuUsbAVSpacePlan(){
   for (x= [-1,+1] * psu_usba_v_apart/2) {
     translate([x, -psu_usba_v_from_edge ]) {
       hull(){
-       for (y= [-1,+1] * (psu_usba_v_space_l - psu_usba_v_space_w)) {
+       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);
        }
@@ -173,7 +179,8 @@ module PsuClamp(){ ////toplevel
     }
     linextr(-10,10) {
       rotate(-90)
-      PsuUsbAVSpacePlan();
+       translate([0, -psu_board_nutbox[0]/2])
+       PsuUsbAVSpacePlan();
     }
   }
 }
@@ -185,7 +192,18 @@ 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]) {
     difference(){
       PsuMountPositive();
@@ -193,10 +211,15 @@ module PsuMountDemo(ceil = 2.5) { ////toplevel
        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])
@@ -204,7 +227,8 @@ module PsuMountDemo(ceil = 2.5) { ////toplevel
   }
 }
 
-module PsuMountTest(ceil = 2.5) { ////toplevel
+module PsuMountTest() { ////toplevel
+  ceil = psu_test_ceil;
   $fs = 0.1;
   $fa = 3;
   difference(){
@@ -212,21 +236,89 @@ module PsuMountTest(ceil = 2.5) { ////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([-ceil, -ceil], [psu_sz[1] + 10, psu_z + 10]);
-           rectfromto([0,0], 400*[1,1]);
+           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);
+  }
+}
+
+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();
+}