// -*- C -*-
include <nutbox.scad>
+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 - 0.5;
+psu_connector_z = 2.9 + 0.1;
+psu_connector_z_overlap = 0.15;
+psu_connector_depth = 6.25;
+psu_connector_w = 8.0 + 0.5;
+psu_usb_protr = 0.6;
+
+psu_clamp_th = 4.0 + 0.75;
+psu_clamp_w = 8.0;
+psu_clamp_gap = 0.4;
+
+psu_board_clamp_ovlp = 4.5;
+psu_board_nutbox = nutbox_data_M3;
+
+psu_board_gap = 0.5;
+psu_board_support_wall = 2;
+psu_board_support_ovlp = 4.5;
+psu_board_support_ovlp_ceil = 2;
+psu_board_support_z = 2;
+
+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)
+ square(center=true, [psu_sz[0],psu_sz[1]]);
+}
+
+module PsuRepresentation(){
+ PsuBoardRepresentation();
+ translate([0, -psu_sz[1]/2, -psu_connector_z])
+ linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
+ rectfromto([ -psu_connector_w/2, -10 ],
+ [ +psu_connector_w/2, psu_connector_depth ]);
+}
+
+module AtPsuMountCorner(mx,my){
+ mirror([mx,0,0])
+ mirror([0,my,0])
+ translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
+ -1 * [0,0, psu_z_down])
+ children();
+}
+
+module PsuMountCornerExtrude(mx,my, plus_z=psu_board_support_z){
+ AtPsuMountCorner(mx,my){
+ linear_extrude(height= psu_z_down + plus_z, convexity=10) {
+ children();
+ }
+ }
+}
+
+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]) {
+ PsuMountCornerExtrude(mx,my){
+ rectfromto(-[1,1]*psu_board_support_wall,
+ +[1,1]*psu_board_support_ovlp);
+ }
+ }
+ // mount above at plug end
+ PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
+ rectfromto(-[1,1]*psu_board_support_wall,
+ [psu_board_support_ovlp,
+ psu_board_support_ovlp_ceil]);
+ }
+ }
+ translate([0,0, -psu_z_down])
+ linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
+ PsuLedBafflePlan();
+}
+
+module PsuMountNegative(){
+ axis = [0, -psu_sz[1]/2, psu_th];
+ PsuRepresentation();
+ translate(axis)
+ rotate([atan(2 * psu_board_support_z / psu_sz[1]),
+ 0,0])
+ translate(-axis)
+ PsuBoardRepresentation();
+}
+
+module PsuMountPositive(){
+ difference(){
+ intersection(){
+ PsuMountPositiveMain();
+ linextr_y_xz(-psu_y, psu_sz[1]*2) square(100, center=true);
+ }
+ PsuMountNegative();
+ intersection(){
+ hull(){
+ PsuBoardRepresentation();
+ translate([0,0,5]) PsuBoardRepresentation();
+ }
+ translate([-20,0,-20]) cube(40);
+ }
+ }
+ for (mx=[0,1]) {
+ PsuMountCornerExtrude(mx,1){
+ translate([psu_sz[0]/2 - psu_hole_pos[1],
+ psu_hole_pos[0]]
+ + psu_board_gap * [1,1] )
+ circle(r= psu_hole_dia/2);
+ }
+ }
+ 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
+ rotate([180,0,0]) difference(){
+ linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
+ difference(){
+ hull(){
+ circle(r = psu_fix_sz/2);
+ translate([ -psu_board_nutbox[0]/2, 0])
+ square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
+ }
+ circle(r = psu_board_nutbox[0]/2);
+ }
+ }
+ translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
+ translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
+ mirror([1,0])
+ translate([0,-20]) square(40);
+ }
+ linextr(-10,10) {
+ rotate(-90)
+ translate([0, -psu_board_nutbox[0]/2])
+ PsuUsbAVSpacePlan();
+ }
+ }
+}
+
+module PsuLedWindowsPlan(){
+ difference(){
+ PsuLedWindowsPlanCore();
+ PsuLedBafflePlan();
+ }
+}
+
+module PsuLedWindowsWindows(ceil){
+ translate([0,0, -psu_z - ceil])
+ linextr(0, psu_initial_layer_thick)
+ offset(delta=psu_window_ledge)
+ PsuLedWindowsPlan();
+}
+
+module PsuFirstLayerNegative(ceil){
+ translate([0, 0, -psu_z - ceil])
+ linextr(-1, psu_initial_layer_thick)
+ children();
+}
+
+module PsuMountWindowsNegative(ceil){
+ linextr(-10, 0.1)
+ PsuLedWindowsPlan();
+ PsuFirstLayerNegative(ceil)
+ offset(delta= psu_window_ledge + psu_multicolour_gap)
+ PsuLedWindowsPlan();
+}
+
+module PsuLedLegendsNegative(ceil){
+ PsuFirstLayerNegative(ceil)
+ offset(delta= psu_multicolour_gap)
+ PsuLedLegendsPlan();
+}
+
+module PsuMountDemo() { ////toplevel
+ ceil = psu_test_ceil;
+
+ translate([0, psu_y, psu_z]) {
+ 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, psu_z]) {
+ PsuMountWindowsNegative(ceil);
+ PsuLedLegendsNegative(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
+ PsuMountTestFullLayerFrame(1);
+ translate([0, psu_y, psu_z + psu_test_ceil])
+ PsuLedWindowsWindows(psu_test_ceil);
+}
+
+module PsuMountTestFullDemo() { ////toplevel
+ color("blue") PsuMountTestFullMain();
+ color("yellow") PsuMountTestFullText();
+ %PsuMountTestFullWindows();
+}
~ianmdlvl / reprap-play.git / blobdiff