--- /dev/null
+// -*- C -*-
+
+include <nutbox.scad>
+
+psu_sz = [ 21.7, 36.0 ] + [ 0.25, 0.25 ];
+
+psu_th = 1.70 + 0.25;
+psu_th_for_clamp = 1.50;
+
+psu_hole_pos = [ 2.05, // from back edge of psu_sz[0]
+ 0.55 * 0.5 * 25.4, // from centreline
+ ];
+psu_hole_dia = 2.5 - 0.3;
+psu_baffle_gap = 1.0 + 0.5;
+psu_baffle_cnr_y = 7.45; // from connector end
+psu_baffle_th = [ 0.8, 3.5 ];
+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_usbend_led_x = 4.5;
+psu_innerend_led_depth = 10;
+
+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_support_wall = 2;
+psu_board_nutbox = nutbox_data_M3;
+
+// ----- calculated -----
+
+psu_usbend_led_depth = psu_baffle_cnr_y*2 - psu_usbend_led_x;
+
+psu_z = NutBox_h_base(psu_board_nutbox);
+psu_z_down = psu_z + 0.1;
+
+
+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=board_support_z){
+ AtPsuMountCorner(mx,my){
+ linear_extrude(height= psu_z_down + plus_z, convexity=10) {
+ children();
+ }
+ }
+}
+
+module PsuLedBafflePlan(){
+ baffle_tr = [0, psu_baffle_cnr_y]
+ + 0.5 * [psu_baffle_th[1], psu_baffle_th[0]];
+ translate([0, -psu_sz[1]/2]) {
+ mirror([1,0,0]) {
+ rectfromto([-psu_baffle_th[1]/2, 0],
+ baffle_tr);
+ rectfromto([-psu_sz[0]/2 - psu_board_support_wall *2,
+ baffle_tr[1] - psu_baffle_th[0]],
+ baffle_tr);
+ }
+ }
+}
+
+module PsuLedWindowsPlan(){
+ difference(){
+ union(){
+ AtPsuMountCorner(1,0) {
+ rectfromto([ -(psu_board_support_wall + 0.1),
+ +psu_usbend_led_x ],
+ [ psu_sz[0]/2,
+ +psu_usbend_led_depth ]);
+ }
+ AtPsuMountCorner(0,0) {
+ sz = psu_baffle_cnr_y - psu_board_support_wall - psu_baffle_th[0];
+ translate([0, psu_baffle_cnr_y])
+ rectfromto([ -(psu_board_support_wall + 0.1),
+ -sz/2 ],
+ [ psu_sz[0]/2,
+ +sz/2 ]);
+ }
+ AtPsuMountCorner(0,1){
+ rectfromto([0,0],
+ [psu_sz[0]/2 - psu_hole_pos[1] - psu_hole_dia/2,
+ psu_innerend_led_depth]);
+ }
+ }
+ PsuLedBafflePlan();
+ translate([0, -psu_sz[1]/2])
+ square(center=true, [psu_baffle_th[1], psu_sz[1]]);;
+ }
+}
+
+module PsuMountPositiveMain(){
+ for (mx=[0,1]) {
+ for (my=[0,1]) {
+ PsuMountCornerExtrude(mx,my){
+ rectfromto(-[1,1]*psu_board_support_wall,
+ +[1,1]*board_support_ovlp);
+ }
+ }
+ // mount above at plug end
+ PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
+ rectfromto(-[1,1]*psu_board_support_wall,
+ [board_support_ovlp,
+ 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 * board_support_z / psu_sz[1]),
+ 0,0])
+ translate(-axis)
+ PsuBoardRepresentation();
+}
+
+module PsuMountPositive(){
+ difference(){
+ PsuMountPositiveMain();
+ 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]]
+ + board_gap * [1,1] )
+ 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);
+}
+
+module PsuClamp(){ ////toplevel
+ rotate([180,0,0]) difference(){
+ linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
+ difference(){
+ hull(){
+ circle(r = 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);
+ }
+ }
+}