improve rack ears

rack-mount/print/tray_P.scad

@@ -2,8 +2,9 @@ use <../tray.scad>
 
 // Config variables
 trayWidth = 140;
-trayDepth = 85;
+trayDepth = 88;
 trayThickness = 3;
+trayLipThickness = 3;
 
 pointHoleRadius = screwRadiusSlacked("m3");
 pointHoleThickness = 2;
@@ -16,4 +17,4 @@ mountPoints = [ // [x,y,elevation,holeRadius,holeThickness]
 mountScrewType = "m3";
 
 // Rack mount tray that supports screws on the bottom of the rack-mount item
-bottomScrewTray(u=1, trayWidth=trayWidth, trayDepth=trayDepth, trayThickness=trayThickness, mountPoints=mountPoints, mountScrewType=mountScrewType);
+bottomScrewTray(u=1, trayWidth=trayWidth, trayDepth=trayDepth, trayThickness=trayThickness, mountPoints=mountPoints, mountScrewType=mountScrewType, lipThickness=trayLipThickness);

rack-mount/rackEars.scad

@@ -1,43 +1,52 @@
 include <./common.scad>
 
 // Rack ear modules.
-// To be used either by itself if the mount-item supports it, or within another module
+// To be used either by itself if the item supports it, or within another module
 
-module rackEarStandAlone(frontThickness, sideThickness, frontWidth, sideDepth, sideHoles) {
+rackEarModule(frontThickness=3,sideThickness=3,frontWidth=30, sideDepth=50, u=4, support=true);
-  // TODO
-}
 
-module rackEarModule(frontThickness, sideThickness, frontWidth, sideDepth, u, triangular=true) {
+module rackEarModule(frontThickness, sideThickness, frontWidth, sideDepth, u, backPlaneHeight=3, support=true) {
 
   earHeight = u*uDiff + 2*rackMountScrewZDist;
 
   difference() {
     translate(v = [-rackMountScrewXDist, 0, -rackMountScrewZDist]) {
+      // front
       cube(size = [frontWidth, frontThickness, earHeight]);
 
-      if (triangular) {
+      // side
-        hull() {
+      hull() {
-          translate(v = [frontWidth-sideThickness, 0, 0])
+        translate(v = [frontWidth-sideThickness, 0, 0])
           cube(size = [sideThickness, frontThickness, earHeight]);
 
-          translate(v = [frontWidth-sideThickness, sideDepth, 0])
+        backSegmentPlane();
-          cube(size = [sideThickness, frontThickness, 1]);
+      }
+
+      if (support) {
+        hull() {
+          extraSpacing = 1;
+          translate(v= [rackMountScrewXDist+railScrewHoleToOuterEdge+extraSpacing,frontThickness,0])
+            cube(size = [sideThickness, eps, earHeight]);
+
+          backSegmentPlane();
         }
-      } else {
-        translate(v = [frontWidth-sideThickness, 0, 0])
-        cube(size = [sideThickness, sideDepth, earHeight]);
       }
     }
 
-    union() {
+    rackMountHoles();
-      rotate(a=[90,0,0])
+  }
+
+  module backSegmentPlane() {
+    translate(v = [frontWidth-sideThickness, sideDepth, 0])
+      cube(size = [sideThickness, eps, backPlaneHeight]);
+  }
+
+  module rackMountHoles() {
+    rotate(a=[90,0,0])
       cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
 
-      translate(v=[0,0,u*uDiff])
+    translate(v=[0,0,u*uDiff])
       rotate(a=[90,0,0])
-      cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
+        cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
-    }
   }
 }
-
-rackEarModule(frontThickness=3,sideThickness=3,frontWidth=30, sideDepth=50, u=4);

rack-mount/sideRail.scad

@@ -10,6 +10,7 @@ sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness +
 
 module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThickness=2, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159) {
 
+  // TODO simplify this
   mountBlockHeight = 10;
   mountBlockDepth = 10;
   screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
@@ -106,7 +107,7 @@ module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThic
         }
         translate(v=[0,supportedY+distanceFromSeparator+r+backThickness,boxDz])
         minkowski() {
-          cube(size = [sideThickness, 25, railSideHeight-2*boxDz]); // TODO calculate 22.5
+          cube(size = [sideThickness, 25, railSideHeight-2*boxDz]);
           sphere(r=r);
         }
 

rack-mount/tray.scad

@@ -2,11 +2,10 @@ include <./common.scad>
 use <./rackEars.scad>
 
 
-module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, mountScrewType) {
+module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, mountScrewType, lipThickness=3) {
 
   frontLipHeight = 2;
   backLipHeight = 1; // also applies to sides
-  lipThickness = 3;
 
   rackEarSideThickness = 3;
   rackEarFrontThickness = 3;
@@ -62,12 +61,12 @@ module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, moun
 
     translate(v = [leftScrewGlobalX, 0, rackMountScrewZDist])
     rackEarModule(frontThickness = rackEarFrontThickness, sideThickness = rackEarSideThickness, frontWidth =
-        leftScrewDistToTray+rackMountScrewXDist+rackEarSideThickness, sideDepth = trayDepth-lipThickness, u = u);
+        leftScrewDistToTray+rackMountScrewXDist+rackEarSideThickness, sideDepth = trayDepth-lipThickness, u = u, backPlaneHeight=trayThickness+backLipHeight);
 
     translate(v = [rightScrewGlobalX, 0, rackMountScrewZDist])
     mirror(v = [1, 0, 0])
     rackEarModule(frontThickness = rackEarFrontThickness, sideThickness = rackEarSideThickness, frontWidth =
-       rightScrewGlobalX-trayWidth+rackMountScrewXDist+rackEarSideThickness, sideDepth = trayDepth-lipThickness, u = u);
+       rightScrewGlobalX-trayWidth+rackMountScrewXDist+rackEarSideThickness, sideDepth = trayDepth-lipThickness, u = u, backPlaneHeight=trayThickness+backLipHeight);
     }
 
 

rack/connector/basePlateYBarConnectors.scad

@@ -39,11 +39,12 @@ module onYBarBasePlateConnectorNegative() {
   hexNutPocket_N("m3", openSide=false, backSpace=5, bridgeBack=true);
 
   hull() {
+    // This has always been a pretty annoying to fit part. Increasing slack to 2*radiusXYSlack to compensate. TODO fix
     translate(v = [_heatSetX, _heatSetY, _baseConnRecession+overhangSlack])
-    roundCutSlice(radius = heatSetInsertSlotRadiusSlacked(rackFrameScrewType)+radiusXYSlack);
+    roundCutSlice(radius = heatSetInsertSlotRadiusSlacked(rackFrameScrewType)+2*radiusXYSlack);
 
     translate(v = [_heatSetX, _heatSetY, 0])
-    roundCutSlice(radius = _baseConnY/2 + radiusXYSlack);
+    roundCutSlice(radius = _baseConnY/2 + 2*radiusXYSlack);
   }
 
 }

rack/sharedVariables.scad

@@ -65,3 +65,6 @@ xBarRoundness = baseRoundness;
 
 rackTotalWidth = 2*yBarWidth + xBarX;
 rackTotalDepth = yBarDepth;
+
+plateGap = 1; // distance between edge of xy plate and other parts
+assert(plateGap >= xySlack);

rack/xyPlate.scad

@@ -20,11 +20,11 @@ module xyPlate() {
   connPosY = basePlateScrewMountToYBarXZFace - connYBarCornerDy;
 
   module plateBody() {
-    plateBodyX = xBarX - xySlack;
+    plateBodyX = xBarX - 2*plateGap;
-    plateBodyY = (yBarDepth - 2*xBarY) - xySlack;
+    plateBodyY = (yBarDepth - 2*xBarY) - 2*plateGap;
     plateBodyH = xBarWallThickness;
 
-    translate(v=[xySlack/2, xySlack/2, 0]) {
+    translate(v=[plateGap, plateGap, 0]) {
       cube(size = [plateBodyX, plateBodyY, plateBodyH]);
 
       // bracing
@@ -86,12 +86,13 @@ module xyPlate() {
     module yBarConnector() {
       difference() {
         hull() {
+          // TODO: we don't need to heatset insert values anymore
           translate(v=[0,0,_baseConnRecession])
           roundCutSlice(radius = heatSetInsertSlotRadiusSlacked(rackFrameScrewType), length=5);
           roundCutSlice(radius = _baseConnY/2, length=15);
         }
-
+        mirror(v=[0,0,1])
-        cylinder(r=screwRadiusSlacked(rackFrameScrewType), h=inf, center=true);
+        counterSunkHead_N(rackFrameScrewType, headExtension = eps, screwExtension = inf10);
 
       }
     }