introduce slack config fale. also small edits to side wall stuff

helper/slack.scad

@@ -0,0 +1,26 @@
+/*
+  Slack config to standardize different usages of slack/tolerance values.
+
+  The purpose of this config is to introduce some consistency with how slack values defined in code. E.g. Why is the
+  slack value defined as 0.3 in this file, but 0.4 in another? This will also allow model-level adjustments for tighter
+  fitting parts, for when it might not convenient to adjust the actual 3d printer (using a 3d printer at a makerspace,
+  for example).
+
+  Some important details:
+    - The general philosophy for slack applications in this project is to subtract space from sockets, while not
+      modifying the plugs. TODO: enforce this
+    - Values are signed. Positive values can be interpreted as how much to remove from the socket along some dimension.
+    - This shouldn't be used to compensate for more serious part shrinkage (> +-0.5mm differences)
+*/
+
+xSlack = 0.3;
+
+ySlack = 0.3;
+
+radiusXYSlack = max(xSlack, ySlack)/2;
+
+zSlack = 0.0; // TODO figure out nice default value for this. keep in mind z shrinkage
+
+overhangSlack = 0.9;
+
+supportedOverhangSlack = 0.9;

notes.txt.save

@@ -0,0 +1,109 @@
+ The following keystrokes are available in the main editor window.
+ Alternative keys are shown in parentheses:
+
+^G     (F1)      Display this help text
+^X     (F2)      Close the current buffer / Exit from nano
+^O     (F3)      Write the current buffer (or the marked region) to disk
+^R     (Ins)     Insert another file into current buffer (or into new buffer)
+
+^W     (F6)      Search forward for a string or a regular expression
+^\     (M-R)     Replace a string or a regular expression
+^K     (F9)      Cut current line (or marked region) and store it in cutbuffer
+^U     (F10)     Paste the contents of cutbuffer at current cursor position
+
+^T               Execute a function or an external command
+^J     (F4)      Justify the current paragraph
+
+^C     (F11)     Display the position of the cursor
+^/     (M-G)     Go to line and column number
+
+M-U              Undo the last operation
+M-E              Redo the last undone operation
+
+M-A    (^6)      Mark text starting from the cursor position
+M-6    (M-^)     Copy current line (or marked region) and store it in cutbuffer
+
+M-]              Go to the matching bracket
+
+^Q               Search backward for a string or a regular expression
+M-Q              Search next occurrence backward
+M-W              Search next occurrence forward
+
+^B     (◂)       Go back one character
+^F     (▸)       Go forward one character
+^◂     (M-Space) Go back one word
+^▸     (^Space)  Go forward one word
+^A     (Home)    Go to beginning of current line
+^E     (End)     Go to end of current line
+
+^P     (▴)       Go to previous line
+^N     (▾)       Go to next line
+M-▴    (M--)     Scroll up one line without moving the cursor textually
+M-▾    (M-+)     Scroll down one line without moving the cursor textually
+
+^▴     (M-7)     Go to previous block of text
+^▾     (M-8)     Go to next block of text
+M-(    (M-9)     Go to beginning of paragraph; then of previous paragraph
+M-)    (M-0)     Go just beyond end of paragraph; then of next paragraph
+
+^Y     (PgUp)    Go one screenful up
+^V     (PgDn)    Go one screenful down
+M-\    (^Home)   Go to the first line of the file
+M-/    (^End)    Go to the last line of the file
+
+M-◂    (M-<)     Switch to the previous file buffer
+M-▸    (M->)     Switch to the next file buffer
+
+^I     (Tab)     Insert a tab at the cursor position (or indent marked lines)
+^M     (Enter)   Insert a newline at the cursor position
+
+^H     (Bsp)     Delete the character to the left of the cursor
+^D     (Del)     Delete the character under the cursor
+M-Bsp  (Sh-^Del) Delete backward from cursor to word start
+^Del             Delete forward from cursor to next word start
+M-T              Cut from the cursor position to the end of the file
+
+M-J              Justify the entire file
+M-D              Count the number of lines, words, and characters
+M-V              Insert the next keystroke verbatim
+
+		 Suspend the editor (return to the shell)
+^L               Refresh (redraw) the current screen
+
+M-}              Indent the current line (or marked lines)
+M-{    (Sh-Tab)  Unindent the current line (or marked lines)
+
+M-3              Comment/uncomment the current line (or marked lines)
+^]               Try and complete the current word
+
+M-:              Start/stop recording a macro
+M-;              Run the last recorded macro
+
+M-Ins            Place or remove an anchor at the current line
+M-PgUp           Jump backward to the nearest anchor
+M-PgDn           Jump forward to the nearest anchor
+
+M-Del            Throw away the current line (or marked region)
+
+F12              Invoke the spell checker, if available
+M-B              Invoke the linter, if available
+M-F              Invoke a program to format/arrange/manipulate the buffer
+
+^L               Center the line where the cursor is
+
+^S               Save file without prompting
+
+M-Z		 Hidden interface enable/disable
+M-X		 Help mode enable/disable
+M-C		 Constant cursor position display enable/disable
+M-S		 Soft wrapping of overlong lines enable/disable
+M-N		 Line numbering enable/disable
+M-P		 Whitespace display enable/disable
+M-Y		 Color syntax highlighting enable/disable
+
+M-H		 Smart home key enable/disable
+M-I		 Auto indent enable/disable
+M-K		 Cut to end enable/disable
+M-L		 Hard wrapping of overlong lines enable/disable
+M-O		 Conversion of typed tabs to spaces enable/disable
+M-M		 Mouse support enable/disable

rack/side/sideWallBase.scad

@@ -1,6 +1,7 @@
 include <../../helper/math.scad>
 include <../../helper/halfspace.scad>
 include <../../helper/magnet.scad>
+include <../../helper/slack.scad>
 include <../config.scad>
 
 include <./sideWallMagnetMount.scad>
@@ -59,7 +60,11 @@ module sideWallBase() {
       }
 
       union() {
-        hingeHole();
+        hingeHole(extraZ=2);
+
+        translate(v=[0,0,sideWallZ])
+        mirror(v=[0,0,1])
+        hingeHole(extraZ=2);
 
         // Trim parts of the wall for rotational clearance
         halfspace(p=[0, sideWallY-2.5, 0], vpos=[-0.5,1,0]); // flat area to limit rotation against the main rail
@@ -81,9 +86,9 @@ module sideWallBase() {
       cube(size=[eps, 2*hingeHoleShellR, sideWallZ]);
     }
 
-    module hingeHole() {
+    module hingeHole(extraZ) {
       translate(v = [hingePoleDx , hingePoleDy, 0])
-      cylinder(r = hingeHoleR, h = sideWallZ);
+      cylinder(r = hingeHoleR, h = hingePoleH+extraZ);
     }
   }
 
@@ -130,19 +135,34 @@ module sideWallBase() {
 
 module sideWallVerticalRibs(numRibs, ribZ, ribYDiff, ribR=1, ribExtrusion=1) {
 
+  ribRampLength = 5;
+
   intersection() {
     for (i = [0:numRibs-1]) {
-      translate(v = [sideWallThickness, i*ribYDiff, (sideWallZ-ribZ)/2])
 
+      translate(v = [sideWallThickness, i*ribYDiff, (sideWallZ-ribZ)/2])
       translate(v = [ribExtrusion-ribR, 0, 0])
-      hull() {
+      verticalRib(ribExtend=4, ribWidth=2);
-        translate(v = [0, 0, ribZ-ribR])
-        sphere(r = ribR);
-        translate(v = [0, 0, ribR])
-        sphere(r = ribR);
-      }
     }
 
     halfspace(vpos=[1,0,0], p=[0,0,0]);
   }
+
+
+  module verticalRib(ribExtend, ribWidth) {
+    minkowski() {
+      hull() {
+        cube(size = [eps, ribWidth, eps]);
+
+        translate(v = [0, 0, ribRampLength])
+        cube(size = [ribExtend, ribWidth, ribZ-2*ribRampLength]);
+
+        translate(v = [0, 0, ribZ])
+        cube(size = [eps, ribWidth, eps]);
+      }
+
+      sphere(r=0.5);
+    }
+
+  }
 }

rack/side/sideWallLeft.scad

@@ -1,25 +1,29 @@
 include <./sideWallBase.scad>
 
-
 *sideWallLeft();
 
 module sideWallLeft() {
 
   applyEpicVentilation()
   applySideWallVerticalRibs()
+  render()
   sideWallBase();
 
   module applyEpicVentilation() {
     apply_n() {
       for (i = [1:8]) {
         translate(v = [0, 35, i * 10 + 8])
+        vent();
+      }
+      children(0);
+    }
+
+    module vent() {
       minkowski() {
         sphere(r=1);
         cube(size = [10, 40, 3]);
       }
     }
-      children(0);
-    }
   }
 
   module applySideWallVerticalRibs() {

rack/side/sideWallRight.scad

@@ -7,23 +7,26 @@ module sideWallRight() {
   applyEpicVentilation()
   mirror(v=[1,0,0])
   applySideWallVerticalRibs()
+  render()
   sideWallBase();
 
   module applyEpicVentilation() {
 
     apply_n() {
-
       for (i = [1:8]) {
-        translate(v = [-10, 35, i * 10 + 8])
+        translate(v = [-10, 35, i*10+8])
+        vent();
+      }
+      children(0);
+    }
+
+    module vent() {
       minkowski() {
         sphere(r=1);
         cube(size = [10, 40, 3]);
       }
     }
 
-      children(0);
-    }
-
   }
 
   module applySideWallVerticalRibs() {

rack/side/sideWallVariables.scad

@@ -2,6 +2,7 @@
 include <../config.scad>
 include <../sharedVariables.scad>
 include <../../helper/magnet.scad>
+include <../../helper/slack.scad>
 
 sideWallConnW = 7;
 sideWallConnD = 20;
@@ -18,7 +19,7 @@ innerSideWallToYBarMagnetConn = magnetFaceToSideWallConnOuterYEdge + sideWallSlo
 
 hingePoleR = 2;
 hingePoleH = 5;
-hingeHoleR = hingePoleR + 0.2;
+hingeHoleR = hingePoleR + radiusXYSlack;
 
 
 sideWallZHingeSlack = 0.3;

stl/rack/print/xBar_P.stl

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@@ -2519,6 +2673,48 @@ solid OpenSCAD_Model
       vertex 3.13495 6 3.82803
     endloop
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@@ -2547,34 +2743,6 @@ solid OpenSCAD_Model
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@@ -2589,174 +2757,6 @@ solid OpenSCAD_Model
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