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parametrize screw/hex nut types

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This commit is contained in:
zhao
2023-01-01 16:20:47 -05:00
parent d0c89d13c6
commit 1b923fa215
4 changed files with 162 additions and 188 deletions
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5
.idea/codeStyles/codeStyleConfig.xml generated Normal file
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@ -0,0 +1,5 @@
<component name="ProjectCodeStyleConfiguration">
<state>
<option name="PREFERRED_PROJECT_CODE_STYLE" value="Default" />
</state>
</component>

8
cases/rack2/config.scad
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@ -23,10 +23,12 @@ screwDiff = 10;
numRailScrews = 20;
// Screw type used for rackmount units. See screws.scad.
railMainScrewType = "m4";
mainRailScrewType = "m4";
// Screw type used to affix side rails.
railSideMountScrewType = "m4";
mainRailSideMountScrewType = "m4";
// Screw type used for constructing the actual rack frame.
rackScrewType = "m3";
rackFrameScrewType = "m3";
// Currently, only m3 screws are supported here (tolerance issues)
assert(rackFrameScrewType == "m3");

74
cases/rack2/mainRail.scad
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@ -1,7 +1,19 @@
include <./config.scad>
include <./screws.scad>
/* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
railFootThickness = 3;
railTotalHeight = screwDiff * (numRailScrews + 1) + 2 * railFootThickness;
mainRail();
echo("Total Rail Height = ", railTotalHeight);
module mainRail() {
// Distance between the middle of a screw mount and the rail's vertical edges
railScrewHoleToInnerEdge = 5;
railScrewHoleToOuterEdge = 5;
@ -16,13 +28,6 @@ railOtherThickness = 2.5;
// Extra spacing for the rack unit screws.
frontScrewSpacing = 8;
/* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
railFootThickness = 3;
railTotalHeight = screwDiff * (numRailScrews+1) + 2*railFootThickness;
sideSupportExtraSpace = 2;
sideSupportScrewHoleToFrontEdge = 5;
sideSupportScrewHoleToBackEdge = 4.5;
@ -30,6 +35,25 @@ sideSupportDepth = sideSupportScrewHoleToBackEdge + sideSupportScrewHoleToFrontE
frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
union() {
_frontRailSegment();
translate(v = [0, railFrontThickness, 0])
_connectingLBracketRailSegment();
translate(v = [frontFaceWidth - sideSupportExtraSpace, railFrontThickness + railOtherThickness + frontScrewSpacing,
0])
rotate(a = [0, 0, 90])
_sideSupportSegment();
translate(v = [0, railFrontThickness + railOtherThickness + frontScrewSpacing, 0]) {
_railFeet();
translate(v = [0, 0, railTotalHeight - railFootThickness])
_railFeet();
}
}
module _frontRailSegment() {
difference() {
@ -38,7 +62,7 @@ module _frontRailSegment() {
for (i = [1:numRailScrews]) {
translate(v = [railScrewHoleToOuterEdge, railFrontThickness / 2, i * screwDiff + railFootThickness])
rotate(a = [90, 0, 0])
m4HexNutPocketNegative();
hexNutPocket_N(mainRailScrewType);
}
}
}
@ -51,11 +75,11 @@ module _connectingLBracketRailSegment() {
union() {
translate(v = [0, 4, railFootThickness + screwDiff / 2])
rotate(a = [0, 90, 0])
cylinder(r=m3RadiusSlacked, h = 10, $fn=32, center=true);
cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = 10, $fn = 32, center = true);
translate(v = [0, 4, railTotalHeight - (railFootThickness + screwDiff / 2)])
rotate(a = [0, 90, 0])
cylinder(r=m3RadiusSlacked, h = 10, $fn=32, center=true);
cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = 10, $fn = 32, center = true);
}
}
@ -73,7 +97,7 @@ module _sideSupportSegment() {
for (i = [1:numRailScrews]) {
translate(v = [sideSupportScrewHoleToFrontEdge, railFrontThickness / 2, i * screwDiff + railFootThickness])
rotate(a = [90, 0, 0])
cylinder(r=m4RadiusSlacked, h=10, $fn=32);
cylinder(r = screwRadiusSlacked(mainRailSideMountScrewType), h = 10, $fn = 32);
}
}
@ -86,36 +110,12 @@ module _railFeet() {
hull() {
translate(v = [1.5, 5, 0])
cylinder(r = m3RadiusSlacked, h = 10, $fn = 32);
cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = 10, $fn = 32);
translate(v = [0, 5, 0])
cube(size=[0.1, m3RadiusSlacked*2, 10], center=true);
cube(size = [0.1, screwRadiusSlacked(rackFrameScrewType) * 2, 10], center = true);
}
}
}
module mainRail() {
union() {
_frontRailSegment();
translate(v = [0, railFrontThickness, 0])
_connectingLBracketRailSegment();
translate(v = [frontFaceWidth-sideSupportExtraSpace, railFrontThickness + railOtherThickness + frontScrewSpacing, 0])
rotate(a = [0, 0, 90])
_sideSupportSegment();
translate(v = [0, railFrontThickness + railOtherThickness + frontScrewSpacing, 0]) {
_railFeet();
translate(v = [0, 0, railTotalHeight-railFootThickness])
_railFeet();
}
}
}
mainRail();
echo("Total Rail Height = ", railTotalHeight);

87
cases/rack2/screws.scad
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@ -1,93 +1,55 @@
/* Some common screw dimensions and helper functions/modules */
/* Some common screw dimensions */
inf = 400; // basically infinity
inf = 400;
/********************************************************************************/
// M3 dimensions
m3HoleRadiusSlack = 0.15;
m3Diameter = 3.0;
m3Radius = m3Diameter / 2.0;
m3RadiusSlacked = m3Radius + m3HoleRadiusSlack;
// legacy TODO: replace
m3ptr = m3RadiusSlacked;
// NUTS!
m3HexNutWidthAcrossFlats = 5.41;
m3HexNutWidthAcrossCorners = FtoG(m3HexNutWidthAcrossFlats);
m3HexNutThickness = 2.18;
module m3HexNutPocketNegative() {
hexNutPocketNegative(m3RadiusSlacked,
m3HexNutWidthAcrossCorners/2 + 0.1,
m3HexNutThickness + 0.2);
}
// TODO: remove test
*difference() {
cube(size=[8,12,5], center=true);
rotate(a=[0,0,20])
m3HexNutPocketNegative();
}
*m3HexNutPocketNegative();
/********************************************************************************/
// M4 dimensions
m4HoleRadiusSlack = 0.15;
m4Diameter = 4.0;
m4Radius = m4Diameter / 2.0;
m4RadiusSlacked = m4Radius + m4HoleRadiusSlack;
m4HexNutWidthAcrossFlats = 6.89;
m4HexNutWidthAcrossCorners = FtoG(m4HexNutWidthAcrossFlats);
m4HexNutThickness = 3.07;
module m4HexNutPocketNegative() {
hexNutPocketNegative(m4RadiusSlacked,
/********************************************************************************/
function screwRadiusSlacked(screwType) =
(screwType == "m3")
? m3RadiusSlacked
: (screwType == "m4")
? m4RadiusSlacked
: error("Unsupported screw type");
module hexNutPocket_N(screwType) {
if (screwType == "m3") {
hexNutPocketHelper_N(m3RadiusSlacked,
m3HexNutWidthAcrossCorners / 2 + 0.1,
m3HexNutThickness + 0.2);
} else if (screwType == "m4") {
hexNutPocketHelper_N(m4RadiusSlacked,
m4HexNutWidthAcrossCorners / 2 + 0.1,
m4HexNutThickness + 0.2);
} else {
error("Unsupported screw type");
}
}
// TODO: remove test
*difference() {
translate(v=[0,1,0])
cube(size=[10,12,6], center=true);
rotate(a=[0,0,20])
m4HexNutPocketNegative();
}
*m4HexNutPocketNegative();
/********************************************************************************/
// Convert a regular hexagon widthAcrossFlats to widthAcrossCorners
function FtoG(widthAcrossFlats) = widthAcrossFlats * (2/sqrt(3));
// Convert a regular hexagon widthAcrossCorners to widthAcrossFlats
function GtoF(widthAcrossCorners) = widthAcrossCorners * (sqrt(3)/2);
module hexNutPocketNegative(
module hexNutPocketHelper_N(
innerRadius,
widthAcrossCorners,
thickness)
{
union() {
hull() {
@ -111,3 +73,8 @@ module hexNutPocketNegative(
}
}
// Convert a regular hexagon widthAcrossFlats to widthAcrossCorners
function FtoG(widthAcrossFlats) = widthAcrossFlats * (2 / sqrt(3));
// Convert a regular hexagon widthAcrossCorners to widthAcrossFlats
function GtoF(widthAcrossCorners) = widthAcrossCorners * (sqrt(3) / 2);