update rack-mount items

TODO.md

@@ -7,6 +7,7 @@
 - Start working on actual cases
 - Figure out why sidewall build is so slow
 - Tidy up imports
+- Standardize meaning of `U`
 
 ### Ideas
 - Clean up `sharedVariables.scad`!!!

helper/keystone.scad

@@ -1,4 +1,6 @@
 
+include <../config/slack.scad>
+
 // rj45 slot-to-slot keystone jack model and negative
 keystoneMainBodyWidth = 15.0;
 keystoneMainBodyHeight = 16.90;
@@ -17,28 +19,29 @@ frontToSideLugFront = 10.63;
 
 module rj45Keystone() {
     // main keystone body (no hooks or lugs)
-    cube(size=[keystoneMainBodyWidth, keystoneMainBodyDepth, keystoneMainBodyHeight]);
+    cube(size=[keystoneMainBodyWidth + xySlack, keystoneMainBodyDepth + xySlack, keystoneMainBodyHeight]);
 
     // slot for top hook
     translate(v=[0,frontToHookCatch,0])
-        cube(size=[keystoneMainBodyWidth, keystoneMainBodyDepth -frontToHookCatch, heightWithHookBody]);
-    cube(size=[keystoneMainBodyWidth, frontToHookCatch, heightWithHookCatch]);
+    cube(size=[keystoneMainBodyWidth + xySlack, keystoneMainBodyDepth-frontToHookCatch + xySlack, heightWithHookBody]);
+
+    cube(size=[keystoneMainBodyWidth + xySlack, frontToHookCatch + xySlack, heightWithHookCatch]);
 
     // slots for side lugs
     translate(v=[-sideLugWidth, frontToSideLugFront,0])
-        cube(size=[widthWithSideLugs, keystoneMainBodyDepth-frontToSideLugFront, keystoneMainBodyHeight]);
+    cube(size=[widthWithSideLugs + xySlack, keystoneMainBodyDepth-frontToSideLugFront + xySlack, keystoneMainBodyHeight]);
 
     // slots for bottom lugs
     translate(v=[0,0,-(heightWithBottomLug-keystoneMainBodyHeight)])
-        cube(size=[keystoneMainBodyWidth, frontToBottomLugBack, keystoneMainBodyHeight]);
+    cube(size=[keystoneMainBodyWidth + xySlack, frontToBottomLugBack + xySlack, keystoneMainBodyHeight]);
 
 }
 
 module rj45KeystoneJack_N() {
     translate(v=[0,-4,0.5]) // why?
-        intersection() {
-            translate(v=[-2.5,4,-4])
-                cube(size=[20,6,28]);
-            rj45Keystone();
-        }
+    intersection() {
+        translate(v=[-2.5,4,-4])
+        cube(size=[20,6,28]);
+        rj45Keystone();
+    }
 }

helper/math.scad

@@ -1,7 +1,7 @@
 // Some misc math-y utils
 
 $fn=64;
-eps=0.0001;
+eps=0.001;
 inf10 = 10;
 inf50 = 50;
 inf1000 = 1000;

rack-mount/frontBoxHolder.scad

@@ -0,0 +1,10 @@
+// To be used with closed sideRails to fully encapsulate a box
+
+include <../config/common.scad>
+include <../helper/common.scad>
+use <./plateBase.scad>
+
+module frontBoxHolder(plateThickness=3, plate) {
+
+
+}

rack-mount/patchPanel.scad

@@ -0,0 +1,35 @@
+include <../config/common.scad>
+include <../helper/common.scad>
+include <../rack/sharedVariables.scad>
+use <./plateBase.scad>
+
+
+patchPanel(slots=2);
+
+module patchPanel (slots=8) {
+    difference() {
+        plateThickness = 3;
+        keystoneSpacing = 19;
+        supportPlateThickness = 5.9;
+        supportPlateHeight = 29;
+        supportPlateEdgeSpacing = 3;
+        supportPlateWidth = slots * keystoneSpacing + supportPlateEdgeSpacing;
+
+        leftRailScrewToSupportDx = railScrewHoleToInnerEdge+4;
+        railScrewToEdge = 4.5;
+
+        union() {
+            plateBase(U = 2, plateThickness = plateThickness, screwType = mainRailScrewType,  screwToXEdge=railScrewToEdge, screwToYEdge=railScrewToEdge, filletR = 2);
+            translate(v = [leftRailScrewToSupportDx, - railScrewToEdge, - supportPlateThickness])
+            cube(size = [supportPlateWidth, supportPlateHeight, supportPlateThickness]);
+        }
+
+        union() {
+            for (i = [0:slots-1]) {
+                translate(v = [leftRailScrewToSupportDx+supportPlateEdgeSpacing + i*keystoneSpacing, 0, eps])
+                rotate(a = [-90, 0, 0])
+                rj45KeystoneJack_N();
+            }
+        }
+    }
+}

rack-mount/plateBase.scad

@@ -3,7 +3,7 @@ include <./common.scad>
 
 plateBase(U=2, plateThickness=3, screwType="m4", filletR=2);
 
-module plateBase(U, plateThickness, screwType, screwToXEdge=4, screwToYEdge=4, filletR=2) {
+module plateBase(U, plateThickness, screwType, screwToXEdge=4.5, screwToYEdge=4.5, filletR=2) {
 
     assert(floor(U) == U && U > 0)
     assert(plateThickness > 0);
@@ -14,11 +14,12 @@ module plateBase(U, plateThickness, screwType, screwToXEdge=4, screwToYEdge=4, f
     plateLength = screwDx + 2*screwToXEdge;
     plateHeight = screwDy + 2*screwToYEdge;
 
-    translate(v=[0,0,-plateThickness]) // easier to work with
+    translate(v=[-screwToXEdge,-screwToYEdge,-plateThickness]) // easier to work with
     difference() {
         base();
 
         mirror4XY(p=[screwToXEdge, screwToYEdge], dx=screwDx, dy=screwDy)
+        translate(v=[0,0,plateThickness])
         cylinder(r=screwRadiusSlacked(screwType), h=plateThickness*2, center=true);
     }
 
@@ -26,7 +27,6 @@ module plateBase(U, plateThickness, screwType, screwToXEdge=4, screwToYEdge=4, f
         minkowski() {
             translate(v=[filletR, filletR, 0])
             cube(size = [plateLength-2*filletR, plateHeight-2*filletR, plateThickness]);
-
             cylinder(r=filletR, h=eps);
         }
     }

rack-mount/print/patchPanel_P.scad

@@ -0,0 +1,3 @@
+use <../patchPanel.scad>
+
+patchPanel(slots=8);

rack-mount/sideRail.scad

@@ -8,7 +8,7 @@ sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness
 // distance between front and back main rail screw mounts
 sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ);
 
-module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThickness=2, backThickness=2, supportedZ=26.5, supportedY=101.5, supportedX=159) {
+module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThickness=2, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159) {
 
   mountBlockHeight = 10;
   mountBlockDepth = 10;

rbuild.py

@@ -3,8 +3,9 @@
 import argparse
 import subprocess
 import os
-import sys
 
+PATH_TO_OPENSCAD = '/Applications/OpenSCAD.app/Contents/MacOS/OpenSCAD'
+PATH_TO_OPENSCAD_NIGHTLY = 'path/to/nightly/build'
 
 # For actual dimensions, please see profiles.scad.
 class BuildSizeConfig:
@@ -23,9 +24,9 @@ RACK_MOUNT_BUILD_TARGET_SUB_DIR = 'rack-mount'
 
 
 def main():
-    if not assert_os():
-        print("Linux Required for OpenSCAD CLI")
-        return
+
+    if not assertOpenscadExists():
+        print("Could not find OpenSCAD binary. Please make sure it's configured in rbuild.py. Currently only Darwin and Linux have been tested to work.")
 
     parser = argparse.ArgumentParser(
         prog='rbuild',
@@ -75,6 +76,10 @@ def main():
 def run_build(args):
 
     build_var = args.b
+
+    if build_var is None:
+        print("Please provide the build (-b) variable") # TODO redundant
+
     config_var = args.c
     target_var = args.t
     dz = args.dz
@@ -166,9 +171,9 @@ def find_scad_file(directory, filename):
 def run_openscad(options, nightly):
 
     if nightly:
-        command = ['openscad-nightly', '--enable', 'all']
+        command = [PATH_TO_OPENSCAD_NIGHTLY, '--enable', 'all']
     else:
-        command = ['openscad']
+        command = [PATH_TO_OPENSCAD]
 
     command += ['--export-format', 'binstl'] + options
     try:
@@ -178,14 +183,8 @@ def run_openscad(options, nightly):
         print('OpenSCAD command not found! '
               'Please make sure that you have OpenSCAD installed and can run OpenSCAD CLI commands. '
               '(Currently needs Linux for this)')
-
-
-def assert_os():
-    if sys.platform == 'linux':
-        return True
-    else:
-        return False
-
+def assertOpenscadExists():
+    return os.path.exists(PATH_TO_OPENSCAD)
 
 if __name__ == '__main__':
     main()