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improve support side rail. also begin refactoring rack-mount to make more friendly

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This commit is contained in:
zhao
2023-08-28 23:31:06 -04:00
parent 54647aa334
commit 3167feea03
5 changed files with 142 additions and 60 deletions
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53
rack-mount/enclosed-box/boxHelper.scad Normal file
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include <../../rack/sharedVariables.scad>
include <../common.scad>
use <../sideRail.scad>
use <../frontBoxHolder.scad>
/*
(WIP) Enclosed box mounting system:
Helper file to use semi-enclosed side rails and a front plate to mount a box.
This system does not require any mounting holes for the enclosed box.
!!! Please also make sure that the correct rack frame preset is set in rackFrame.scad !!!
*/
// begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
boxWidth = 160;
boxHeight = 27;
boxDepth = 100;
railDefaultThickness = 1.2;
zOrientation = "middle";
// Does not affect any part dimensions. Set this to true to visualize how a box wound be mounted.
visualize = true;
// end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
#cube(size=[boxWidth, boxDepth, boxHeight]);
sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation);
translate(v=[boxWidth,0,0])
mirror(v=[1,0,0])
sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation);
translate(v=[0,0,10])
rotate(a=[-90,0,0])
*frontBoxHolder(
u=2,
plateThickness=3,
cutoutOffsetX=(rackMountScrewWidth-147)/2,
cutoutOffsetY=4.25,
cutoutX=147,
cutoutY=21.5,
support=true,
supportedZ=boxHeight,
supportWidth=120,
supportDepth=5,
supportRailBaseThickness=1.75
);

2
rack-mount/print/sideSupportRail_P1.scad
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@ -1,3 +1,3 @@
use <../sideRail.scad>
sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.2, supportedY=101.5, supportedX=159);
sideSupportRailBase(top=true, defaultThickness=1.4, supportedZ=27.2, supportedY=101.5, supportedX=159);

2
rack-mount/print/sideSupportRail_P2.scad
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@ -1,4 +1,4 @@
use <../sideRail.scad>
mirror(v=[1,0,0])
sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.2, supportedY=101.5, supportedX=159);
sideSupportRailBase(top=true, defaultThickness=1.4, supportedZ=27.2, supportedY=101.5, supportedX=159);

2
rack-mount/print/tray_P.scad
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@ -1,7 +1,7 @@
use <../tray.scad>
/*
Parametric rack-mount tray -
Parametric rack-mount tray:
Dimensions can be adjusted using the variables below. You can also add mounting holes to fasten things that have
screw holes at the bottom.

143
rack-mount/sideRail.scad
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@ -3,115 +3,144 @@ include <../config/common.scad>
include <../rack/sharedVariables.scad>
include <./common.scad>
sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.2, supportedY=101.5, supportedX=159);
//sideSupportRailBase(top=true, defaultThickness=1.5, supportedZ=27.2, supportedY=101.5, supportedX=159);
// 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=27.5, supportedY=101.5, supportedX=159) {
module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrientation="middle", defaultThickness=2) {
// TODO simplify this
mountBlockHeight = 10;
mountBlockDepth = 10;
screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
sideRailScrewToMainRailFrontDx = frontScrewSpacing+railFrontThickness;
railLength = max(sideRailScrewMountDist + sideRailScrewToMainRailFrontDx + mountBlockDepth/2, supportedY+backThickness);
railBaseThickness = baseThickness;
railSideThickness = sideThickness;
railLength = max(sideRailScrewMountDist + sideRailScrewToMainRailFrontDx + mountBlockDepth/2, supportedY+defaultThickness);
railBaseThickness = defaultThickness; // default thickness value
railSideThickness = 4;
railBackThickness = 3;
railBaseWidth = 15;
railSideHeight = supportedZ + railBaseThickness*2 + overhangSlack;
// Minimum U to enclose box, while also have a minimum defaultThickness for top and bottom.
minU = max(1, ceil((supportedZ + 2*railBaseThickness) / uDiff)-1);
railBottomThickness =
(zOrientation == "middle")
? (((minU+1) * uDiff) - supportedZ)/2
: (zOrientation == "bottom")
? railBaseThickness
: railBaseThickness;
assert(supportedX <= maxUnitWidth);
assert (zOrientation == "middle" || zOrientation == "bottom", "Z-Orientation not supported");
assert(railBottomThickness >= railBaseThickness);
railSideHeight = supportedZ + railBaseThickness + railBottomThickness + overhangSlack;
frontMountPad = (sideRailScrewToMainRailFrontDx-mountBlockDepth/2)-xySlack;
translate(v=[-railSideThickness, 0, -railBottomThickness])
applyMainRailMounts()
sideSupportRailBase();
echo(frontScrewSpacing);
echo(sideRailScrewToMainRailFrontDx);
module applyMainRailMounts() {
mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
assert(mountBlockExtension >= 10);
apply_p() {
union() {
translate(v = [0, frontMountPad, 0])
mountBlockColumn(mountBlockExtension=mountBlockExtension, u=u);
translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
mountBlockColumn(mountBlockExtension=mountBlockExtension, u=u);
}
mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
minHexNutPocketToXYDist = mountBlockHeight/2;
minHexNutPocketToXZDist = mountBlockDepth/2;
minHexNutPocketToYZDist = 4;
screwU = floor((railSideHeight) / uDiff)-1;
apply_pn() {
mountBlockPositive();
mountBlockNegative();
children(0);
}
}
module mountBlockColumn(mountBlockExtension, u) {
module mountBlockPositive() {
translate(v = [0, frontMountPad, 0])
singleMountBlockPositive();
translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
singleMountBlockPositive();
}
difference() {
module mountBlockNegative() {
translate(v = [0, frontMountPad, 0])
singleMountBlockNegative();
translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
singleMountBlockNegative();
}
module singleMountBlockPositive() {
translate(v = [-mountBlockExtension, 0, 0])
cube(size = [mountBlockExtension, mountBlockDepth, railSideHeight]);
cube(size = [mountBlockExtension, mountBlockDepth, railSideHeight]);
}
union() {
module singleMountBlockNegative() {
nutPocket();
translate(v = [0, 0, uDiff*screwU])
nutPocket();
if (double) {
translate(v=[0,0,uDiff * u]) // screwMountToGlobalZ
nutPocket();
}
module nutPocket() {
translate(v=[-mountBlockExtension+minHexNutPocketToYZDist, minHexNutPocketToXZDist, minHexNutPocketToXYDist])
rotate(a=[-90,0,90])
hexNutPocket_N(rackFrameScrewType, openSide=false, backSpace=min((railSideThickness-1)+mountBlockExtension-minHexNutPocketToYZDist,15));
}
}
module nutPocket() {
translate(v=[-mountBlockExtension/2,mountBlockDepth/2,mountBlockHeight/2]) // screwMountToGlobalZ
rotate(a=[90,0,0])
rotate(a=[0,90,0])
hexNutPocket_N(rackFrameScrewType, openSide=false);
}
}
module sideSupportRailBase() {
backThickness = 3;
difference () {
union() {
cube(size = [railBaseWidth, railLength, railBaseThickness]);
cube(size = [railBaseWidth, railLength, railBottomThickness]);
cube(size = [railSideThickness, railLength, railSideHeight]);
// back support
translate(v = [0, max(railLength-backThickness, supportedY), 0])
cube(size = [railBaseWidth, backThickness, railSideHeight]);
translate(v = [0, max(railLength-railBackThickness, supportedY), 0])
cube(size = [railBaseWidth, railBackThickness, railSideHeight]);
// back support for box
translate(v = [0, supportedY, 0])
cube(size = [railBaseWidth, backThickness, railSideHeight]);
cube(size = [railBaseWidth, railBackThickness, railSideHeight]);
// top support
if (top) {
translate(v = [0, 0, railSideHeight-baseThickness])
translate(v = [0, 0, railSideHeight-railBaseThickness])
cube(size = [railBaseWidth, railLength, railBaseThickness]);
}
}
union() {
distanceFromSeparator = 3;
r = 5;
r = 4;
boxDy = frontMountPad+r+mountBlockDepth+distanceFromSeparator;
boxDz = baseThickness+distanceFromSeparator+r;
translate(v=[0,boxDy,boxDz])
minkowski() {
cube(size = [sideThickness, supportedY-(boxDy+distanceFromSeparator+r), railSideHeight-2*boxDz]);
sphere(r=r);
}
translate(v=[0,supportedY+distanceFromSeparator+r+backThickness,boxDz])
minkowski() {
cube(size = [sideThickness, 25, railSideHeight-2*boxDz]);
sphere(r=r);
ventDy1 = frontMountPad+mountBlockDepth+distanceFromSeparator;
ventY1 = min(supportedY-(ventDy1+distanceFromSeparator), sideRailScrewMountDist-(2*distanceFromSeparator+mountBlockDepth));
ventDy2 = max(ventDy1, supportedY+railBackThickness+distanceFromSeparator);
ventY2 = max(0, railLength - (ventDy2 + distanceFromSeparator + mountBlockDepth));
ventDz = railBottomThickness+distanceFromSeparator+r;
ventZ = railSideHeight-(ventDz+distanceFromSeparator+r+railBaseThickness);
if (ventY1 > 2*r) {
translate(v = [0, ventDy1+r, ventDz])
minkowski() {
cube(size = [inf, ventY1-2*r, ventZ]);
sphere(r = r);
}
}
cylindricalFiletNegative(p0=[railBaseWidth,0,0],p1=[railBaseWidth,0,inf], n=[1,-1,0],r=4);
if (ventY2 > 2*r) {
translate(v = [0, ventDy2+r, ventDz])
minkowski() {
cube(size = [inf, ventY2-2*r, ventZ]);
sphere(r = r);
}
}
cylindricalFiletNegative(p0=[railBaseWidth,0,0],p1=[railBaseWidth,0,inf], n=[1,-1,0],r=r);
}
}
}