rename connectingBar to yBar, and add mockup of new xBar. Also mess around with the full assembly

misc/magnet.scad

@@ -1,6 +1,11 @@
 
 
 // Dimensions for small cylindrical neodymium magnets that I bought off Amazon
-magnetD = 6;
+magnetR = 3;
-magnetR = magnetD/2;
+magnetH = 1.7;
-magnetH = 1.7;
+
+magnetRSlack = 0.1;
+magnetHSlack = 0.05;
+
+magnetRSlacked = magnetR + magnetRSlack;
+magnetHSlacked = magnetH + magnetHSlack;

rack2/assemble.scad

@@ -1,8 +1,41 @@
 include <../math.scad>
 include <./config.scad>
 include <./mainRail.scad>
-include <./sideBar.scad>
+include <./yBar.scad>
+include <./xBar.scad>
 
+translate(v=[12,2,18])
+mainRail();
 
-*mainRail();
+translate(v=[12,2 + 200,18])
-sideBar();
+mirror(v=[0,1,0])
+mainRail();
+
+translate(v=[12 + 216,2,18])
+mirror(v=[1,0,0])
+mainRail();
+
+translate(v=[12 + 216,2 + 200,18])
+rotate(a=[0,0,180])
+mainRail();
+
+xyPlane();
+
+translate(v=[0,0,250])
+mirror(v=[0,0,1])
+xyPlane();
+
+module xyPlane() {
+  yBar();
+
+  translate(v = [240, 0, 0])
+  mirror(v = [1, 0, 0])
+  yBar();
+
+  translate(v = [30, 0, 0])
+  xBar();
+
+  translate(v = [30, 206, 0])
+  mirror(v = [0, 1, 0])
+  xBar();
+}

rack2/config.scad

@@ -20,7 +20,7 @@ maxUnitDepth = 200;
 screwDiff = 10;
 
 // Number screw slots on the main rail. Affects build volume.
-numRailScrews = 3;
+numRailScrews = 20;
 
 // Screw type used for rackmount units. See screws.scad.
 mainRailScrewType = "m4";

rack2/mainRail.scad

@@ -31,6 +31,7 @@ railTotalDepth = railFrontThickness+sideSupportDepth;
 
 echo("Total Rail Height: ", railTotalHeight);
 
+// Also known as the z-bar :)
 module mainRail() {
 
   union() {

rack2/misc/magnet.scad

@@ -1,11 +0,0 @@
-
-
-// Dimensions for small cylindrical neodymium magnets that I bought off Amazon
-magnetR = 3;
-magnetH = 1.7;
-
-magnetRSlack = 0.1;
-magnetHSlack = 0.05;
-
-magnetRSlacked = magnetR + magnetRSlack;
-magnetHSlacked = magnetH + magnetHSlack;

rack2/sideBar.scad

@@ -1,132 +0,0 @@
-include <../math.scad>
-include <./config.scad>
-include <./screws.scad>
-include <./misc/magnet.scad>
-
-include <./mainRail.scad>
-include <./helper/sphericalFilet.scad>
-include <./helper/cylindricalFilet.scad>
-
-// TODO clean up
-// TODO: How do I nicely explain this?
-railSlotSpacing = 3;
-sideSpacing = 12;
-
-barDepth = maxUnitDepth + 2*railSlotSpacing;
-barWidth = railSlotSpacing + railTotalWidth + sideSpacing;
-barHeight = 15;
-
-barWallThickness = 3;
-barRoundness = 5;
-
-echo("Bar total depth: ", barDepth);
-echo("Bar total width: ", barWidth);
-
-
-module sideBar() {
-
-  module positive() {
-      difference() {
-        sphericalFiletEdge(barWidth, barDepth, barHeight, barRoundness);
-
-        translate(v = [barWallThickness, 32, barWallThickness])
-        cylindricalFiletEdge(barWidth, barDepth-32*2, barHeight, barRoundness);
-      }
-
-  }
-
-  module stackConn_N() {
-    taperH = 2;
-
-    translate(v=[0,0,0])
-    cube(size = [10, 10, taperH]);
-
-
-    hull() {
-      translate(v = [0, 0, taperH])
-      linear_extrude(height=eps)
-      square(size = [10, 10]);
-
-      translate(v=[5,5,5])
-      linear_extrude(height=eps)
-      circle(r=magnetRSlacked);
-    }
-
-    // -1 is for male support
-    translate(v=[5,5,5 - 1])
-    cylinder(r=magnetRSlacked, h=magnetHSlacked);
-  }
-
-  // TODO move this to custom file
-  // negatives on the y-z plane to be imprinted on the side of the main
-  module frontBarConnector_N() {
-
-    y1 = 6;
-    y2 = 27;
-    z = 6;
-
-    translate(v = [-m3HeatSetInsertSlotHeightSlacked, y1, z])
-    rotate(a = [0, 90, 0])
-    heatSetInsertSlot_N(rackFrameScrewType);
-
-    translate(v = [-m3HeatSetInsertSlotHeightSlacked, y2, z])
-    rotate(a = [0, 90, 0])
-    heatSetInsertSlot_N(rackFrameScrewType);
-
-    // TODO fix this up, no center=true
-    translate(v=[-1, y1 + (y2 - y1)/2, 0])
-    rotate(a=[0,45,0])
-    cube(size=[3,10,6], center=true);
-  }
-
-  // TODO move this in custom file, like for railFeetSlot_N
-  module sideWallConnector_N() {
-
-    lugW = 7;
-    lugD = 20;
-    lugH = 2;
-
-    insertDw = lugW/2;
-
-    insertDd = lugD - 4;
-
-    translate(v=[0,0, -lugH])
-    cube(size=[lugW, lugD, lugH]);
-
-    translate(v=[insertDw, insertDd, -(m3HeatSetInsertSlotHeightSlacked + lugH)])
-    heatSetInsertSlot_N(rackFrameScrewType);
-  }
-
-
-  module singleCorner_N() {
-    union() {
-      translate(v=[5,5,0])
-      stackConn_N();
-
-      translate(v=[barWidth - (railTotalWidth + railSlotSpacing), railSlotSpacing, barHeight - railFootThickness])
-      railFeetSlot_N();
-
-      translate(v=[barWidth + eps, 0,0])
-      frontBarConnector_N();
-
-
-      translate(v=[barWidth - (railTotalWidth + railSlotSpacing) - 9, railSlotSpacing, barHeight])
-      sideWallConnector_N();
-    }
-  }
-
-  module sideBar() {
-    difference() {
-      positive();
-
-      singleCorner_N();
-
-      translate(v=[0,barDepth,0])
-      mirror(v=[0,1,0]) {
-        singleCorner_N();
-      }
-    }
-
-  }
-  sideBar();
-}

rack2/stackConnector.scad

@@ -0,0 +1,111 @@
+include <../math.scad>
+include <../misc/magnet.scad>
+include <../common.scad>
+
+connectorTaperStartHeight = 2;
+connectorRectWidth = 10;
+connectorRectDepth = 10;
+
+connectorTotalHeight = 5;
+
+connectorRectPlugSlack = -0.1;
+connectorRectSocketSlack = 0.1;
+
+connectorSocketMagnetExtrudeHeight = 1;
+
+module stackConnectorBase(rectSlack) {
+
+  _wSlacked = connectorRectWidth + rectSlack;
+  _dSlacked = connectorRectDepth + rectSlack;
+
+  module connRect() {
+    linear_extrude(height=eps)
+    square(size = [_wSlacked, _dSlacked]);
+  }
+
+  module connMagnetMount() {
+    linear_extrude(height=eps)
+    circle(r=magnetRSlacked);
+  }
+
+  hull() {
+    connRect();
+
+    translate(v=[0,0,connectorTaperStartHeight])
+    connRect();
+  }
+
+  hull() {
+    translate(v = [0, 0, connectorTaperStartHeight])
+    connRect();
+
+    translate(v=[_wSlacked/2, _dSlacked/2, connectorTotalHeight])
+    connMagnetMount();
+  }
+}
+
+module stackConnectorPlug() {
+  assert(magnetHSlacked > connectorSocketMagnetExtrudeHeight);
+
+  _wSlacked = connectorRectWidth + connectorRectPlugSlack;
+  _dSlacked = connectorRectDepth + connectorRectPlugSlack;
+
+  magnetLevelHeight = connectorTotalHeight - (magnetHSlacked - connectorSocketMagnetExtrudeHeight);
+
+  difference() {
+
+    intersection() {
+      stackConnectorBase(connectorRectPlugSlack);
+      cube(size=[_dSlacked, _wSlacked, magnetLevelHeight]);
+    }
+
+      translate(v = [_wSlacked/2, _dSlacked/2, magnetLevelHeight - magnetHSlacked])
+      cylinder(r = magnetRSlacked, h = magnetHSlacked);
+
+  }
+}
+
+module stackConnectorSocket_N() {
+
+  _wSlacked = connectorRectWidth + connectorRectSocketSlack;
+  _dSlacked = connectorRectDepth + connectorRectSocketSlack;
+
+  _bevelSlack = 0.5;
+  _bevelR = _wSlacked + _bevelSlack;
+  _bevelW = _dSlacked + _bevelSlack;
+  _bevelH = 0.5;
+
+
+  stackConnectorBase(connectorRectSocketSlack);
+
+  translate(v=[_wSlacked/2, _wSlacked/2, connectorTotalHeight - connectorSocketMagnetExtrudeHeight])
+  cylinder(r=magnetRSlacked, h=magnetHSlacked);
+
+  // bevel at the lip of the socket to guide the plug, as well as mitigate elephant foot during 3d printing
+  hull() {
+    translate(v=[0,0,_bevelH])
+    linear_extrude(height=eps)
+    square(size = [_wSlacked, _dSlacked]);
+
+    translate(v=[-_bevelSlack/2, -_bevelSlack/2, 0])
+    linear_extrude(height=eps)
+    square(size = [_bevelR, _bevelW]);
+  }
+}
+
+module test() {
+  difference() {
+    union() {
+      translate(v = [-2.5, -2.5, 0])
+      cube(size = [15, 15, 10]);
+
+      translate(v = [0, 0, 10])
+      stackConnectorPlug();
+    }
+
+    stackConnectorSocket_N();
+  }
+}
+
+*test();
+

rack2/xBar.scad

@@ -0,0 +1,34 @@
+include <../helper/sphericalFilet.scad>
+include <../helper/cylindricalFilet.scad>
+include <./config.scad>
+include <./screws.scad>
+
+xBarDepth = 180;
+xBarWidth = 32;
+xBarHeight = 15;
+
+xBarWallThickness = 3;
+xBarRoundness = 5;
+
+module xBar() {
+
+  module positive() {
+    mirror(v=[0,1,0])
+    rotate(a=[0,0,-90])
+    difference() {
+      cylindricalFiletEdge(xBarWidth, xBarDepth, xBarHeight, xBarRoundness);
+
+      translate(v = [xBarWallThickness, xBarWallThickness, xBarWallThickness])
+      cylindricalFiletEdge(xBarWidth, xBarDepth - 2*xBarWallThickness, xBarHeight, xBarRoundness);
+    }
+  }
+
+  module xBar() {
+    positive();
+  }
+
+  xBar();
+}
+
+
+//xBar();

rack2/yBar.scad

@@ -0,0 +1,114 @@
+include <../math.scad>
+include <../misc/magnet.scad>
+include <../helper/sphericalFilet.scad>
+include <../helper/cylindricalFilet.scad>
+include <./config.scad>
+include <./screws.scad>
+include <./mainRail.scad>
+include <./stackConnector.scad>
+
+// TODO clean up
+// TODO: How do I nicely explain this?
+railSlotSpacing = 3;
+sideSpacing = 12;
+
+yBarDepth = maxUnitDepth + 2*railSlotSpacing;
+yBarWidth = railSlotSpacing + railTotalWidth + sideSpacing;
+yBarHeight = 15;
+
+yBarWallThickness = 3;
+yBarRoundness = 5;
+
+echo("Bar total depth: ", yBarDepth);
+echo("Bar total width: ", yBarWidth);
+
+
+module yBar() {
+
+  module positive() {
+    difference() {
+      sphericalFiletEdge(yBarWidth, yBarDepth, yBarHeight, yBarRoundness);
+
+      translate(v = [yBarWallThickness, 32, yBarWallThickness])
+      cylindricalFiletEdge(yBarWidth, yBarDepth-32*2, yBarHeight, yBarRoundness);
+    }
+  }
+
+  // TODO move this to custom file
+  // negatives on the y-z plane to be imprinted on the side of the main
+  module frontBarConnector_N() {
+
+    y1 = 6;
+    y2 = 27;
+    z = 6;
+
+    translate(v = [-m3HeatSetInsertSlotHeightSlacked, y1, z])
+    rotate(a = [0, 90, 0])
+    heatSetInsertSlot_N(rackFrameScrewType);
+
+    translate(v = [-m3HeatSetInsertSlotHeightSlacked, y2, z])
+    rotate(a = [0, 90, 0])
+    heatSetInsertSlot_N(rackFrameScrewType);
+
+    // TODO fix this up, no center=true
+    translate(v = [-1, y1+(y2-y1)/2, 0])
+    rotate(a = [0, 45, 0])
+    cube(size = [3, 10, 6], center = true);
+  }
+
+  // TODO move this in custom file, like for railFeetSlot_N
+  module sideWallConnector_N() {
+
+    lugW = 7;
+    lugD = 20;
+    lugH = 2;
+
+    insertDw = lugW/2;
+
+    insertDd = lugD-4;
+
+    translate(v = [0, 0, -lugH])
+    cube(size = [lugW, lugD, lugH]);
+
+    translate(v = [insertDw, insertDd, -(m3HeatSetInsertSlotHeightSlacked+lugH)])
+    heatSetInsertSlot_N(rackFrameScrewType);
+  }
+
+
+  module singleCornerNoStackConnector_N() {
+    union() {
+      translate(v = [5, 5, 0])
+      stackConnectorSocket_N();
+
+      translate(v = [yBarWidth-(railTotalWidth+railSlotSpacing), railSlotSpacing, yBarHeight-railFootThickness])
+      railFeetSlot_N();
+
+      translate(v = [yBarWidth+eps, 0, 0])
+      frontBarConnector_N();
+
+      translate(v = [yBarWidth-(railTotalWidth+railSlotSpacing)-9, railSlotSpacing, yBarHeight])
+      sideWallConnector_N();
+    }
+  }
+
+  module sideBar() {
+
+    module mirrorOtherCorner() {
+      children(0);
+
+      translate(v = [0, yBarDepth, 0])
+      mirror(v = [0, 1, 0]) {
+        children(0);
+      }
+    }
+
+    difference() {
+      positive();
+
+      mirrorOtherCorner()
+      singleCornerNoStackConnector_N();
+    }
+  }
+
+  sideBar();
+}