update stack connector

helper/screws.scad

@@ -15,7 +15,7 @@ m3CounterSunkHeadLength = 1.7;
 
 m3HexNutWidthAcrossFlats = 5.41;
 m3HexNutWidthAcrossCorners = FtoG(m3HexNutWidthAcrossFlats);
-m3HexNutThickness = 2.18;
+m3HexNutThickness = 2.2;
 
 m3HeatSetInsertSlotRadiusSlack = -0.1;
 m3HeatSetInsertSlotHeightSlack = 0.5;
@@ -80,17 +80,17 @@ module counterSunkHead_N(screwType, screwExtension=0, headExtension=0) {
 }
 
 
-module hexNutPocket_N(screwType) {
+module hexNutPocket_N(screwType, openSide=true) {
   if (screwType == "m3") {
-    hexNutPocketHelper_N(m3RadiusSlacked, m3HexNutWidthAcrossCorners / 2 + 0.1, m3HexNutThickness + 0.2);
+    hexNutPocketHelper_N(m3RadiusSlacked, m3HexNutWidthAcrossCorners / 2 + 0.1, m3HexNutThickness + 0.2, openSide=openSide);
   } else if (screwType == "m4") {
-    hexNutPocketHelper_N(m4RadiusSlacked, m4HexNutWidthAcrossCorners / 2 + 0.1, m4HexNutThickness + 0.2);
+    hexNutPocketHelper_N(m4RadiusSlacked, m4HexNutWidthAcrossCorners / 2 + 0.1, m4HexNutThickness + 0.2, openSide=openSide);
   } else {
     error("Unsupported screw type");
   }
 }
 
-module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness) {
+module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness, openSide=true) {
   union() {
     hull() {
       // hexagonal cylinder representing where the nut should fit
@@ -105,6 +105,7 @@ module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness) {
     translate(v = [0, 0, - 10])
     cylinder(r = innerRadius, h = inf50, $fn = 32);
 
+    if (openSide) {
       hull() {
         translate(v = [inf50, 0, 0])
         cylinder(r = innerRadius, h = inf50, $fn = 32);
@@ -112,6 +113,7 @@ module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness) {
       }
     }
   }
+}
 
 // Convert a regular hexagon widthAcrossFlats to widthAcrossCorners
 function FtoG(widthAcrossFlats) = widthAcrossFlats * (2 / sqrt(3));

rack/stackConnector.scad

@@ -4,13 +4,15 @@ include <../misc/magnet.scad>
 
 connectorRectWidth = 10;
 connectorRectDepth = 10;
-connectorTotalHeight = 5;
+connectorTotalHeight = 10;
 connectorSocketMagnetExtrudeHeight = 1;
-connectorTaperStartHeight = 2;
+connectorTaperStartHeight = 3;
 
 connectorRectPlugSlack = -0.1;
 connectorRectSocketSlack = 0.1;
 
+connectorBottomToScrew = 6;
+
 module stackConnectorBase(rectSlack) {
 
   wSlacked = connectorRectWidth + rectSlack;
@@ -21,9 +23,9 @@ module stackConnectorBase(rectSlack) {
     square(size = [wSlacked, dSlacked]);
   }
 
-  module connMagnetMount() {
+  module connTop() {
     linear_extrude(height=eps)
-    circle(r=magnetRSlacked);
+    circle(r=3);
   }
 
   hull() {
@@ -38,45 +40,29 @@ module stackConnectorBase(rectSlack) {
     connRect();
 
     translate(v=[wSlacked/2, dSlacked/2, connectorTotalHeight])
-    connMagnetMount();
+    connTop();
   }
 }
 
-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;
+  bevelSlack = 0.6;
   bevelR = wSlacked + bevelSlack;
   bevelW = dSlacked + bevelSlack;
-  bevelH = 0.5;
+  bevelH = 0.6;
 
+  screwExtension = 4;
+
+  union() {
     stackConnectorBase(connectorRectSocketSlack);
 
-  translate(v=[wSlacked/2, wSlacked/2, connectorTotalHeight - connectorSocketMagnetExtrudeHeight])
+    translate(v = [-screwExtension, connectorRectDepth/2, connectorBottomToScrew])
-  cylinder(r=magnetRSlacked, h=magnetHSlacked);
+    rotate(a = [0, -90, 0])
+    counterSunkHead_N(rackFrameScrewType, screwExtension = 5, headExtension = 10);
 
     // bevel at the lip of the socket to guide the plug, as well as mitigate elephant foot during 3d printing
     hull() {
@@ -89,3 +75,16 @@ module stackConnectorSocket_N() {
       square(size = [bevelR, bevelW]);
     }
   }
+}
+
+module stackConnectorPlug() {
+
+  difference() {
+    stackConnectorBase(connectorRectPlugSlack);
+
+    translate(v=[connectorRectWidth/2,connectorRectDepth/2,connectorBottomToScrew])
+    rotate(a=[0,0,90])
+    rotate(a=[90,0,0])
+    hexNutPocket_N(rackFrameScrewType, openSide=false);
+  }
+}

rack/yBar.scad

@@ -13,7 +13,12 @@ include <./yBarBasePlateConnector.scad>
 include <./side/yBarSideWallConnector.scad>
 include <./sharedVariables.scad>
 
-*yBar();
+yBar();
+
+translate(v=[20,0,0])
+*stackConnectorPlug();
+
+*stackConnectorSocket_N();
 
 module yBar() {