Add option for fixed side modules. This simplifies assembly and removes some awkward printing topology

README.md

@@ -27,28 +27,25 @@ Please see [the assembly guide](./assembly-guide).
 
 | Item                                                          | Name                      | Quantity | Comment                                                                                                                          |
 |---------------------------------------------------------------|---------------------------|----------|----------------------------------------------------------------------------------------------------------------------------------|
-| <img src="media/bom/fhcs_short.gif"  height="60" width="72">  | M3x8 FHCS                 | 8        | Extras are useful and inexpensive. If you plan on eventually stacking multiple racks together, don't hesitate to get a lot more. |
+| <img src="media/bom/fhcs_medium.gif"  height="60" width="72"> | M3x12 FHCS                | 12       | Extras are useful and inexpensive. If you plan on eventually stacking multiple racks together, don't hesitate to get a lot more. |
-| <img src="media/bom/fhcs_medium.gif"  height="60" width="72"> | M3x12 FHCS                | 12       | ☝️                                                                                                                               |
+| <img src="media/bom/fhcs_long.gif"  height="60" width="72">   | M3x16 FHCS                | 16       | ☝️                                                                                                                                |
-| <img src="media/bom/fhcs_long.gif"  height="60" width="72">   | M3x16 FHCS                | 16       | ☝️                                                                                                                               |
+| <img src="media/bom/hex_nut.gif"  height="60" width="72">     | M3 hex nut                | 28       | ☝️                                                                                                                                |
-| <img src="media/bom/hex_nut.gif"  height="60" width="72">     | M3 hex nut                | 36       | ☝️                                                                                                                               |
 | <img src="media/bom/dowel.gif"  height="60" width="72">       | 3x10 steel dowel pin      | 4        | 3mm diameter, 10mm height                                                                                                        |
 | <img src="media/bom/magnet.gif"  height="60" width="72">      | 6x2 neodymium disc magnet | 8        | 6mm diameter, 2mm height                                                                                                         |
 | <img src="media/bom/glue.gif"  height="60" width="72">        | super glue                | \>= 2ml  | Used to glue magnets to plastic                                                                                                  |
 
 
 ### Printing - Single Rack:
-| Part                                                         | Quantity |
+| Part                                                 | Quantity |
-|--------------------------------------------------------------|----------|
+|------------------------------------------------------|----------|
-| [Y-Bar](./rack/print/yBar_P.scad)                            | 4        |
+| [Left Y-Bar](./rack/print/yBarLeft_P.scad)           | 2        |
-| [X-Bar](./rack/print/xBar_P.scad)                            | 4        |
+| [Right Y-Bar](./rack/print/yBarRight_P.scad)         | 2        |
-| [Main Rail](./rack/print/mainRail_P.scad)                    | 4        |
+| [X-Bar](./rack/print/xBar_P.scad)                    | 4        |
-| [Left Magnet Module](./rack/print/magnetModuleLeft_P.scad)   | 2        |
+| [Main Rail](./rack/print/mainRail_P.scad)            | 4        |
-| [Right Magnet Module](./rack/print/magnetModuleRight_P.scad) | 2        |
+| [Left Side Wall](./rack/print/sideWallLeft_P.scad)   | 1        |
-| [Hinge Module](./rack/print/hingeModule.scad)                | 4        |
+| [Right Side Wall](./rack/print/sideWallRight_P.scad) | 1        |
-| [Left Side Wall](./rack/print/sideWallLeft_P.scad)           | 1        |
+| [XY-Plate](./rack/print/xyPlate_P.scad)              | 2        |
-| [Right Side Wall](./rack/print/sideWallRight_P.scad)         | 1        |
+| [Feet](./rack/print/rackFeet_P.scad) (optional)      | 2        |
-| [XY-Plate](./rack/print/xyPlate_P.scad)                      | 2        |
-| [Feet](./rack/print/rackFeet_P.scad) (optional)              | 2        |
 
 
 #### Notes: 

assembly-guide/README.md

@@ -8,7 +8,7 @@
 Slide in M3 hex nuts into the Y-bars - 4 times. Each corner should have 3 hex nuts:
 ![slideHexNutsIntoYBar](./gifs/slideHexNutsIntoYBar.gif)
 
-Glue magnets into magnet side-modules - 4 times:
+Glue magnets into magnet side-modules on the Y-bars - 4 times:
 ![addMagnetsToMagnetModules](./gifs/addMagnetsToMagnetModules.gif)
 
 Glue top and bottom magnets into side walls - 2 times:
@@ -17,14 +17,15 @@ Glue top and bottom magnets into side walls - 2 times:
 Insert top and bottom dowel rods into side walls - 2 times:
 ![insertDowelsIntoSideWall](./gifs/insertDowelsIntoSideWall.gif)
 
-Slide Y-bars into X-bars - 2 times:
+Slide Y-bars into X-bars. Do this 2 times. You should end up with 2 trays. Orientation on the Y-bars matters here; make sure that the magnets are on the same side:
 ![attachXBarWithYBar](./gifs/attachXBarWithYBar.gif)
 
 Screw together Y-bars and X-bars using 4 M3x16 FHCS screws (one screw per corner) - 2 times: 
 ![screwXBarAndYBar](./gifs/screwXBarAndYBar.gif)
 
-Screw in the side-modules with M3x8 FHCS screws. Orientation matters here. The magnets modules should be on the eventual front side, facing outwards, and the two hinge modules should be in the back. Do this 2 times (for both trays):
+<!-- This step is only needed if the fixedSideModules is set to false. -->
-![attachSideConnectorModulesToYBars](./gifs/attachSideConnectorModulesToYBars.gif)
+<!-- Screw in the side-modules with M3x8 FHCS screws. Orientation matters here. The magnets modules should be on the eventual front side, facing outwards, and the two hinge modules should be in the back. Do this 2 times (for both trays): -->
+<!-- ![attachSideConnectorModulesToYBars](./gifs/attachSideConnectorModulesToYBars.gif) -->
 
 Screw in the main rails with M3x16 FHCS screws.
 ![connectXYTrayWithMainRails](./gifs/connectXYTrayWithMainRails.gif)
@@ -49,4 +50,4 @@ Screw in feet using 4 M3x12 FHCS screws:
 ![screwFeet](./gifs/screwFeet.gif)
 
 
-**FIN**
+**FIN**

config/rackFrame.scad

@@ -1,5 +1,7 @@
 // Manually set this variable to toggle rack profile
-profileName = "micro";
+profileName = "default";
+
+fixedSideModules = true;
 
 _profileConfigs = [
     // You can introduce a custom profile like:

rack-mount/enclosed-box/entry.scad

@@ -21,9 +21,9 @@ visualize = false,
 zOrientation = "middle", // ["middle" | "bottom"]
 recessSideRail = false,
 
-boxWidth = 170,
+boxWidth = 200,
 boxHeight = 27,
-boxDepth = 100,
+boxDepth = 120,
 
 railDefaultThickness = 1.5,
 railSideThickness = 3,
@@ -71,4 +71,4 @@ frontPlateCutoutXSpace = 5,
     );
 }
 
-enclosedBoxSystem();
+enclosedBoxSystem();

rack/assembly/addMagnetsToMagnetModules.scad

@@ -1,4 +1,5 @@
 include <./common.scad>
+use <./slideHexNutsIntoYBar.scad>
 
 $vpt = [21,-15,20];
 $vpr = [65,0,40];
@@ -10,8 +11,16 @@ addMagnetsToMagnetModules(at=$t);
 module addMagnetsToMagnetModules(at=0) {
   t = lerp(a=6,b=0,t=at);
 
+  
   if (!plasticMask) {
-    magnetModule();
+
+      if (fixedSideModules) {
+          multmatrix(yBarToMagnetModuleTrans)
+          slideHexNutsIntoYBar(at=1);
+      }
+      else {
+          magnetModule();
+      }
   }
 
   function insertMagnetTrans(t=0) =
@@ -20,6 +29,9 @@ module addMagnetsToMagnetModules(at=0) {
       magnetModuleMagnetMountDz]) *
     rotate(a=[0,90,0]);
 
-  multmatrix(insertMagnetTrans(t=t))
+
-    magnet();
+
+   multmatrix(insertMagnetTrans(t=t))
+     magnet();
+
 }

rack/assembly/attachSideConnectorModulesToYBars.scad

@@ -2,6 +2,11 @@ include <./common.scad>
 use <./screwXBarAndYBar.scad>
 use <./addMagnetsToMagnetModules.scad>
 
+
+/*
+  NOTE You only need to do this step if the `fixedSideModules` option is set to false. 
+*/
+
 $vpt = [116,90,18];
 $vpr = [56,0,42];
 $vpd = 550;
@@ -10,50 +15,57 @@ $vpf = 22.50;
 attachSideConnectorModulesToYBars(at=$t);
 
 module attachSideConnectorModulesToYBars(at=0) {
-  elevation = lerp(a=8, b=0, t=at);
+    elevation = lerp(a=8, b=0, t=at);
 
-  // side module to front corner ybar
+    // side module to front corner ybar
-  function sideModuleTrans(t=0) =
+    function sideModuleTrans(t=0) =
-      translate(v=[sideWallConnW,0,t-sideWallConnLugDepression])
+        translate(v=[sideWallConnW,0,t-sideWallConnLugDepression])
-      * yBarSideModuleConnectorTrans
+        * yBarSideModuleConnectorTrans
-    * mirror(v=[1,0,0]); // mirror for magnetModule
+        * mirror(v=[1,0,0]); // mirror for magnetModule
 
-  screwXBarAndYBar(at=1);
+    screwXBarAndYBar(at=1);
 
-  multmatrix(sideModuleTrans(elevation))
+    if (!fixedSideModules) {
-    union() {
+        multmatrix(sideModuleTrans(elevation))
-      addMagnetsToMagnetModules(at=1);
+            union() {
 
-      translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
+
-        caseScrewShort();
+            addMagnetsToMagnetModules(at=1);
+
+
+            translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
+                caseScrewShort();
+        }
+
+        multmatrix(xBarSpaceToYBarSpace * xBarMirrorOtherCornerTrans * yBarSpaceToXBarSpace * sideModuleTrans(elevation))
+            union() {
+
+            addMagnetsToMagnetModules(at=1);
+
+
+            translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
+                caseScrewShort();
+        }
+
+        multmatrix(yBarMirrorOtherCornerTrans * sideModuleTrans(elevation))
+            union() {
+
+            if (!plasticMask) {
+                hingeModule();
+            }
+
+            translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
+                caseScrewShort();
+        }
+
+        multmatrix(xBarSpaceToYBarSpace * xBarMirrorOtherCornerTrans * yBarSpaceToXBarSpace * yBarMirrorOtherCornerTrans * sideModuleTrans(elevation))
+            union() {
+            if (!plasticMask) {
+                hingeModule();
+            }
+
+            translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
+                caseScrewShort();
+        }
     }
-
+}
-  multmatrix(xBarSpaceToYBarSpace * xBarMirrorOtherCornerTrans * yBarSpaceToXBarSpace * sideModuleTrans(elevation))
-    union() {
-      addMagnetsToMagnetModules(at=1);
-
-      translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
-        caseScrewShort();
-    }
-
-  multmatrix(yBarMirrorOtherCornerTrans * sideModuleTrans(elevation))
-    union() {
-
-      if (!plasticMask) {
-        hingeModule();
-      }
-
-      translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
-        caseScrewShort();
-    }
-
-  multmatrix(xBarSpaceToYBarSpace * xBarMirrorOtherCornerTrans * yBarSpaceToXBarSpace * yBarMirrorOtherCornerTrans * sideModuleTrans(elevation))
-    union() {
-      if (!plasticMask) {
-        hingeModule();
-      }
-
-      translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
-        caseScrewShort();
-    }
-}

rack/assembly/attachXBarWithYBar.scad

@@ -1,5 +1,6 @@
 include <./common.scad>
 use <./slideHexNutsIntoYBar.scad>
+use <./addMagnetsToMagnetModules.scad>
 
 $vpt = [116,90,18];
 $vpr = [56,0,42];
@@ -14,10 +15,22 @@ module attachXBarWithYBar(at=0) {
 
   // assemble x-y bar trays
   multmatrix(translate(v = [0, 0, t]))
-    slideHexNutsIntoYBar(at=1);
+
+      if (fixedSideModules) {
+          multmatrix(inv4x4(yBarToMagnetModuleTrans))
+              addMagnetsToMagnetModules(at=1); // same as slideHexNutsIntoYBar, but the magnet has already been inserted
+      } else {
+          slideHexNutsIntoYBar(at=1);
+      }
+    
 
   multmatrix(translate(v = [0, 0, t])*xBarSpaceToYBarSpace*xBarMirrorOtherCornerTrans*yBarSpaceToXBarSpace)
-    slideHexNutsIntoYBar(at=1);
+      if (fixedSideModules) {
+          multmatrix(inv4x4(yBarToMagnetModuleTrans))
+          addMagnetsToMagnetModules(at=1);
+      } else {
+          slideHexNutsIntoYBar(at=1);
+      }
 
   if (!plasticMask) {
     multmatrix(xBarSpaceToYBarSpace)

rack/assembly/attachXYTrays.scad

@@ -33,4 +33,4 @@ module attachXYTrays(at=0,r=0) {
     }
 
   propUpBottomXYTraywithSideWalls(at=1,r=r);
-}
+}

rack/assembly/common.scad

@@ -56,6 +56,14 @@ module mirrorAllTrayCornersFromYBarSpace() {
 
 secondStackTrans = upperXYTrayTrans * mirror(v=[0,0,1]);
 
+
+
+yBarToMagnetModuleTrans =
+    translate(v=[13,0,sideWallConnLugDepression]) *
+    inv4x4(yBarSideModuleConnectorTrans) *
+    mirror(v=[1,0,0]);
+
+
 module caseScrewShort() {
   if (!screwMask) {
     color([1, 1, 1]) {
@@ -117,4 +125,4 @@ module arrow(length) {
 
     cylinder(r = 1, h = length-2);
   }
-}
+}

rack/assembly/slideHexNutsIntoYBar.scad

@@ -32,8 +32,11 @@ module slideHexNutsIntoYBar(at=0)
     rotate(a=[0,90,0]);
 
   module slideHexNutsOneCorner(t=0) {
-    multmatrix(sideModuleTrans(t = t))
+
-      hexNut(rackFrameScrewType);
+      if (!fixedSideModules) {
+          multmatrix(sideModuleTrans(t = t))
+              hexNut(rackFrameScrewType);
+      }
 
     multmatrix(mainRailTrans(t = t))
       hexNut(rackFrameScrewType);
@@ -49,4 +52,4 @@ module slideHexNutsIntoYBar(at=0)
       slideHexNutsOneCorner(t = t);
   }
 
-}
+}

rack/connector/connectors.scad

@@ -52,6 +52,10 @@ module connectorPositive(on, to) {
     onYBarToXBarPositive();
   } else if (on == "yBar" && to == "basePlate") {
     onYBarBasePlateConnectorPositive();
+  } else if (on == "yBar" && to == "magnetModule") {
+    onYBarMagnetModulePositive();
+  } else if (on == "yBar" && to == "hingeModule") {
+    onYBarHingeModulePositive();
   } else if (on == "basePlate" && to == "yBar") {
     onBasePlateToYBarConnectorPositive();
   } else if (on == "xBar" && to == "yBar") {
@@ -69,6 +73,8 @@ module connectorNegative(on, to) {
     onXBarToYBarNegative();
   } else if (on == "yBar" && to == "sideModule") {
     onYBarSideModuleNegative();
+  } else if (on == "yBar" && to == "hingeModule") {
+    onYBarHingeModuleNegative();
   } else if (on == "yBar" && to == "mainRail") {
     onYBarToMainRailNegative();
   } else if (on == "yBar" && to == "stackConnector") {

rack/connector/sideModuleYBarConnectors.scad

@@ -2,13 +2,47 @@ include <../../helper/common.scad>
 include <../../config/common.scad>
 include <../sharedVariables.scad>
 include <../side/sideWallVariables.scad>
+include <../side/magnetModule.scad>
+include <../side/hingeModule.scad>
 
-module onYBarSideModuleNegative() {
+
+module onYBarSideModuleNegative(fixed=false) {
 
   translate(v = [-xySlack/2, -xySlack/2, -sideWallConnLugDepression])
   cube(size = [sideWallConnW+xySlack, sideWallConnD+xySlack, sideWallConnLugDepression]);
 
-  translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, -(4+sideWallConnLugDepression)])
+
-  rotate(a=[0,0,90])
+  if (!fixed) {
-  hexNutPocket_N("m3", openSide=false, backSpace=5, bridgeFront=true);
+    translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, -(4+sideWallConnLugDepression)])
-}
+    rotate(a=[0,0,90])
+    hexNutPocket_N("m3", openSide=false, backSpace=5, bridgeFront=true);
+  }
+}
+
+
+module onYBarMagnetModulePositive() {
+    
+
+    translate(v=[sideWallConnW,0,-sideWallConnLugDepression])
+        mirror(v=[1,0,0])
+        magnetModule(fixed=true);
+
+
+}
+
+module onYBarHingeModulePositive() {
+    
+    translate(v=[sideWallConnW,0,-sideWallConnLugDepression])
+    mirror(v=[1,0,0])
+        hingeModule(fixed=false);
+}
+
+module onYBarHingeModuleNegative() {
+    
+    translate(v=[sideWallConnW,0,-sideWallConnLugDepression])
+        mirror(v=[1,0,0])
+        difference() {
+            cube(size=[sideWallConnW,sideWallConnD,sideWallConnLugDepression]);            
+            hingeModule(fixed=true);
+        }
+}

rack/print/yBarRight_P.scad

@@ -0,0 +1,7 @@
+use <../yBar.scad>
+
+// Oriented for 3d printing.
+// Supports required at XY wall connections, and depending on roundness
+
+mirror(v=[1,0,0])
+yBar();

rack/side/hingeModule.scad

@@ -3,18 +3,18 @@ include <../../config/common.scad>
 include <../sharedVariables.scad>
 include <./sideWallVariables.scad>
 
-hingeModule();
 
-module hingeModule() {
+module hingeModule(fixed=false) {
 
   applyHingePole()
-  applyYBarScrewMount()
+  applyYBarScrewMount(fixed)
   base();
 
-  connW = sideWallConnW;
-  connD = sideWallConnD;
-
   module base() {
+      
+    connW = sideWallConnW;
+    connD = sideWallConnD;
+
     intersection() {
 
       union() {
@@ -57,10 +57,13 @@ module hingeModule() {
   }
 
 
-  module applyYBarScrewMount() {
+  module applyYBarScrewMount(fixed=false) {
     apply_n() {
-      translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, sideWallConnLugDepression])
+
-      counterSunkHead_N(rackFrameScrewType, headExtension = eps, screwExtension = inf10);
+      if (!fixed) {
+        translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, sideWallConnLugDepression])
+           counterSunkHead_N(rackFrameScrewType, headExtension = eps, screwExtension = inf10);
+      }
 
       children(0);
     }

rack/side/magnetModule.scad

@@ -4,20 +4,19 @@ include <../sharedVariables.scad>
 include <./sideWallVariables.scad>
 
 
-magnetModule();
+module magnetModule(fixed=false) {
 
-module magnetModule() {
+  applyYBarScrewMount(fixed)
-
-  applyYBarScrewMount()
   applyMagnetMount()
   base();
 
-  connW = sideWallConnW;
-  connD = sideWallConnD;
-
   module base() {
 
+    connW = sideWallConnW;
+    connD = sideWallConnD;
+
     intersection() {
+    
       cube(size = [connW, connD, sideWallConnLugDepression]);
 
       // TODO: pattern for this? beef up mirror4XY?
@@ -29,10 +28,14 @@ module magnetModule() {
     }
   }
 
-  module applyYBarScrewMount() {
+  module applyYBarScrewMount(fixed=false) {
+  
     apply_n() {
-      translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, sideWallConnLugDepression])
+
-      counterSunkHead_N(rackFrameScrewType, headExtension = eps, screwExtension = inf10);
+      if (!fixed) {
+        translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, sideWallConnLugDepression])
+           counterSunkHead_N(rackFrameScrewType, headExtension = eps, screwExtension = inf10);
+      }
 
       children(0);
     }

rack/yBar.scad

@@ -9,7 +9,7 @@ module yBar() {
 
   applyOnYBarBothCorners(to="basePlate", trans=yBarBasePlateConnectorTrans)
   applyOnYBarBothCorners(to="stackConnector", trans=yBarStackConnectorTrans)
-  applyOnYBarBothCorners(to="sideModule", trans=yBarSideModuleConnectorTrans)
+  applySideModules()
   applyOnYBarBothCorners(to="mainRail", trans=yBarMainRailConnectorTrans)
   applyOnYBarBothCorners(to="xBar", trans=yBarXBarConnectorTrans)
   yBarBase();
@@ -33,4 +33,20 @@ module yBar() {
     applyConnector(on="yBar", to=to, trans=yBarMirrorOtherCornerTrans * trans)
     children(0);
   }
+
+
+  module applySideModules() {
+
+      if (!fixedSideModules) {          
+          applyOnYBarBothCorners(to="sideModule", trans=yBarSideModuleConnectorTrans)
+          children(0);
+          
+      } else {
+
+          applyConnector(on="yBar", to="magnetModule", trans=yBarSideModuleConnectorTrans)
+          applyConnector(on="yBar", to="hingeModule", trans=yBarMirrorOtherCornerTrans * yBarSideModuleConnectorTrans)
+          children(0);
+      }
+      
+  }
 }

rbuild.py

@@ -253,7 +253,7 @@ def construct_openscad_animation_args(build_dir, target_dir, filename, config, d
     target = os.path.join(target_dir, os.path.splitext(filename)[0] + '.png')
 
     openscad_args = []
-    openscad_args += ['--colorscheme', 'BeforeDawn']
+    openscad_args += ['--colorscheme', 'Tomorrow Night']
     openscad_args += ['--render']
     openscad_args += ['--imgsize', '1920,1080']
     openscad_args += ['--projection', 'o']
@@ -286,7 +286,7 @@ def find_scad_file(directory, filename):
 
 def run_openscad(options, nightly):
     if nightly:
-        command = [PATH_TO_OPENSCAD_NIGHTLY, '--enable', 'all']
+        command = [PATH_TO_OPENSCAD_NIGHTLY, '--enable', 'fast-csg', '--enable', 'manifold']
     else:
         command = [PATH_TO_OPENSCAD]