work on connectingBar

cases/rack2/connectingBar.scad

@@ -0,0 +1,85 @@
+include <../math.scad>
+include <./config.scad>
+include <./screws.scad>
+include <./mainRail.scad>
+include <./helper/sphericalFilet.scad>
+include <./helper/cylindricalFilet.scad>
+
+
+// TODO: How do I nicely explain this?
+railSlotSpacing = 4;
+sideSpacing = 12;
+
+barDepth = maxUnitDepth + 2*railSlotSpacing;
+barWidth = railSlotSpacing + railTotalWidth + sideSpacing;
+barHeight = 15;
+
+barWallThickness = 3;
+barRoundness = 12;
+
+echo("Bar total depth: ", barDepth);
+echo("Bar total width: ", barWidth);
+
+module connectingBar() {
+
+  module _positive() {
+    minkowski() {
+      difference() {
+        sphericalFiletEdge(barWidth, barDepth, barHeight, barRoundness);
+
+        translate(v = [barWallThickness, 40, barWallThickness])
+        cylindricalFiletEdge(barWidth, barDepth-80, barHeight, barRoundness);
+      }
+    }
+  }
+
+
+  module _stackConn() {
+    translate(v=[0,0,0])
+    cube(size = [10, 10, 5]);
+
+    translate(v=[5,5,5])
+    cylinder(r=2, h=2);
+  }
+
+  module _sideConnector() {
+    //translate(v=[1.5, railTotalDepth - 4, -m3HeatSetInsertSlotHeightSlacked])
+    rotate(a=[0,90,0])
+    heatSetInsertSlot_N(rackFrameScrewType);
+  }
+
+  module _test() {
+    difference() {
+      _positive();
+
+      union() {
+        translate(v=[10,10,0])
+        _stackConn();
+
+        translate(v=[barWidth - (railTotalWidth + railSlotSpacing), railSlotSpacing, barHeight - railFootThickness])
+        railFeetSlot_N();
+
+        translate(v=[barWidth - m3HeatSetInsertSlotHeightSlacked + eps, 6, 7.5])
+        _sideConnector();
+
+        translate(v=[barWidth - m3HeatSetInsertSlotHeightSlacked + eps, 35, 7.5])
+        _sideConnector();
+      }
+    }
+
+  }
+  _test();
+
+  translate(v=[barWidth - m3HeatSetInsertSlotHeightSlacked + eps, 6, 7.5])
+  _sideConnector();
+
+}
+
+connectingBar();
+
+
+intersection() {
+  connectingBar();
+
+  cube(size=[15,100,100]);
+}

cases/rack2/helper/cylindricalFilet.scad

@@ -0,0 +1,16 @@
+
+module cylindricalFiletEdge(width, depth, height, roundness) {
+  rd = roundness;
+
+  intersection() {
+    minkowski() {
+      rotate(a = [90, 0, 0])
+      cylinder(r = rd, h = eps);
+
+      translate(v = [rd, 0, rd])
+      cube(size = [width, depth, height]);
+    }
+
+    cube(size = [width, depth, height]);
+  }
+}

cases/rack2/helper/sphericalFilet.scad

@@ -0,0 +1,15 @@
+
+module sphericalFiletEdge(width, depth, height, roundness) {
+  rd = roundness;
+
+  intersection() {
+    minkowski() {
+      sphere(r = rd);
+
+      translate(v = [rd, rd, rd])
+      cube(size = [width*2, depth - 2*rd, height*2]);
+    }
+
+    cube(size = [width, depth, height]);
+  }
+}

cases/rack2/mainRail.scad

@@ -1,4 +1,5 @@
 include <./config.scad>
+include <../math.scad>
 include <./screws.scad>
 
 /* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
@@ -7,47 +8,49 @@ railFootThickness = 3;
 
 railTotalHeight = screwDiff * (numRailScrews + 1) + 2 * railFootThickness;
 
-mainRail();
-echo("Total Rail Height = ", railTotalHeight);
+// Distance between the middle of a screw mount and the rail's vertical edges
+railScrewHoleToInnerEdge = 5;
+railScrewHoleToOuterEdge = 5;
+
+// Distance between the midpoint of the rail screw holes.
+rackMountScrewWidth = maxUnitWidth + 2 * railScrewHoleToInnerEdge;
+
+railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
+railSideMountThickness = 2.5;
+railOtherThickness = 2.5;
+
+// Extra spacing for screws.
+frontScrewSpacing = 8;
+
+sideSupportExtraSpace = 2;
+sideSupportScrewHoleToFrontEdge = 5;
+sideSupportScrewHoleToBackEdge = 4.5;
+sideSupportDepth = sideSupportScrewHoleToBackEdge + sideSupportScrewHoleToFrontEdge;
+
+frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
+
+railTotalWidth = frontFaceWidth;
+railTotalDepth = railFrontThickness+railOtherThickness+frontScrewSpacing+sideSupportDepth;
+
+
+*mainRail();
+echo("Total Rail Height: ", railTotalHeight);
 
 module mainRail() {
 
-  // Distance between the middle of a screw mount and the rail's vertical edges
-
-  railScrewHoleToInnerEdge = 5;
-  railScrewHoleToOuterEdge = 5;
-
-  // Distance between the midpoint of the rail screw holes.
-  rackMountScrewWidth = maxUnitWidth + 2 * railScrewHoleToInnerEdge;
-
-  railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
-  railSideMountThickness = 2.5;
-  railOtherThickness = 2.5;
-
-
-  // Extra spacing for the rack unit screws.
-  frontScrewSpacing = 8;
-
-  sideSupportExtraSpace = 2;
-  sideSupportScrewHoleToFrontEdge = 5;
-  sideSupportScrewHoleToBackEdge = 4.5;
-  sideSupportDepth = sideSupportScrewHoleToBackEdge + sideSupportScrewHoleToFrontEdge;
-
-  frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
-
   union() {
     _frontRailSegment();
 
     translate(v = [0, railFrontThickness, 0])
     _connectingLBracketRailSegment();
 
-    translate(v = [frontFaceWidth - sideSupportExtraSpace, railFrontThickness + railOtherThickness + frontScrewSpacing,
-      0])
+    translate(v = [frontFaceWidth-sideSupportExtraSpace, railFrontThickness+railOtherThickness+frontScrewSpacing, 0])
     rotate(a = [0, 0, 90])
     _sideSupportSegment();
 
 
     translate(v = [0, railFrontThickness + railOtherThickness + frontScrewSpacing, 0]) {
+
       _railFeet();
 
       translate(v = [0, 0, railTotalHeight - railFootThickness])
@@ -68,7 +71,6 @@ module mainRail() {
   }
 
   module _connectingLBracketRailSegment() {
-
     difference() {
       cube(size = [railOtherThickness, frontScrewSpacing + railOtherThickness, railTotalHeight]);
 
@@ -79,7 +81,7 @@ module mainRail() {
 
         translate(v = [0, 4, railTotalHeight - (railFootThickness + screwDiff / 2)])
         rotate(a = [0, 90, 0])
-        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = 10, $fn = 32, center = true);
+        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32, center = true);
       }
     }
 
@@ -90,32 +92,40 @@ module mainRail() {
 
 
   module _sideSupportSegment() {
-
     difference() {
       cube(size = [sideSupportDepth, railSideMountThickness, railTotalHeight]);
 
       for (i = [1:numRailScrews]) {
         translate(v = [sideSupportScrewHoleToFrontEdge, railFrontThickness / 2, i * screwDiff + railFootThickness])
         rotate(a = [90, 0, 0])
-        cylinder(r = screwRadiusSlacked(mainRailSideMountScrewType), h = 10, $fn = 32);
+        cylinder(r = screwRadiusSlacked(mainRailSideMountScrewType), h = inf10, $fn = 32);
       }
     }
 
   }
 
   module _railFeet() {
-
     difference() {
       cube(size = [frontFaceWidth - sideSupportExtraSpace, sideSupportDepth, railFootThickness]);
 
       hull() {
         translate(v = [1.5, 5, 0])
-        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = 10, $fn = 32);
+        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32);
 
         translate(v = [0, 5, 0])
-        cube(size = [0.1, screwRadiusSlacked(rackFrameScrewType) * 2, 10], center = true);
+        cube(size = [eps, screwRadiusSlacked(rackFrameScrewType) * 2, 10], center = true);
       }
     }
   }
 
 }
+
+module railFeetSlot_N() {
+
+  union() {
+    cube(size = [railTotalWidth, railTotalDepth, railFootThickness]);
+
+    translate(v=[1.5, railTotalDepth - 4, -m3HeatSetInsertSlotHeightSlacked])
+    heatSetInsertSlot_N(rackFrameScrewType);
+  }
+}

cases/rack2/screws.scad

@@ -1,6 +1,7 @@
 /* Some common screw dimensions and helper functions/modules */
 
-inf = 400;
+include <../math.scad>
+include <../common.scad>
 
 /********************************************************************************/
 // M3 dimensions
@@ -8,10 +9,20 @@ m3HoleRadiusSlack = 0.15;
 m3Diameter = 3.0;
 m3Radius = m3Diameter / 2.0;
 m3RadiusSlacked = m3Radius + m3HoleRadiusSlack;
+
 m3HexNutWidthAcrossFlats = 5.41;
 m3HexNutWidthAcrossCorners = FtoG(m3HexNutWidthAcrossFlats);
 m3HexNutThickness = 2.18;
 
+m3HeatSetInsertSlotRadiusSlack = 0.0;
+m3HeatSetInsertSlotHeightSlack = 0.5;
+
+m3HeatSetInsertSlotRadius = 2.5;
+m3HeatSetInsertSlotHeight = 6;
+
+m3HeatSetInsertSlotRadiusSlacked = m3HeatSetInsertSlotRadius+m3HeatSetInsertSlotRadiusSlack;
+m3HeatSetInsertSlotHeightSlacked = m3HeatSetInsertSlotHeight+m3HeatSetInsertSlotHeightSlack;
+
 /********************************************************************************/
 // M4 dimensions
 m4HoleRadiusSlack = 0.15;
@@ -23,6 +34,22 @@ m4HexNutWidthAcrossCorners = FtoG(m4HexNutWidthAcrossFlats);
 m4HexNutThickness = 3.07;
 
 /********************************************************************************/
+
+module heatSetInsertSlot_N(screwType) {
+  if (screwType == "m3") {
+    union() {
+      // actual slot for insert
+      cylinder(h = m3HeatSetInsertSlotHeightSlacked, r = m3HeatSetInsertSlotRadiusSlacked);
+
+      // extra space above slot to help with insertion
+      translate(v=[0, 0, m3HeatSetInsertSlotHeightSlacked])
+      cylinder(h = inf50, r = 1.3*m3HeatSetInsertSlotRadiusSlacked);
+    }
+  } else {
+    error("Unsupported screw type");
+  }
+}
+
 function screwRadiusSlacked(screwType) =
   (screwType == "m3")
   ? m3RadiusSlacked
@@ -30,45 +57,35 @@ function screwRadiusSlacked(screwType) =
   ? m4RadiusSlacked
   : error("Unsupported screw type");
 
-
 module hexNutPocket_N(screwType) {
   if (screwType == "m3") {
-    hexNutPocketHelper_N(m3RadiusSlacked,
-        m3HexNutWidthAcrossCorners / 2 + 0.1,
-      m3HexNutThickness + 0.2);
+    hexNutPocketHelper_N(m3RadiusSlacked, m3HexNutWidthAcrossCorners / 2 + 0.1, m3HexNutThickness + 0.2);
   } else if (screwType == "m4") {
-    hexNutPocketHelper_N(m4RadiusSlacked,
-        m4HexNutWidthAcrossCorners / 2 + 0.1,
-      m4HexNutThickness + 0.2);
+    hexNutPocketHelper_N(m4RadiusSlacked, m4HexNutWidthAcrossCorners / 2 + 0.1, m4HexNutThickness + 0.2);
   } else {
     error("Unsupported screw type");
   }
 }
 
-module hexNutPocketHelper_N(
-innerRadius,
-widthAcrossCorners,
-thickness)
-{
+module hexNutPocketHelper_N(innerRadius, widthAcrossCorners, thickness) {
   union() {
-
     hull() {
       // hexagonal cylinder representing where the nut should fit
       cylinder(r = widthAcrossCorners, h = thickness, center = true, $fn = 6);
 
       // negative volume for sliding in the nut
-      translate(v = [inf, 0, 0])
+      translate(v = [inf50, 0, 0])
       cylinder(r = widthAcrossCorners, h = thickness, center = true, $fn = 6);
     }
 
     // negative volume for screw lead
     translate(v = [0, 0, - 10])
-    cylinder(r = innerRadius, h = inf, $fn = 32);
+    cylinder(r = innerRadius, h = inf50, $fn = 32);
 
     hull() {
-      translate(v = [inf, 0, 0])
-      cylinder(r = innerRadius, h = inf, $fn = 32);
-      cylinder(r = innerRadius, h = inf, $fn = 32);
+      translate(v = [inf50, 0, 0])
+      cylinder(r = innerRadius, h = inf50, $fn = 32);
+      cylinder(r = innerRadius, h = inf50, $fn = 32);
     }
   }
 }