Rewrite keystone.scad (#35)

* helper/keystone: rewrite completely

* rack-mount/patch-panel: edit to adapt to the new keystone

* helper/keystone: fill the lug-side opening

* rack-mount/patch-panel: allow combining two types of keystones and
plates freely

* rack-mount/patch-panel/entry: apply suggestions

Co-authored-by: Zhao (Jack) Wang <jazwang@proton.me>

* rack-mount/patch-panel: fix animate.scad & regen gif

---------

Co-authored-by: Zhao (Jack) Wang <jazwang@proton.me>

helper/common.scad

@@ -3,7 +3,8 @@
 include <./apply.scad>
 include <./dovetail.scad>
 include <./filet.scad>
-include <./keystone.scad>
+include <./keystone1.scad>
+include <./keystone2.scad>
 include <./math.scad>
 include <./matrix.scad>
 include <./screws.scad>

helper/keystone1.scad

@@ -1,4 +1,3 @@
-
 include <../config/common.scad>
 
 // rj45 slot-to-slot keystone jack model and negative
@@ -45,3 +44,15 @@ module rj45KeystoneJack_N() {
         rj45Keystone();
     }
 }
+
+module keystone1(outerWidth, outerHeight) {
+    rotate([0, 0, 180]) // To keep the same direction with keystone2
+    difference() {
+        translate([0, 0, 5.9 / 2])
+        cube([outerWidth, outerHeight, 5.9], center = true);
+
+        translate([-(keystoneMainBodyWidth + xySlack) / 2, (heightWithHookCatch + heightWithBottomLug - keystoneMainBodyHeight) / 2, 0])
+        rotate([90, 0, 0])
+        rj45KeystoneJack_N();
+    }
+}

helper/keystone2.scad

@@ -0,0 +1,42 @@
+include <../config/common.scad>
+
+//   These all constants are obtained by measuring rj45 keystone modules
+// in hand. frontToRearDepth and rearPanelThickness are adjusted after testing.
+// Before printing the Patch Panel, print a keystone2(outerWidth = 19,
+// outerHeight = 27) to test if it fits.
+frontWidth = 14.5;
+frontHeight = 16.2;
+
+frontToRearDepth = 8.4;
+
+rearWidth = frontWidth;
+rearHeight = 19.55;
+rearPanelThickness = 2 - supportedOverhangSlack;
+
+maximumWidth = frontWidth;
+maximumHeight = 22.15;
+
+lugHeight = 1.3;
+
+module keystone2(plateThickness = 1, outerWidth, outerHeight) {
+    assert(outerWidth > maximumWidth);
+    assert(outerHeight > maximumHeight);
+
+    difference() {
+        // Outer cube
+        translate([-outerWidth / 2, -outerHeight / 2, 0])
+        cube([outerWidth, outerHeight, frontToRearDepth + rearPanelThickness]);
+
+        // Front panel hole
+        translate([-(frontWidth + xySlack) / 2, -(frontHeight + xySlack) / 2, 0])
+        cube([frontWidth + xySlack, frontHeight + xySlack, plateThickness]);
+
+        // Middle cavity
+        translate([-(maximumWidth + xySlack) / 2, -frontHeight / 2 - lugHeight - xySlack / 2, plateThickness])
+        cube([rearWidth + xySlack, outerHeight + 1000, frontToRearDepth - plateThickness]);
+
+        // Rear panel hole
+        translate([-(rearWidth + xySlack) / 2, -(frontHeight + xySlack) / 2, frontToRearDepth])
+        cube([rearWidth + xySlack, rearHeight + xySlack, rearPanelThickness]);
+    }
+}

rack-mount/patch-panel/animate.scad

@@ -12,17 +12,12 @@ module animatePatchPanel(at=$t) {
 
   plateThickness = 3;
   keystoneSpacing = 19;
-  slots = max(1,ceil(at*8));
+  allSlots = [2, 2, 2, 2, 2, 2, 2, 5, 2];
+  numSlots = max(1,ceil(at*8));
+  slots = [each [for (i=[1:numSlots]) allSlots[i]]];
 
   rotate(a=[90,0,0])
-  mirror(v=[0,0,1])
   render()
-  patchPanelSystem(numSlots = slots, plateThickness=plateThickness, keystoneSpacing=keystoneSpacing);
-
-  // keystone visualization
-  for (i = [0:slots-1]) {
-    translate(v=[keystoneSpacing*i + 12, 0,0,]) // hardcoded offset
-    %rj45Keystone();
-  }
+  patchPanelSystem(slots = slots, plateThickness=plateThickness, keystoneSpacing=keystoneSpacing);
 
 }

rack-mount/patch-panel/entry.scad

@@ -12,7 +12,11 @@ module patchPanelSystem (
 
 // begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
 
-numSlots = 8,
+// 1 for the original keystone mount design, 2 for a visually cleaner keystone mount
+// but where the keystone is a bit harder to remove
+// 3 for a cube with the height of plateThickness,
+// 4 and 5 for cubes with the same height as keystone1 and 2
+slots = [2, 2, 2, 2, 2, 2, 2, 5, 2],
 plateThickness = 3,
 keystoneSpacing = 19,
 center = false
@@ -21,7 +25,7 @@ center = false
 
 ) {
   mirror(v = [0, 0, 1])
-    patchPanel(slots = numSlots, center=center);
+    patchPanel(slots = slots, plateThickness = 3, keystoneSpacing = 19, center=center);
 }
 
 patchPanelSystem();

rack-mount/patch-panel/patchPanel.scad

@@ -8,35 +8,34 @@ use <../plateBase.scad>
   Please also make sure that the correct rack frame preset is set in rackFrame.scad.
 */
 
-module patchPanel (slots=8, plateThickness=3, keystoneSpacing=19, center=false) {
+module patchPanel(slots, plateThickness = 3, screwToXEdge = 4.5, screwToYEdge = 4.5, keystoneSpacing = 19, center = false) {
+    slotsWidth = len(slots) * keystoneSpacing;
+    slotsMinPadding = railScrewHoleToInnerEdge+4;
+    plateLength = rackMountScrewWidth + 2 * screwToXEdge;
+    plateHeight = 2 * uDiff + 2 * screwToXEdge;
+    leftRailScrewToSlots = center
+            ? (plateLength-(slotsWidth+slotsMinPadding))/2
+            : slotsMinPadding;
+
     difference() {
-        supportPlateThickness = 5.9;
-        supportPlateHeight = 29;
-        supportPlateEdgeSpacing = 3;
-        supportPlateWidth = slots * keystoneSpacing + supportPlateEdgeSpacing;
-        supportPlateMinPadding = railScrewHoleToInnerEdge+4;
-
-        // TODO: these values should belong somewhere closer to plateBase.scad
-        railScrewToEdge = 4.5;
-        plateLength = rackMountScrewWidth + 2*railScrewToEdge;
-
-        leftRailScrewToSupportDx = center
-            ? (plateLength-(supportPlateWidth+supportPlateMinPadding))/2
-            : supportPlateMinPadding;
-
-        union() {
-            plateBase(U = 2, plateThickness = plateThickness, screwType = mainRailScrewType,  screwToXEdge=railScrewToEdge, screwToYEdge=railScrewToEdge, filletR = 2);
-            translate(v = [leftRailScrewToSupportDx, - railScrewToEdge, - supportPlateThickness])
-            cube(size = [supportPlateWidth, supportPlateHeight, supportPlateThickness]);
+        plateBase(U =  2, plateThickness = plateThickness, screwType = mainRailScrewType, screwToXEdge = screwToXEdge, screwToYEdge = screwToYEdge, filletR = 2);
+        translate([leftRailScrewToSlots, -screwToYEdge - 10 * eps, -plateThickness - 10 * eps])
+        cube([slotsWidth, plateHeight + 2 * 10 * eps, plateThickness + 2 * 10 * eps]);
     }
 
-        render() 
-        union() {
-            for (i = [0:slots-1]) {
-                translate(v = [leftRailScrewToSupportDx+supportPlateEdgeSpacing + i*keystoneSpacing, 0, eps])
-                rotate(a = [-90, 0, 0])
-                rj45KeystoneJack_N();
-            }
+    for(i = [0 : len(slots) - 1]) {
+        translate([leftRailScrewToSlots + keystoneSpacing / 2 + i * keystoneSpacing, uDiff, -plateThickness])
+        let (slot = slots[i])
+        if (slot == 1) keystone1(outerWidth = keystoneSpacing, outerHeight = plateHeight);
+        else if (slot == 2) keystone2(outerWidth = keystoneSpacing, outerHeight = plateHeight);
+        else if (slot == 3) plate(outerWidth = keystoneSpacing, outerHeight = plateHeight, thickness = plateThickness);
+        else if (slot == 4) plate(outerWidth = keystoneSpacing, outerHeight = plateHeight, thickness = 5.9);
+        else if (slot == 5) plate(outerWidth = keystoneSpacing, outerHeight = plateHeight, thickness = 9.9);
+        else assert(false);
     }
 }
+
+module plate(outerWidth, outerHeight, thickness) {
+    translate([0, 0, thickness / 2])
+    cube([outerWidth, outerHeight, thickness], center = true);
 }