Improve rack-mount. Individual rack-mount systems are now organized in their own directories, with a standard entry.scad file.

rack-mount/enclosed-box/boxHelper.scad

@@ -1,53 +0,0 @@
-include <../../rack/sharedVariables.scad>
-include <../common.scad>
-
-use <../sideRail.scad>
-use <../frontBoxHolder.scad>
-
-/*
-  (WIP) Enclosed box mounting system:
-  Helper file to use semi-enclosed side rails and a front plate to mount a box.
-  This system does not require any mounting holes for the enclosed box.
-
-  !!! Please also make sure that the correct rack frame preset is set in rackFrame.scad !!!
-*/
-
-// begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
-
-boxWidth = 160;
-boxHeight = 27;
-boxDepth = 100;
-
-
-railDefaultThickness = 1.2;
-
-zOrientation = "middle";
-
-// Does not affect any part dimensions. Set this to true to visualize how a box wound be mounted.
-visualize = true;
-
-// end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
-
-#cube(size=[boxWidth, boxDepth, boxHeight]);
-
-sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation);
-
-translate(v=[boxWidth,0,0])
-mirror(v=[1,0,0])
-sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation);
-
-translate(v=[0,0,10])
-rotate(a=[-90,0,0])
-*frontBoxHolder(
-u=2,
-plateThickness=3,
-cutoutOffsetX=(rackMountScrewWidth-147)/2,
-cutoutOffsetY=4.25,
-cutoutX=147,
-cutoutY=21.5,
-support=true,
-supportedZ=boxHeight,
-supportWidth=120,
-supportDepth=5,
-supportRailBaseThickness=1.75
-);

rack-mount/enclosed-box/entry.scad

@@ -0,0 +1,65 @@
+include <../../rack/sharedVariables.scad>
+include <../common.scad>
+include <./helper.scad>
+
+use <./sideRail.scad>
+use <./frontBoxHolder.scad>
+
+/*
+  Enclosed box mounting system:
+  Helper file to use semi-enclosed side rails and a front plate to mount a box.
+  This system does not require any mounting holes on the enclosed box.
+
+  !!! Please also make sure that the correct rack frame preset is set in rackFrame.scad !!!
+
+  TODO support full box (so for the micro profile it would be 180) this may require widening the main rail
+*/
+
+// begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
+
+// Does not affect any part dimensions. Set this to true to visualize how a box would be mounted.
+visualize = false;
+
+boxWidth = 170;
+boxHeight = 27.0;
+boxDepth = 100;
+
+railDefaultThickness = 1.5;
+railSideThickness = 3;
+
+frontPlateThickness = 3;
+frontPlateCutoutYSpace = 3;
+frontPlateCutoutXSpace = 5;
+
+zOrientation = "middle"; // or "bottom"
+
+// end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
+
+
+leftRailTrans = identity;
+rightRailTrans = visualize
+  ? translate(v=[boxWidth,0,0]) * mirror(v=[1,0,0])
+  : translate(v=[sideRailBaseWidth*2,0,0]) * mirror(v=[1,0,0]);
+
+u = findU(boxHeight, railDefaultThickness);
+railBottomThickness = railBottomThickness(u, boxHeight, railDefaultThickness, zOrientation);
+frontBoxHolderTrans = visualize
+  ? translate(v=[railSideThickness-(railSupportsDx-boxWidth)/2,0, sideRailLowerMountPointToBottom-railBottomThickness]) * mirror(v=[0,1,0]) * rotate(a=[90,0,0])
+  : mirror(v=[0,1,0]) * translate(v=[0,uDiff,frontPlateThickness - railBottomThickness]);
+
+if (visualize) {
+  %cube(size = [boxWidth, boxDepth, boxHeight]);
+}
+
+multmatrix(leftRailTrans)
+sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation, railSideThickness=railSideThickness);
+
+multmatrix(rightRailTrans)
+sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation, railSideThickness=railSideThickness);
+
+multmatrix(frontBoxHolderTrans)
+frontBoxHolder(
+  cutoutOffsetX=(rackMountScrewWidth-(boxWidth-2*frontPlateCutoutXSpace))/2, cutoutOffsetY=railBottomThickness+frontPlateCutoutYSpace,
+  cutoutX=boxWidth-2*frontPlateCutoutXSpace, cutoutY=boxHeight-2*frontPlateCutoutYSpace,
+  zOrientation = zOrientation, supportedZ=boxHeight, supportWidth=max(10, boxWidth-(sideRailBaseWidth+10)), supportRailDefaultThickness = railDefaultThickness, plateThickness=frontPlateThickness
+);

rack-mount/enclosed-box/frontBoxHolder.scad

@@ -0,0 +1,40 @@
+include <../common.scad>
+include <./helper.scad>
+use <../plateBase.scad>
+
+// To be used with closed sideRails to fully encapsulate a box
+
+module frontBoxHolder(plateThickness=3, cutoutOffsetX, cutoutOffsetY, cutoutX, cutoutY, supportedZ, supportWidth, supportDepth=5, supportRailDefaultThickness, zOrientation) {
+
+  //assert(supportedZ + 2*supportThickness <= boxPlateScrewToYEdge*2 + u*uDiff);
+  //assert(supportWidth < rackMountScrewWidth); // not tight, need to include screw radii
+
+  u = findU(supportedZ, supportRailDefaultThickness);
+  supportRailBottomThickness = railBottomThickness(u, supportedZ, supportRailDefaultThickness, zOrientation);
+
+  difference() {
+    union() {
+      plateBase(U=u, plateThickness=plateThickness, screwToXEdge=boxPlateScrewToXEdge, screwToYEdge=boxPlateScrewToYEdge, screwType=mainRailScrewType, filletR=2);
+
+      // bottom support
+      translate(v=[(rackMountScrewWidth-supportWidth)/2, -boxPlateScrewToYEdge,0])
+      cube(size=[supportWidth, supportRailBottomThickness, supportDepth]);
+
+        // top support
+      translate(v=[(rackMountScrewWidth-supportWidth)/2, -boxPlateScrewToYEdge+supportRailBottomThickness+supportedZ,0])
+      cube(size=[supportWidth, supportRailDefaultThickness, supportDepth]);
+    }
+
+    union() {
+      translate(v=[cutoutOffsetX, cutoutOffsetY-boxPlateScrewToYEdge,-inf/2])
+      minkowski() {
+        r=2;
+        cylinder(r=r,h=inf);
+        translate(v=[r, r, 0])
+        cube(size = [cutoutX-2*r, cutoutY-2*r, inf]);
+      }
+
+    }
+  }
+
+}

rack-mount/enclosed-box/helper.scad

@@ -0,0 +1,21 @@
+include <../common.scad>
+
+// Some utility functions, as well as global functions to make code cleaner
+
+sideRailLowerMountPointToBottom = uDiff/2;
+sideRailBaseWidth = 15;
+// distance between front and back main rail screw mounts
+sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ);
+
+boxPlateScrewToXEdge = 4.5; // wow these are named poorly
+boxPlateScrewToYEdge = 5;
+
+
+function findU(boxHeight, minRailThickness) = max(1, ceil((boxHeight + 2*minRailThickness)/uDiff) - 1);
+
+function railBottomThickness(u, boxHeight, minRailThickness, zOrientation) =
+  (zOrientation == "middle")
+  ? (((u+1) * uDiff) - boxHeight)/2
+  : (zOrientation == "bottom")
+  ? minRailThickness
+  : minRailThickness;

rack-mount/enclosed-box/sideRail.scad

@@ -0,0 +1,138 @@
+include <../common.scad>
+include <./helper.scad>
+
+//sideSupportRailBase(top=true, defaultThickness=1.5, supportedZ=27.2, supportedY=101.5, supportedX=159);
+
+
+module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrientation="middle", defaultThickness=2, railSideThickness=4) {
+
+  mountBlockDepth = 10;
+  screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
+  sideRailScrewToMainRailFrontDx = frontScrewSpacing+railFrontThickness;
+  railLength = max(sideRailScrewMountDist + sideRailScrewToMainRailFrontDx + mountBlockDepth/2, supportedY+defaultThickness);
+  railBaseThickness = defaultThickness; // default thickness value
+  railBackThickness = 3;
+  // Minimum U to enclose box, while also have a minimum defaultThickness for top and bottom.
+  u = findU(supportedZ, railBaseThickness);
+  railBottomThickness = railBottomThickness(u, supportedZ, railBaseThickness, zOrientation);
+
+  assert(supportedX <= maxUnitWidth);
+  assert (zOrientation == "middle" || zOrientation == "bottom", "Z-Orientation not supported");
+  assert(railBottomThickness >= railBaseThickness);
+
+  railSideHeight = supportedZ + railBaseThickness + railBottomThickness + overhangSlack;
+  frontMountPad = (sideRailScrewToMainRailFrontDx-mountBlockDepth/2)-xySlack;
+
+  translate(v=[-railSideThickness, 0, -railBottomThickness])
+  applyMainRailMounts()
+  sideSupportRailBase();
+
+  module applyMainRailMounts() {
+
+    mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
+    minHexNutPocketToXYDist = sideRailLowerMountPointToBottom;
+    minHexNutPocketToXZDist = mountBlockDepth/2;
+    minHexNutPocketToYZDist = 4;
+    screwU = floor((railSideHeight) / uDiff)-1;
+
+    apply_pn() {
+      mountBlockPositive();
+      mountBlockNegative();
+      children(0);
+    }
+
+    module mountBlockPositive() {
+      translate(v = [0, frontMountPad, 0])
+        singleMountBlockPositive();
+      translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
+        singleMountBlockPositive();
+    }
+
+    module mountBlockNegative() {
+      translate(v = [0, frontMountPad, 0])
+        singleMountBlockNegative();
+      translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
+        singleMountBlockNegative();
+    }
+
+    module singleMountBlockPositive() {
+      translate(v = [-mountBlockExtension, 0, 0])
+        cube(size = [mountBlockExtension, mountBlockDepth, railSideHeight]);
+    }
+
+    module singleMountBlockNegative() {
+      nutPocket();
+
+      translate(v = [0, 0, uDiff*screwU])
+        nutPocket();
+
+      module nutPocket() {
+        translate(v=[-mountBlockExtension+minHexNutPocketToYZDist, minHexNutPocketToXZDist, minHexNutPocketToXYDist])
+        rotate(a=[-90,0,90])
+          hexNutPocket_N(rackFrameScrewType, openSide=false, backSpace=min((railSideThickness-1)+mountBlockExtension-minHexNutPocketToYZDist,15));
+      }
+    }
+  }
+
+
+  module sideSupportRailBase() {
+
+    difference () {
+      union() {
+        cube(size = [sideRailBaseWidth, railLength, railBottomThickness]);
+
+        cube(size = [railSideThickness, railLength, railSideHeight]);
+
+        // back support
+        translate(v = [0, max(railLength-railBackThickness, supportedY), 0])
+        cube(size = [sideRailBaseWidth, railBackThickness, railSideHeight]);
+
+        // back support for box
+        translate(v = [0, supportedY, 0])
+        cube(size = [sideRailBaseWidth, railBackThickness, railSideHeight]);
+
+        // top support
+        if (top) {
+          translate(v = [0, 0, railSideHeight-railBaseThickness])
+          cube(size = [sideRailBaseWidth, railLength, railBaseThickness]);
+        }
+      }
+
+      union() {
+        distanceFromSeparator = 3;
+        r = 4;
+
+        ventDy1 = frontMountPad+mountBlockDepth+distanceFromSeparator;
+        ventY1 = min(supportedY-(ventDy1+distanceFromSeparator), sideRailScrewMountDist-(2*distanceFromSeparator+mountBlockDepth));
+
+        ventDy2 = max(ventDy1, supportedY+railBackThickness+distanceFromSeparator);
+        ventY2 = max(0, railLength - (ventDy2 + distanceFromSeparator + mountBlockDepth));
+
+        ventDz = railBottomThickness+distanceFromSeparator+r;
+        ventZ = railSideHeight-(ventDz+distanceFromSeparator+r+railBaseThickness);
+
+        if (ventY1 > 2*r) {
+          translate(v = [0, ventDy1+r, ventDz])
+            minkowski() {
+              cube(size = [inf, ventY1-2*r, ventZ]);
+              sphere(r = r);
+            }
+        }
+
+        if (ventY2 > 2*r) {
+          translate(v = [0, ventDy2+r, ventDz])
+            minkowski() {
+              cube(size = [inf, ventY2-2*r, ventZ]);
+              sphere(r = r);
+            }
+        }
+
+        cylindricalFiletNegative(p0=[sideRailBaseWidth,0,0],p1=[sideRailBaseWidth,0,inf], n=[1,-1,0],r=r);
+      }
+    }
+  }
+
+}
+
+
+