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

README.md

@@ -12,7 +12,7 @@
 ## Assembly
 
 Pre-generated STLs for roughly 200mm^3 (mini), 180mm^3 (micro), and 100mm^3 (nano) rack frames can be found in the [stl](stl) dir.
-These STLs are generated from the files in [rack/print](rack/print), and [rack-mount/print](rack-mount/print) - further information about printing these parts 
+These STLs are generated from the files in [rack/print](rack/print) - further information about printing these parts 
 (supports, orientation) can be found in these files.
 
 ### Assembly Instructions
@@ -63,9 +63,12 @@ but beware of PLA's thermal limits. Higher infill is recommended for all parts.
 
 ## Trays, Boxes, etc
 
-Some parametric trays and support rails for your rack can be found in [rack-mount/print](./rack-mount/print).
+Some parametric rack mount items can be found in [rack-mount](./rack-mount). The following rack-mount systems 
-These files are currently pretty rough around the edges. However, they still make a great jumping off point for designing 
+are currently supported:
-rack-mount items.
+- [Enclosed Box](./rack-mount/enclosed-box/entry.scad): For mounting box-shaped objects, without the need for any mounting holes on the box.
+- [Tray](./rack-mount/tray/entry.scad): Simple tray mounted using only the front rails. Can be configured to have screw mounts at the bottom of the tray.
+- [Patch Panel](./rack-mount/patch-panel/entry.scad): Linear patch panel array. Number of keystone slots can be configured.
+
 
 ## Configuring + Generating STLs
 A python script:  [rbuild.py](./rbuild.py) is provided to generate different project stls. **Before running the script**, please 

helper/test.txt

@@ -1,5 +0,0 @@
-  basePlateConnYBarCornerDx = yBarWidth; // distance from a plate body corner and the nearest yBar corner
-  basePlateConnYBarCornerDy = xBarY; // distance from a plate body corner and the nearest yBar corner
-
-  basePlateConnPosX = basePlateScrewMountToYBarYZFace - basePlateConnYBarCornerDx; // distance between plateBody corner at (0,0,0) and the related corner
-  basePlateConnPosY = basePlateScrewMountToYBarXZFace - basePlateConnYBarCornerDy;

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

@@ -1,33 +1,20 @@
-include <../helper/common.scad>
+include <../common.scad>
-include <../config/common.scad>
+include <./helper.scad>
-include <../rack/sharedVariables.scad>
-include <./common.scad>
 
 //sideSupportRailBase(top=true, defaultThickness=1.5, supportedZ=27.2, supportedY=101.5, supportedX=159);
 
-// distance between front and back main rail screw mounts
-sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ);
 
-module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrientation="middle", defaultThickness=2) {
+module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrientation="middle", defaultThickness=2, railSideThickness=4) {
 
-  mountBlockHeight = 10;
   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
-  railSideThickness = 4;
   railBackThickness = 3;
-  railBaseWidth = 15;
   // Minimum U to enclose box, while also have a minimum defaultThickness for top and bottom.
-  minU = max(1, ceil((supportedZ + 2*railBaseThickness) / uDiff)-1);
+  u = findU(supportedZ, railBaseThickness);
-
+  railBottomThickness = railBottomThickness(u, supportedZ, railBaseThickness, zOrientation);
-  railBottomThickness =
-    (zOrientation == "middle")
-    ? (((minU+1) * uDiff) - supportedZ)/2
-    : (zOrientation == "bottom")
-    ? railBaseThickness
-    : railBaseThickness;
 
   assert(supportedX <= maxUnitWidth);
   assert (zOrientation == "middle" || zOrientation == "bottom", "Z-Orientation not supported");
@@ -43,7 +30,7 @@ module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrient
   module applyMainRailMounts() {
 
     mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
-    minHexNutPocketToXYDist = mountBlockHeight/2;
+    minHexNutPocketToXYDist = sideRailLowerMountPointToBottom;
     minHexNutPocketToXZDist = mountBlockDepth/2;
     minHexNutPocketToYZDist = 4;
     screwU = floor((railSideHeight) / uDiff)-1;
@@ -92,22 +79,22 @@ module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrient
 
     difference () {
       union() {
-        cube(size = [railBaseWidth, railLength, railBottomThickness]);
+        cube(size = [sideRailBaseWidth, railLength, railBottomThickness]);
 
         cube(size = [railSideThickness, railLength, railSideHeight]);
 
         // back support
         translate(v = [0, max(railLength-railBackThickness, supportedY), 0])
-        cube(size = [railBaseWidth, railBackThickness, railSideHeight]);
+        cube(size = [sideRailBaseWidth, railBackThickness, railSideHeight]);
 
         // back support for box
         translate(v = [0, supportedY, 0])
-        cube(size = [railBaseWidth, railBackThickness, railSideHeight]);
+        cube(size = [sideRailBaseWidth, railBackThickness, railSideHeight]);
 
         // top support
         if (top) {
           translate(v = [0, 0, railSideHeight-railBaseThickness])
-          cube(size = [railBaseWidth, railLength, railBaseThickness]);
+          cube(size = [sideRailBaseWidth, railLength, railBaseThickness]);
         }
       }
 
@@ -140,7 +127,7 @@ module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrient
             }
         }
 
-        cylindricalFiletNegative(p0=[railBaseWidth,0,0],p1=[railBaseWidth,0,inf], n=[1,-1,0],r=r);
+        cylindricalFiletNegative(p0=[sideRailBaseWidth,0,0],p1=[sideRailBaseWidth,0,inf], n=[1,-1,0],r=r);
       }
     }
   }

rack-mount/frontBoxHolder.scad

@@ -1,55 +0,0 @@
-// To be used with closed sideRails to fully encapsulate a box
-
-include <../config/common.scad>
-include <../helper/common.scad>
-include <./common.scad>
-use <./plateBase.scad>
-
-
-frontBoxHolder(u=2, plateThickness=3, cutoutOffsetX=20, cutoutOffsetY=2, cutoutX=147, cutoutY=26,
-    support=true, supportedZ = 27.5, supportWidth=120, supportDepth=5, supportRailBaseThickness=1.25);
-
-
-module frontBoxHolder(u, plateThickness=3, cutoutOffsetX, cutoutOffsetY, cutoutX, cutoutY, support=false, supportedZ, supportWidth, supportDepth, bottomSupportThickness = 2, supportRailBaseThickness = 2) {
-
-  plateScrewToXEdge = 4.5; // wow these are named poorly
-  plateScrewToYEdge = 5;
-
-  if (support) {
-    //assert(supportedZ + 2*supportThickness <= plateScrewToYEdge*2 + u*uDiff);
-    //assert(supportWidth < rackMountScrewWidth); // not tight, need to include screw radii
-  }
-
-  difference() {
-    union() {
-      plateBase(U=u, plateThickness=plateThickness, screwToXEdge=plateScrewToXEdge, screwToYEdge=plateScrewToYEdge, screwType=mainRailScrewType, filletR=2);
-
-      if (support) {
-
-        bottomSuportThickness = supportRailBaseThickness;
-
-        translate(v=[(rackMountScrewWidth-supportWidth)/2, -plateScrewToYEdge,0])
-        cube(size=[supportWidth, bottomSuportThickness, supportDepth]);
-
-        translate(v=[(rackMountScrewWidth-supportWidth)/2, (-plateScrewToYEdge+bottomSuportThickness) + supportedZ,0])
-        cube(size=[supportWidth, bottomSuportThickness, supportDepth]);
-      }
-    }
-
-    union() {
-      translate(v=[cutoutOffsetX, cutoutOffsetY-plateScrewToYEdge,-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/patch-panel/entry.scad

@@ -0,0 +1,18 @@
+use <./patchPanel.scad>
+
+/*
+  Parametric patch panel -
+
+  Please also make sure that the correct rack frame preset is set in rackFrame.scad.
+
+  TODO add support for 2d arrays
+*/
+
+// begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
+
+numSlots = 8;
+
+// end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
+
+mirror(v=[0,0,1])
+patchPanel(slots=numSlots);

rack-mount/patch-panel/patchPanel.scad

@@ -1,9 +1,12 @@
-include <../config/common.scad>
+include <../common.scad>
-include <../helper/common.scad>
+use <../plateBase.scad>
-include <../rack/sharedVariables.scad>
-use <./plateBase.scad>
 
+/*
+  Parametric patch panel -
+  Please see ./entry.scad for configuring/printing
 
+  Please also make sure that the correct rack frame preset is set in rackFrame.scad.
+*/
 *patchPanel(slots=2);
 
 module patchPanel (slots=8) {

rack-mount/print/frontBoxHolder_P.scad

@@ -1,16 +0,0 @@
-include <../../rack/sharedVariables.scad>
-use <../frontBoxHolder.scad>
-
-frontBoxHolder(
-  u=2,
-  plateThickness=3,
-  cutoutOffsetX=(rackMountScrewWidth-147)/2,
-  cutoutOffsetY=4.25,
-  cutoutX=147,
-  cutoutY=21.5,
-  support=true,
-  supportedZ = 26.5,
-  supportWidth=120,
-  supportDepth=5,
-  supportRailBaseThickness=1.75
-);

rack-mount/print/patchPanel_P.scad

@@ -1,5 +0,0 @@
-use <../patchPanel.scad>
-
-
-mirror(v=[0,0,1])
-patchPanel(slots=8);

rack-mount/print/sideSupportRail_P1.scad

@@ -1,3 +0,0 @@
-use <../sideRail.scad>
-
-sideSupportRailBase(top=true, defaultThickness=1.4, supportedZ=27.2, supportedY=101.5, supportedX=159);

rack-mount/print/sideSupportRail_P2.scad

@@ -1,4 +0,0 @@
-use <../sideRail.scad>
-
-mirror(v=[1,0,0])
-sideSupportRailBase(top=true, defaultThickness=1.4, supportedZ=27.2, supportedY=101.5, supportedX=159);

rack-mount/tray/entry.scad

@@ -1,4 +1,4 @@
-use <../tray.scad>
+use <./tray.scad>
 
 /*
   Parametric rack-mount tray:

rack-mount/tray/tray.scad

@@ -1,9 +1,9 @@
-include <./common.scad>
+include <../common.scad>
-use <./rackEars.scad>
+use <../rackEars.scad>
 
 /*
   Parametric rack-mount tray -
-  Please see print/tray_P.scad for configuring/printing
+  Please see ./entry.scad for configuring/printing
 
   Please also make sure that the correct rack frame preset is set in rackFrame.scad.
 */

rack/assembly/common.scad

@@ -17,7 +17,6 @@ screwMask = false;
 plasticMask = false;
 sideSupportRailMask = true;
 
-
 xBarSpaceToYBarSpace =
     yBarXBarConnectorTrans *
     xBarConnectorToYBarConnectorTrans *

rbuild.py

@@ -128,36 +128,36 @@ def run_build(args):
         final_target_directory_name = config_var
 
     rackBuildDirFull = os.path.join(BUILD_PARENT_DIR, final_target_directory_name, RACK_BUILD_TARGET_SUB_DIR)
-    rackMountBuildDirFull = os.path.join(BUILD_PARENT_DIR, final_target_directory_name,
+    #rackMountBuildDirFull = os.path.join(BUILD_PARENT_DIR, final_target_directory_name,
-                                         RACK_MOUNT_BUILD_TARGET_SUB_DIR)
+    #                                     RACK_MOUNT_BUILD_TARGET_SUB_DIR)
 
     if not os.path.exists(rackBuildDirFull):
         os.makedirs(rackBuildDirFull)
 
-    if not os.path.exists(rackMountBuildDirFull):
+    #if not os.path.exists(rackMountBuildDirFull):
-        os.makedirs(rackMountBuildDirFull)
+    #    os.makedirs(rackMountBuildDirFull)
 
     if build_var == 'all':
         for dir_file in os.listdir(RACK_BUILD_DIR):
             build_single(RACK_BUILD_DIR, rackBuildDirFull, dir_file, config_var, dz, nightly)
 
-        for dir_file in os.listdir(RACK_MOUNT_BUILD_DIR):
+        #for dir_file in os.listdir(RACK_MOUNT_BUILD_DIR):
-            build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, dir_file, config_var, dz,
+        #    build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, dir_file, config_var, dz,
-                         nightly)
+        #                 nightly)
         return
 
     filename_rack = find_rack(build_var)
-    filename_rack_mount = find_rack_mount(build_var)
+    #filename_rack_mount = find_rack_mount(build_var)
 
-    if not (filename_rack or filename_rack_mount):
+    if not (filename_rack): #or filename_rack_mount):
         print('File:', build_var, 'not found!')
         return
 
     if filename_rack:
         build_single(RACK_BUILD_DIR, rackBuildDirFull, filename_rack, config_var, dz, nightly)
 
-    if filename_rack_mount:
+    #if filename_rack_mount:
-        build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, filename_rack_mount, config_var, dz, nightly)
+    #    build_single(RACK_MOUNT_BUILD_DIR, rackMountBuildDirFull, filename_rack_mount, config_var, dz, nightly)
 
 
 def build_single(build_dir, target_dir, filename, config, dz, nightly):
@@ -224,8 +224,8 @@ def find_rack(filename):
     return find_scad_file(RACK_BUILD_DIR, filename)
 
 
-def find_rack_mount(filename):
+#def find_rack_mount(filename):
-    return find_scad_file(RACK_MOUNT_BUILD_DIR, filename)
+#    return find_scad_file(RACK_MOUNT_BUILD_DIR, filename)
 
 
 def find_scad_file(directory, filename):