add profiles.scad

helper/screws.scad

@@ -20,8 +20,8 @@ m3HexNutThickness = 2.18;
 m3HeatSetInsertSlotRadiusSlack = -0.1;
 m3HeatSetInsertSlotHeightSlack = 0.5;
 
-m3HeatSetInsertSlotRadius = 2.5;
+m3HeatSetInsertSlotRadius = 2.3;
-m3HeatSetInsertSlotHeight = 6;
+m3HeatSetInsertSlotHeight = 5.7;
 
 m3HeatSetInsertSlotRadiusSlacked = m3HeatSetInsertSlotRadius+m3HeatSetInsertSlotRadiusSlack;
 m3HeatSetInsertSlotHeightSlacked = m3HeatSetInsertSlotHeight+m3HeatSetInsertSlotHeightSlack;

rack/config.scad

@@ -6,32 +6,39 @@
    - "_N" appended to a module is meant to denote that this module is a negative volume, and should only be used to
      substract from other volumes. "_P" is meant to denote a positive value. Modules are positive by default.
 */
+include <./profiles.scad>
+
+profile = "default";
+
+echo("Profile:", profile);
 
 // Maximum width for rackmount units. Change this according your max expected enclosure width.
 // Changing this will directly affect the required build volume.
-maxUnitWidth = 200;
+maxUnitWidth = getConfigValue(profile, "maxUnitWidth");
 
 // Maximum (recommended) unit depth. There technically isn't a max unit depth because there's no physical bound on
 // how far a rack unit can extrude back. This parameter basically controls the distance between the front of the front
 // rails and the back of the back rails. Changing this will directly affect the required build volume.
-maxUnitDepth = 200;
+maxUnitDepth = getConfig("maxUnitDepth");
 
 // Vertical distance between the midpoint of adjacent screws mounts. Affects build volume.
-screwDiff = 10;
+screwDiff = getConfig("screwDiff");
 
 // Number screw slots on the main rail. Affects build volume.
-numRailScrews = 20;
+numRailScrews = getConfig("numRailScrews");
 
 // Screw type used for rackmount units. See screws.scad.
-mainRailScrewType = "m4";
+mainRailScrewType = getConfig("mainRailScrewType");
 
 // Screw type used to affix side rails.
-mainRailSideMountScrewType = "m4";
+mainRailSideMountScrewType = getConfig("mainRailSideMountScrewType");
 
 // Screw type used for constructing the actual rack frame.
-rackFrameScrewType = "m3";
+rackFrameScrewType = getConfig("rackFrameScrewType");
 // Currently, only m3 screws are supported here (tolerance issues)
 assert(rackFrameScrewType == "m3");
 
 // Fillet radius for main rack profile
-baseRoundness = 5;
+baseRoundness = getConfig("baseRoundness");
+
+echo("numRailScrews", numRailScrews);

rack/fullAssembly.scad

@@ -9,21 +9,21 @@ mainRail();
 
 translate(v=[12,2 + 200,18])
 mirror(v=[0,1,0])
-mainRail();
+*mainRail();
 
 translate(v=[12 + 216,2,18])
 mirror(v=[1,0,0])
-mainRail();
+*mainRail();
 
 translate(v=[12 + 216,2 + 200,18])
 rotate(a=[0,0,180])
-mainRail();
+*mainRail();
 
-xyPlane();
+*xyPlane();
 
 translate(v=[0,0,250])
 mirror(v=[0,0,1])
-xyPlane();
+*xyPlane();
 
 module xyPlane() {
   yBar();
@@ -39,3 +39,8 @@ module xyPlane() {
   mirror(v = [0, 1, 0])
   xBar();
 }
+
+yBar();
+
+translate(v = [30, 0, 0])
+xBar();

rack/mainRail.scad

@@ -30,7 +30,7 @@ frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
 railTotalWidth = frontFaceWidth;
 railTotalDepth = railFrontThickness+sideSupportDepth;
 
-*mainRail();
+mainRail();
 
 echo("Total Rail Height: ", railTotalHeight);
 

rack/profiles.scad

@@ -0,0 +1,44 @@
+/*
+    case-files v2
+    This file contains
+    Example usage:
+
+ profileName = "mini";
+ varName = "mainRailSideMountScrewType";
+
+ profile = getProfile(profileName);
+ echo("val:", getConfigValue(profile, varName));
+ */
+
+_profileConfigs = [
+    ["default", [
+      ["maxUnitWidth", 205],
+      ["maxUnitDepth", 205],
+      ["screwDiff", 10],
+      ["numRailScrews", 20],
+      ["mainRailScrewType", "m4"],
+      ["mainRailSideMountScrewType", "m4"],
+      ["rackFrameScrewType", "m3"],
+      ["baseRoundness", 5],
+    ]],
+    ["micro", [
+      ["maxUnitWidth", 105],
+      ["maxUnitDepth", 105],
+      ["numRailScrews", 10],
+      ["baseRoundness", 5]
+    ]],
+    ["mini", [
+      ["maxUnitWidth", 205],
+      ["maxUnitDepth", 205],
+      ["numRailScrews", 20],
+      ["baseRoundness", 5]
+    ]]
+  ];
+
+function _getConfigValueRaw(profile, varName) = profile[search([varName], profile)[0]][1];
+function _getProfileRaw(profileName) = _profileConfigs[search([profileName], _profileConfigs)[0]][1];
+
+function _getConfigValueOrThrowError(val) = val == undef? assert(false, "blah") 0: val;
+
+function getConfigValue(profile, varName) = _getConfigValueOrThrowError(_getConfigValueRaw(profile, varName));
+function getProfile(profileName) = _getConfigValueOrThrowError(_getProfileRaw(profileName));

rack/xBar.scad

@@ -17,7 +17,7 @@ xBarHeight = 15;
 xBarWallThickness = 2;
 xBarRoundness = baseRoundness;
 
-//echo(xBarDepth);
+*xBar();
 
 module xBar() {
 
@@ -71,6 +71,4 @@ module xBar() {
   xBar();
 }
 
-xBar();
-
 

rack/yBar.scad

@@ -42,18 +42,22 @@ module yBar() {
   yBarBase();
 
   module yBarBase() {
+    intersection() {
       difference() {
         sphericalFiletEdge(yBarWidth, yBarDepth, yBarHeight, yBarRoundness);
 
         translate(v = [yBarWallThickness, joinCornerDepth, yBarWallThickness])
         cylindricalFiletEdge(yBarWidth, yBarDepth-2*joinCornerDepth, yBarHeight, yBarRoundness);
       }
+
+      halfspace(vpos=[-1, 0, 1], p=[yBarWidth-0.5, 0,0]);
+    }
   }
 
   module applyBasePlateConnector() {
     apply_pn() {
       mirrorOtherCorner() {
-        translate(v = [yBarWidth-12, joinCornerDepth, 0.01]) // why do we need 0.01 here???
+        translate(v = [yBarWidth-12, joinCornerDepth, yBarWallThickness]) // why do we need 0.01 here???
         yBarBasePlateMount_P();
       }
 

rack/yBarBasePlateConnector.scad

@@ -5,7 +5,7 @@ include <./config.scad>
 
 _mountX = 12;
 _mountY = 14;
-_mountZ = 13;
+_mountZ = 10;
 
 // x and y faces of the yBarBasePlateMount_P block
 _innerXFaceToScrew = 6;
@@ -31,20 +31,30 @@ module yBarBasePlateMount_N() {
   mirror(v=[0,0,1])
     heatSetInsertSlot_N(rackFrameScrewType, topExtension=inf10);
 
-
   hull() {
-
     translate(v = [heatSetX, heatSetY, 0])
     cylinder(r=_baseConnY/2, h=_baseConnRecession);
 
     translate(v = [inf50, heatSetY-_baseConnY/2, 0])
     cube(size = [eps, _baseConnY, _baseConnRecession]);
   }
+
+  hull() {
+    translate(v = [heatSetX, heatSetY, 0])
+    cylinder(r=_baseConnY/2+0.25, h=eps);
+
+    translate(v = [inf50, heatSetY-_baseConnY/2, 0])
+    cube(size = [eps, _baseConnY + 0.5, eps]);
+
+    translate(v = [heatSetX, heatSetY, 1])
+    cylinder(r=_baseConnY/2, h=eps);
+
+    translate(v = [inf50, heatSetY-_baseConnY/2, 1])
+    cube(size = [eps, _baseConnY, eps]);
+  }
 }
 
 *difference() {
   yBarBasePlateMount_P();
   yBarBasePlateMount_N();
 }
-
-//yBarBasePlateMount_N();