WIP on sideWall and sideWallConnector

TODO.md

@@ -9,7 +9,8 @@
 - Start working on actual cases
 
 ### Ideas
-
+- Clean up `sharedVariables.scad`!!!
+- Start using matrices for transformations. Enforce strict local/global hierarchy of matrix transformations.
 - Instead of using names like 'mainRailSlotToInnerYZFace', experiment with a central distance/dimension directory. Like:
 ```openscad
 // Define identifiers:

rack/mainRail.scad

@@ -2,33 +2,7 @@ include <./config.scad>
 include <../helper/screws.scad>
 include <../helper/math.scad>
 include <../helper/halfspace.scad>
-
+include <./sharedVariables.scad>
-/* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
-   Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
-railFootThickness = 3;
-
-railTotalHeight = screwDiff * (numRailScrews + 1) + 2 * railFootThickness;
-
-railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
-railSideMountThickness = 2.5;
-
-// Distance between the middle of a screw mount and the rail's vertical edges
-railScrewHoleToInnerEdge = 5;
-railScrewHoleToOuterEdge = 7;
-
-// Distance between the midpoint of the rail screw holes.
-rackMountScrewWidth = maxUnitWidth + 2 * railScrewHoleToInnerEdge;
-
-// Extra spacing for screws.
-frontScrewSpacing = 15;
-
-sideSupportScrewHoleToBackEdge = 4;
-sideSupportDepth = sideSupportScrewHoleToBackEdge + frontScrewSpacing;
-
-frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
-
-railTotalWidth = frontFaceWidth;
-railTotalDepth = railFrontThickness+sideSupportDepth;
 
 *mainRail();
 

rack/sharedVariables.scad

@@ -1,4 +1,53 @@
+// Main rail variables:
+
+/* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
+   Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
+railFootThickness = 3;
+
+railTotalHeight = screwDiff * (numRailScrews + 1) + 2 * railFootThickness;
+
+railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
+railSideMountThickness = 2.5;
+
+// Distance between the middle of a screw mount and the rail's vertical edges
+railScrewHoleToInnerEdge = 5;
+railScrewHoleToOuterEdge = 7;
+
+// Distance between the midpoint of the rail screw holes.
+rackMountScrewWidth = maxUnitWidth + 2 * railScrewHoleToInnerEdge;
+
+// Extra spacing for screws.
+frontScrewSpacing = 15;
+
+sideSupportScrewHoleToBackEdge = 4;
+sideSupportDepth = sideSupportScrewHoleToBackEdge + frontScrewSpacing;
+
+frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
+
+railTotalWidth = frontFaceWidth;
+railTotalDepth = railFrontThickness+sideSupportDepth;
+
+
+// Side Wall variables:
 sideWallThickness = 2.5;
 
 sideWallSlotToOuterYEdge = 3;
-sideWallSlotToOuterXEdge = 3; // TODO rename to variables found in ybar;
+sideWallSlotToOuterXEdge = 3; // TODO rename to variables found in ybar;
+sideWallConnectorSlotWidth = 7;
+
+
+// Y Bar variables:
+railSlotToXZ = 3;
+sideWallSlotToXZ = 3;
+
+railSlotToInnerYEdge = 2;
+railSlotToSideWallSlot = 2;
+
+yBarWidth = railSlotToInnerYEdge + railTotalWidth+ railSlotToSideWallSlot
+  + sideWallSlotToOuterYEdge + sideWallConnectorSlotWidth;
+yBarDepth = maxUnitDepth + 2*railSlotToInnerYEdge;
+yBarHeight = 15;
+yBarWallThickness = 3;
+yBarRoundness = baseRoundness;
+
+joinCornerDepth = 32;

rack/sideWall.scad

@@ -2,30 +2,35 @@ include <../helper/math.scad>
 include <../helper/halfspace.scad>
 include <../misc/magnet.scad>
 include <./config.scad>
-include <./yBar.scad>
+include <./mainRail.scad>
-include <./sideWallConnector.scad>
+
 include <./sharedVariables.scad>
 
+include <./sideWallConnector.scad>
 
-sideWallZ = 110;
-sideWallY = 110;
-sideWallX = 12;
 
 sideWallZGapClearance = 0.2;
+sideWallZ = railTotalHeight - 2*(railFootThickness + sideWallZGapClearance);
 
+sideWallY = yBarDepth;
 
-// make these global
+sideWallXGapClearance = 0.2;
-hingePoleToInnerSideWallX = (hingePoleToConnectorOuterYZFace + sideWallSlotToOuterYEdge) - sideWallThickness;
+sideWallX = (yBarWidth-(railTotalWidth+railSlotToInnerYEdge)) - sideWallXGapClearance;
-hingePoleToInnerSideWallY = (hingePoleToConnectorOuterXZFace + sideWallSlotToOuterXEdge) - sideWallThickness;
 
+hingePoleDx = hingePoleToConnectorOuterYZFace + sideWallSlotToOuterYEdge;
+hingePoleDy = hingePoleToConnectorOuterXZFace + sideWallSlotToOuterXEdge;
+
+echo("Side Wall Height", sideWallZ);
+echo("Side Wall Depth", sideWallY);
 
 module sideWall() {
 
   applyHingeConnector()
   applyMagnetConnector()
+  applyEpicVentilation()
+  applyHingeHandle()
   sideWallBase();
 
-
   module sideWallBase() {
 
     module roundThingHelper(x,y,z,r) {
@@ -50,54 +55,80 @@ module sideWall() {
     }
   }
 
-
   module applyHingeConnector() {
 
-    hingeHolePositiveRad = hingeHoleR+1;
+    hingeHoleShellR = hingeHoleR+1;
-
-    module hingeProjectConstructionPlane() {
-      translate(v=[sideWallX-(sideWallThickness+hingePoleToInnerSideWallX) - hingeHolePositiveRad,sideWallY,0])
-      cube(size=[2*hingeHolePositiveRad, eps, sideWallZ]);
-    }
 
     apply_pn() {
-
       hull() {
-        translate(v = [sideWallX-(sideWallThickness+hingePoleToInnerSideWallX), sideWallY-(sideWallThickness+
+        hingeShell();
-          hingePoleToInnerSideWallY), 0])
+        hingeBacksideProjectionPlane();
-        cylinder(r = hingeHoleR+1, h = sideWallZ);
-
-        hingeProjectConstructionPlane();
       }
 
       union() {
-        translate(v = [sideWallX-(sideWallThickness+hingePoleToInnerSideWallX), sideWallY-(sideWallThickness+
+        hingeHole();
-          hingePoleToInnerSideWallY), 0])
+        // Trim parts of the wall for rotational clearance
-        cylinder(r = hingeHoleR, h = sideWallZ);
+        halfspace(p=[sideWallX-5, sideWallY, 0], vpos=[1,1.5,0]);
-
-        // TODO annoying constant
-        halfspace(p=[sideWallX-3.3, sideWallY, 0], vpos=[1,1,0]);
       }
 
       children(0);
     }
+
+    module hingeShell() {
+      translate(v = [sideWallX-hingePoleDx, sideWallY-(sideWallThickness+hingePoleDy), 0])
+      cylinder(r = hingeHoleShellR, h = sideWallZ);
+    }
+
+    // XZ plane in line with the back of the case. Project the hinge pole shell onto this to fill any weird
+    // geometries from the curves of the side wall
+    module hingeBacksideProjectionPlane() {
+      translate(v=[sideWallX-hingePoleDx - hingeHoleShellR,sideWallY,0])
+      cube(size=[2*hingeHoleShellR, eps, sideWallZ]);
+    }
+
+    module hingeHole() {
+      translate(v = [sideWallX-hingePoleDx, sideWallY-(sideWallThickness+hingePoleDy), 0])
+      cylinder(r = hingeHoleR, h = sideWallZ);
+    }
   }
 
+  // TODO: add correct magnet translations, also remove random variables
   module applyMagnetConnector() {
     apply_p() {
+      union() {
+        translate(v = [sideWallThickness, magnetMountToYBarFront + 2, magnetMountToYBarTop+1])
+        sideMagnetMount();
 
-      translate(v=[sideWallThickness,10,10])
+        translate(v = [sideWallThickness, magnetMountToYBarFront + 2, sideWallZ - (magnetMountToYBarTop + 1)])
-      rotate(a=[0,90,0])
+        sideMagnetMount();
-      sideWallConnectorMagnetSide();
+      }
 
       children(0);
     }
+
+
+    module sideMagnetMount() {
+      rotate(a=[0,90,0])
+      sideWallConnectorMagnetSide();
+    }
   }
 
   module applyEpicVentilation() {
+    children(0);
+  }
 
+  module applyHingeHandle() {
+    children(0);
   }
 }
 
+
 sideWall();
 
+translate(v=[10,sideWallSlotToXZ,-2])
+mirror(v=[1,0,0])
+sideWallConnectorMagnet();
+
+translate(v=[3,100,0])
+mirror(v=[0,1,0])
+sideWallConnectorHinge();

rack/sideWallConnector.scad

@@ -4,7 +4,6 @@ include <../helper/halfspace.scad>
 include <../misc/magnet.scad>
 include <./sharedVariables.scad>
 
-sideWallConnectorSlotWidth = 7;
 
 sideWallConnW = 7;
 sideWallConnD = 20;
@@ -15,10 +14,13 @@ yBarScrewHoleToOuterYEdge = 3.5;
 yBarScrewHoleToFrontXEdge = 16;
 
 magnetFaceToSideWallConnOuterYEdge = 2;
-magnetMountExtraRadius = magnetRSlacked + 1;
+magnetMountShellRadius = magnetRSlacked + 1;
 
 innerSideWallToYBarMagnetConn = magnetFaceToSideWallConnOuterYEdge + sideWallSlotToOuterYEdge - sideWallThickness;
 
+magnetMountToYBarTop = magnetMountShellRadius;
+magnetMountToYBarFront = magnetMountShellRadius + sideWallSlotToXZ;
+
 hingePoleR = 2;
 hingePoleH = 5;
 hingeHoleR = hingePoleR + 0.2;
@@ -67,27 +69,40 @@ module sideWallConnectorMagnet() {
         }
     }
 
-    // TODO: clean up
+
     module applyMagnetMount() {
-        apply_p() {
-            difference() {
-                hull() {
-                    translate(v = [0, 4, magnetMountExtraRadius+sideWallConnH])
-                    rotate(a = [0, 90, 0])
-                    cylinder(r = magnetMountExtraRadius, h = sideWallConnW-magnetFaceToSideWallConnOuterYEdge);
 
-                    translate(v = [0, 0, sideWallConnH])
+        magnetMountDx = magnetMountShellRadius;
-                    cube(size = [sideWallConnW-magnetFaceToSideWallConnOuterYEdge, 2*magnetMountExtraRadius, eps]);
+        magnetMountDy = magnetMountShellRadius + 2;
-                }
+        magnetMountDz = magnetMountShellRadius + sideWallConnLugDepression  +1;
-
-                translate(v = [sideWallConnW-(magnetFaceToSideWallConnOuterYEdge+magnetHSlacked), 4, 6])
-                rotate(a = [0, 90, 0])
-                cylinder(r = magnetRSlacked, h = magnetHSlacked);
-            }
 
+        apply_pn() {
+            magnetMountShell();
+            magnetMountHole();
             children(0);
         }
+
+        module magnetMountShell() {
+            hull() {
+                translate(v = [0, magnetMountDy, magnetMountDz])
+                rotate(a = [0, 90, 0])
+                cylinder(r = magnetMountShellRadius, h = sideWallConnW-magnetFaceToSideWallConnOuterYEdge);
+
+                translate(v = [0, 2, sideWallConnH])
+                cube(size = [sideWallConnW-magnetFaceToSideWallConnOuterYEdge, 2*magnetMountShellRadius, eps]);
+            }
+        }
+
+        module magnetMountHole() {
+            translate(v = [sideWallConnW-(magnetFaceToSideWallConnOuterYEdge+magnetHSlacked),
+                           magnetMountDy,
+                           magnetMountDz])
+            rotate(a = [0, 90, 0])
+            cylinder(r = magnetRSlacked, h = magnetHSlacked);
+        }
     }
+
+
 }
 
 module sideWallConnectorHinge() {
@@ -134,7 +149,7 @@ module sideWallConnectorHinge() {
 module sideWallConnectorMagnetSide() {
     // oriented so that the xy face is the side wall's inner face
     difference() {
-        cylinder(r1=magnetMountExtraRadius+2 ,r2 = magnetMountExtraRadius, h = innerSideWallToYBarMagnetConn);
+        cylinder(r1=magnetMountShellRadius + 0.5,r2 = magnetMountShellRadius, h = innerSideWallToYBarMagnetConn);
 
         translate(v=[0, 0, innerSideWallToYBarMagnetConn-magnetHSlacked])
         cylinder(r = magnetRSlacked, h = magnetHSlacked);

rack/yBar.scad

@@ -3,7 +3,6 @@ include <../helper/sphericalFilet.scad>
 include <../helper/cylindricalFilet.scad>
 include <../helper/screws.scad>
 include <../misc/magnet.scad>
-
 include <./config.scad>
 include <./mainRail.scad>
 
@@ -13,19 +12,8 @@ include <./xyBarConnector.scad>
 include <./sideWallConnector.scad>
 include <./yBarBasePlateConnector.scad>
 
-railSlotToInnerYEdge = 2;
+include <./sharedVariables.scad>
-railSlotToXZ = 3;
-railSlotToSideWallSlot = 2;
-sideWallSlotToXZ = 3;
 
-yBarDepth = maxUnitDepth + 2*railSlotToInnerYEdge;
-yBarWidth = railSlotToInnerYEdge + railTotalWidth+ railSlotToSideWallSlot
-  + sideWallSlotToOuterYEdge + sideWallConnectorSlotWidth;
-yBarHeight = 15;
-yBarWallThickness = 3;
-yBarRoundness = baseRoundness;
-
-joinCornerDepth = 32;
 
 echo("Bar total depth: ", yBarDepth);
 echo("Bar total width: ", yBarWidth);