update side support

config/slack.scad

@@ -13,7 +13,7 @@
     - These values depend on print orientation and it's assumed parts are printed in their recommended orientations.
 */
 
-xySlack = 0.4;
+xySlack = 0.35;
 
 radiusXYSlack = xySlack/2;
 

rack-mount/common.scad

@@ -9,14 +9,8 @@ include <../config/common.scad>
 
 uDiff = screwDiff;
 
-rackMountScrewXDist = 4;
-rackMountScrewZDist = 4;
-
-
-
-
-
-
-
-
+rackMountScrewXDist = 4.5;
+rackMountScrewZDist = 4.5;
 
+mainRailSideSupportToInnerEdge = frontFaceWidth - railSideMountThickness;
+railSupportsDx = 2*mainRailSideSupportToInnerEdge + maxUnitWidth;

rack-mount/side-rail/dualMount.scad

@@ -1,68 +1,63 @@
 include <../../helper/common.scad>
-include <../../helper/math.scad>
-include <../../helper/screws.scad>
-include <../../rack/config.scad>
+include <../../config/common.scad>
 include <../../rack/sharedVariables.scad>
+include <../common.scad>
 
-*sideSupportRailBase("lBracket");
-// TODO: make this parametric
+sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159);
 
 // distance between front and back main rail screw mounts
-sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ); // TODO use transformation matrices
+sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ);
 
-module sideSupportRailBase(type) {
+module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThickness=2, backThickness=2, supportedZ=26.5, supportedY=101.5, supportedX=159) {
 
-  // vertical distance between local origin and main rail screw mount
-  screwMountGlobalDz = screwDiff / 2.0;
+  mountBlockHeight = 10;
+  mountBlockDepth = 10;
+  screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
+  railLength = max(sideRailScrewMountDist + frontScrewSpacing + mountBlockDepth, supportedY+backThickness);
+  railBaseThickness = baseThickness;
+  railSideThickness = sideThickness;
+  railBaseWidth = 15;
+  railSideHeight = supportedZ + railBaseThickness*2;
+  frontMountPad = frontScrewSpacing;
 
-  railLength = sideRailScrewMountDist + 30; // TODO calculate this
-  railBaseThickness = 2;
-  railBaseWidth = 18;
-  railSideThickness = 2;
-  railSideHeight = 15;
-  sideDy = -2;
-  frontMountPad = 10; // depends on y of box to be mounted TODO calculate this
-  sideMountPad = 10; // depends on x of box TODO calculate this
-
-  translate(v=[sideMountPad,-(frontMountPad + 5),-5])
   applyMainRailMounts()
-  sideSupportRailBaseHolder();
-
-  module sideSupportRailBaseHolder() {
-    if (type == "lBracket") {
-      sideSupportRailBaseLBracket();
-    } else {
-      error("Unsupported side support type");
-    }
-  }
-
+  sideSupportRailBase();
 
   module applyMainRailMounts() {
 
+    mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
+    assert(mountBlockExtension >= 10);
+
     apply_p() {
-      translate(v=[0,frontMountPad,0])
       union() {
-        dualMount();
-
-        translate(v=[0,sideRailScrewMountDist,0])
-        dualMount();
+        translate(v = [0, frontMountPad, 0])
+        mountBlockColumn(mountBlockExtension=mountBlockExtension, u=u);
+        translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
+        mountBlockColumn(mountBlockExtension=mountBlockExtension, u=u);
       }
-
       children(0);
     }
   }
 
-  module dualMount() {
-
-    blockHeight = railSideHeight - sideDy;
+  module mountBlockColumn(mountBlockExtension, u) {
 
     difference() {
-      // mount block
-      translate(v = [-sideMountPad, 0, sideDy])
-      cube(size = [sideMountPad, 10, blockHeight+sideDy]);
+      translate(v = [-mountBlockExtension, 0, 0])
+      cube(size = [mountBlockExtension, mountBlockDepth, railSideHeight]);
 
-      // screw mount
-      translate(v=[-5,5,5]) // screwMountToGlobalZ
+      union() {
+        nutPocket();
+
+        if (double) {
+          translate(v=[0,0,uDiff * u]) // screwMountToGlobalZ
+          nutPocket();
+        }
+
+      }
+    }
+
+    module nutPocket() {
+      translate(v=[-mountBlockExtension/2,mountBlockDepth/2,mountBlockHeight/2]) // screwMountToGlobalZ
       rotate(a=[90,0,0])
       rotate(a=[0,90,0])
       hexNutPocket_N(rackFrameScrewType, openSide=false);
@@ -70,23 +65,51 @@ module sideSupportRailBase(type) {
 
   }
 
-  module sideSupportRailBaseLBracket(backSupport=true, backThickness=3) {
+  module sideSupportRailBase() {
+    backThickness = 3;
 
-    translate(v=[0, 0, sideDy])
+    difference () {
       union() {
         cube(size = [railBaseWidth, railLength, railBaseThickness]);
+
         cube(size = [railSideThickness, railLength, railSideHeight]);
 
-      if (backSupport) {
-        translate(v=[0, railLength-backThickness, 0])
+        // back support
+        translate(v = [0, max(railLength-backThickness, supportedY), 0])
         cube(size = [railBaseWidth, backThickness, railSideHeight]);
-      }
-    }
+
+        // back support for box
+        translate(v = [0, supportedY, 0])
+        cube(size = [railBaseWidth, backThickness, railSideHeight]);
+
+        // top support
+        if (top) {
+          translate(v = [0, 0, railSideHeight-baseThickness])
+          cube(size = [railBaseWidth, railLength, railBaseThickness]);
         }
 
-  module sideSupportRailBaseDovetail() {}
+      }
+      union() {
+        distanceFromSeparator = 3;
+        r = 5;
 
-  module sideSupportRailBaseBoxed() {}
+        boxDy = frontMountPad+r+mountBlockDepth+distanceFromSeparator;
+        boxDz = baseThickness+distanceFromSeparator+r;
+        translate(v=[0,boxDy,boxDz])
+        minkowski() {
+          cube(size = [sideThickness, supportedY-(boxDy+distanceFromSeparator+r), railSideHeight-2*boxDz]);
+          sphere(r=r);
+        }
+        translate(v=[0,supportedY+distanceFromSeparator+r+backThickness,boxDz])
+        minkowski() {
+          cube(size = [sideThickness, 25, railSideHeight-2*boxDz]); // TODO calculate 22.5
+          sphere(r=r);
+        }
+
+        cylindricalFiletNegative(p0=[railBaseWidth,0,0],p1=[railBaseWidth,0,inf], n=[1,-1,0],r=4);
+      }
+    }
+  }
 
 }
 

rack-mount/tray.scad

@@ -2,6 +2,8 @@ include <./common.scad>
 use <./rackEars.scad>
 
 // Rack mount tray that supports screws on the bottom of the rack-mount item
+bottomScrewTray(u=1);
+
 
 // Config variables
 //trayAlignment = "middle"; // middle, right, left
@@ -13,9 +15,7 @@ mountPoints = [];
 mountScrewType = "m3";
 
 
-bottomScrewTray(u=1);
-
-module bottomScrewTray(u) {
+module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, mountScrewType) {
 
   frontLipHeight = 2;
   backLipHeight = 1; // also applies to sides