bulk

cases/rack/.#rackCase.scad

@@ -0,0 +1 @@
+zhao@zhao-desktop.12132:1663410391

cases/rack/base1.scad

@@ -1,29 +1,24 @@
+include <../common.scad>
+include <./screws.scad>
 
 $fn=64;
 
-eps=0.1;
-
-slack = 0.5;
-m3Diameter = 3.0;
-m3Radius = m3Diameter/2.0;
-m3ptr = m3Radius + slack;
-
 module baseFrame() {
   difference() {
     cube(size=[200,200,4], center=true);
     cube(size=[180,180,4], center=true);
   }
 
-  translate(v=[90,90,0])
+  translate(v=[80,80,0])
   cube(size=[20,20, 4],center=true);
 
-  translate(v=[-90,90,0])
+  translate(v=[-80,80,0])
   cube(size=[20,20, 4],center=true);
 
-  translate(v=[90,-90,0])
+  translate(v=[80,-80,0])
   cube(size=[20,20, 4],center=true);
 
-  translate(v=[-90,-90,0])
+  translate(v=[-80,-80,0])
   cube(size=[20,20, 4],center=true);
 }
 
@@ -31,7 +26,7 @@ module lugBottom() {
   difference() {
     cube(size=[9.7,9.7,6], center=true);
 
-    translate(v=[1,1,0])
+    translate(v=[2,2,0])
     cube(size=[9.1,9.1,5+1], center=true);
   }
   
@@ -63,16 +58,16 @@ module base() {
     }
 
     union() {
-      translate(v=[90,90,0]) 
+      translate(v=[80,80,0]) 
       cylinder(h = 100, r = m3ptr, $fn=32, center=true);
 
-      translate(v=[-90,90,0]) 
+      translate(v=[-80,80,0]) 
       cylinder(h = 100, r = m3ptr, $fn=32, center=true);
 
-      translate(v=[90,-90,0]) 
+      translate(v=[80,-80,0]) 
       cylinder(h = 100, r = m3ptr, $fn=32, center=true);
 
-      translate(v=[-90,-90,0]) 
+      translate(v=[-80,-80,0]) 
       cylinder(h = 100, r = m3ptr, $fn=32, center=true);
       
     }
@@ -81,6 +76,4 @@ module base() {
 
 base();
 
-*lugBottom();
-
 

cases/rack/frontPlate.scad

@@ -0,0 +1,71 @@
+include <../common.scad>
+include <./screws.scad>
+include <../rpi/voronoi.scad>
+
+vU = 2;
+uHeight = 10;
+
+plateScrewDiffV = uHeight*vU;
+plateScrewDiffH = 180;
+
+plateScrewToHEdge = 4.5;
+plateScrewToVEdge = 5.5;
+
+frontPlateThickness = 2.5;
+
+frontPlateV = plateScrewDiffV + 2*plateScrewToHEdge;
+frontPlateH = plateScrewDiffH + 2*plateScrewToVEdge;
+
+
+plateScrewToBoxMin = 6;
+
+module _frontPlateBody() {
+  translate(v=[-plateScrewToVEdge,0,-plateScrewToHEdge])
+    cube(size=[frontPlateH,frontPlateThickness,frontPlateV]);
+}
+
+module _plateHole() {
+  rotate(a=[90,0,0])
+  cylinder(r=m4RadiusSlacked, h=inf, center=true);
+}
+
+
+module frontPlate() {
+
+  difference() {
+    _frontPlateBody();
+
+    union() {
+      // TODO: introduce helper modules for this pattern
+      _plateHole();
+
+      translate(v=[plateScrewDiffH,0,0])
+        _plateHole();
+
+      translate(v=[0,0,plateScrewDiffV])
+        _plateHole();
+
+      translate(v=[plateScrewDiffH,0,plateScrewDiffV])
+        _plateHole();
+    }
+  }
+}
+
+difference() {
+  difference () {
+    rotate(a=[-90,0,0])
+      frontPlate();
+    translate(v=[0,0,-5])
+      voronoi3u_N(10);  
+  }
+// lug holes
+  union() {
+    translate(v=[160,-3,-frontPlateThickness])
+    cube(size=[5.2, 5.2, 3]);
+    translate(v=[160-88,-3,-frontPlateThickness])
+    cube(size=[5.2, 5.2, 3]);
+  }
+}
+
+
+

cases/rack/m4Leg.scad

@@ -0,0 +1,158 @@
+include <../common.scad>
+include <./screws.scad>
+
+
+//slack = 0.5;
+//m3Diameter = 3.0;
+//m3Radius = m3Diameter/2.0;
+//m3ptr = m3Radius + slack;
+
+legWidth = 16;
+legLength = 16;
+legHeight = 60;
+
+legFrontThickness = 6;
+legSupportThickness = 4;
+
+legWingThickness = 4;
+legWingLength = 9;
+
+// 9.5 to account for space for inserting hex nuts at the top
+legWingWidth = 9.5+legSupportThickness;
+
+
+module legWing() {
+  difference() {
+    cube(size=[legWingLength, legWingThickness, legWingWidth]);
+
+    union() {
+      translate(v=[4,0,10])
+        rotate(a=[90,0,0])
+        cylinder(r=m3RadiusSlacked, h=20, center=true);
+
+      translate(v=[14,0,10])
+        rotate(a=[90,0,0])
+        cylinder(r=m3RadiusSlacked, h=20, center=true);
+    }
+  }
+}
+
+module base() {
+    difference() {
+      cube(size=[25,25,legWingThickness]);
+
+      union() {
+      translate(v=[20,20,0])
+        cylinder(r=m3RadiusSlacked, h=100, center=true);
+
+      translate(v=[10,10,0])
+        cylinder(r=m3RadiusSlacked, h=100, center=true);
+
+      translate(v=[20,10,0])
+        cylinder(r=m3RadiusSlacked, h=100, center=true);
+
+      translate(v=[10,20,0])
+        cylinder(r=m3RadiusSlacked, h=100, center=true);
+      }
+      
+    }
+}
+
+module baseLeg(legHeight) {
+  union() {
+    difference() {
+      cube(size=[16,16, legHeight]);
+
+      union() {
+        translate(v=[4,6,0])
+          cube(size=[16, 16, legHeight]);
+
+        // compensate for differences between leg/wing thickness
+        translate(v=[legSupportThickness,legSupportThickness,0])
+          cube(size=[legWidth,legWidth,legSupportThickness+10]);
+
+        translate(v=[legSupportThickness,legSupportThickness,legHeight-legWingWidth])
+          cube(size=[legWidth,legWidth,legSupportThickness+10]);
+
+      }
+    }
+
+    translate(v=[16,0,0])
+      legWing();
+
+
+    translate(v=[16,0,legHeight])
+      mirror(v=[0,0,1]) {
+      legWing();
+    }
+
+    mirror(v=[1,-1,0]) {
+      translate(v=[16,0,0])
+        legWing();
+
+
+      translate(v=[16,0,legHeight])
+        mirror(v=[0,0,1]) {
+        legWing();
+      }
+    }
+
+  }
+
+  base();
+
+  translate(v=[0,0,legHeight-legWingThickness])
+    base();
+}
+
+*baseLeg(180);
+
+module leg(ui) {
+  assert(ui > 0);
+
+  legLength = 20 + (ui-1)*10;
+  
+  difference() {
+    baseLeg(legLength);
+
+    union() {
+        
+      intersection() {
+        union() {
+          for (i = [1:ui-2]) {
+            translate(v=[0,10,(i+1)*10])
+              rotate(a=[0,90,0])
+              *cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+            translate(v=[10,3,(i+1)*10])
+              rotate(a=[90,-10,0])
+              m4HexNutPocketNegative();
+          }
+        }      
+        translate(v=[-1,-1,legWingWidth])
+          cube(size=[1000,1000,legLength-2*legWingWidth]);
+      }
+
+      translate(v=[0,10,10])
+        rotate(a=[0,90,0])
+        cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+      translate(v=[0,10,ui*10])
+        rotate(a=[0,90,0])
+        cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+
+      translate(v=[10,0,10])
+        rotate(a=[90,0,0])
+        cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+      translate(v=[10,0,ui*10])
+        rotate(a=[90,0,0])
+        cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+    }
+  }
+}
+
+
+//mirror(v=[1,0,0])
+leg(20);

cases/rack/rackCase.scad

@@ -0,0 +1,133 @@
+include <../common.scad>
+include <./screws.scad>
+include <../rockpro/rockpro.scad>
+
+vU = 4;
+uHeight = 10;
+
+plateScrewDiffV = uHeight*vU;
+plateScrewDiffH = 180;
+
+plateScrewToHEdge = 4.5;
+plateScrewToVEdge = 5.5;
+
+frontPlateThickness = 2.5;
+
+frontPlateV = plateScrewDiffV + 2*plateScrewToHEdge;
+frontPlateH = plateScrewDiffH + 2*plateScrewToVEdge;
+
+
+plateScrewToBoxMin = 6;
+
+// BOX CONFIG
+
+// box dimensions
+boxDepth = 135;
+boxWidth = 95;
+
+boxBottomThickness = 1;
+boxSideThickness = 2;
+boxBackThickness = 2;
+// boxFrontThickness is just frontPlateThickness
+
+
+
+boxTopSpace = 1; // meant for lids?
+boxBottomSpace = 1; // meant to be used for boxes that expect support rails
+
+
+boxHeight = vU * uHeight + 2*plateScrewToHEdge - (boxBottomSpace+boxTopSpace);
+
+
+
+// all of these are defined on the xy plane with centered zLen height
+// 'rise' is meant model how raised a pcb is. More specifically, the distance between the top of
+// the pcb and the bottom of the inside of the case
+module frontFaceHoles(zLen, rise) {
+
+  //mirror(v=[0,1,0])
+//    translate(v=[5,-eps,rise])
+  //frontFaceIOCutouts_N();
+}
+
+module backFaceHoles(zLen, rise) {
+}
+
+module leftFaceHoles(zLen, rise) {
+}
+
+module rightFaceHoles(zLen, rise) {
+}
+
+
+
+
+module boxBody() {
+  // save this transformation...
+  // translate(v=[(plateScrewDiffH-boxWidth)/2.0,0,boxBottomSpace -plateScrewToHEdge])
+
+  // convert to inside box space
+  translate(v=[-boxSideThickness, -frontPlateThickness, -boxBottomThickness])
+  difference() {
+    cube(size=[boxWidth, boxDepth, boxHeight]);
+    translate(v=[boxSideThickness, frontPlateThickness, boxBottomThickness])
+      cube(size=[boxWidth-2*boxSideThickness, boxDepth-(boxBackThickness+frontPlateThickness), inf]);
+  }
+
+  
+}
+
+
+*difference() {
+  boxBody();
+
+  translate(v=[7,2,5])
+    cutoutProfile_N();
+}
+
+translate(v=[7,2,5])
+*cutoutProfile_N();
+
+
+
+
+module _frontPlateBody() {
+  translate(v=[-plateScrewToVEdge,0,-plateScrewToHEdge])
+    cube(size=[frontPlateH,frontPlateThickness,frontPlateV]);
+}
+
+module _plateHole() {
+  rotate(a=[90,0,0])
+  cylinder(r=m4RadiusSlacked, h=inf, center=true);
+}
+
+
+module frontPlate() {
+
+  difference() {
+    _frontPlateBody();
+
+    union() {
+      // TODO: introduce helper modules for this pattern
+      _plateHole();
+
+      translate(v=[plateScrewDiffH,0,0])
+        _plateHole();
+
+      translate(v=[0,0,plateScrewDiffV])
+        _plateHole();
+
+      translate(v=[plateScrewDiffH,0,plateScrewDiffV])
+        _plateHole();
+    }
+
+    // TODO REMOVE. Used to save on filament and print time
+    scale(v=[0.8, 1+eps, 0.5])
+      translate(v=[0,-eps,0])
+      translate(v=[21,0,5])
+      _frontPlateBody();
+  }
+}
+
+
+frontPlate();

cases/rack/rackCaseForBox.scad

@@ -8,11 +8,12 @@ slack = 0.4;
 
 boxWidth = 157.67;
 boxHeight = 27.0;
-boxLength = 101.5;
+boxLength = 101.5+1;
 
 topThickness = 1.0;
 bottomThickness = 1.0;
 
+faceThickness = 3.0;
 sideThickness = 2.0;
 sideSupportWidth = 10;
 
@@ -23,19 +24,21 @@ totalLength = boxLength+2*sideThickness;
 
 
 railMountWidthDiff = (200.0 - (boxWidth + 2*sideThickness)) / 2.0;
+
+totalMountLength = 200.0 + 2*faceThickness + 1;
   
 module sideHolder() {
 
 
   module frontLowerCaseSegment() {
     translate(v=[0,0,0])
-      cube(size=[sideSupportWidth, sideThickness, bottomThickness]);
+      cube(size=[sideSupportWidth, faceThickness, bottomThickness]);
   }
 
   module frontUpperCaseSegment() {
     // no room for slack? :(
     translate(v=[0,0,boxHeight+bottomThickness])
-      cube(size=[sideSupportWidth, sideThickness, topThickness]);
+      cube(size=[sideSupportWidth, faceThickness, topThickness]);
   }
 
   module backLowerCaseSegment() {
@@ -49,25 +52,25 @@ module sideHolder() {
   }
 
   module backLowerRailSegment() {
-    translate(v=[0,198.0-sideThickness,0])
-      cube(size=[sideSupportWidth, sideThickness, bottomThickness]);
+    translate(v=[0,200.0+1,0])
+      cube(size=[sideSupportWidth, faceThickness, bottomThickness]);
   }
 
   
   module backUpperRailSegment() {
-    translate(v=[0,198.0-sideThickness,boxHeight+bottomThickness])
-      cube(size=[sideSupportWidth, sideThickness, topThickness]);
+    translate(v=[0,200.0+1,boxHeight+bottomThickness])
+      cube(size=[sideSupportWidth, faceThickness, topThickness]);
   }
 
   module frontRailMountSegment() {
     // +2 is slack
     translate(v=[-railMountWidthDiff+5,0,0])
       // should technically use different totalHeight, as current totalHeight is for case holder
-      cube(size=[railWidth,sideThickness,totalHeight]);
+      cube(size=[railWidth,faceThickness,totalHeight]);
   }
 
   module backRailMountSegment() {
-    translate(v=[0,198.0-sideThickness,0])
+    translate(v=[0,200+1,0])
       // should technically use different totalHeight, as current totalHeight is for case holder
       frontRailMountSegment();
   }
@@ -82,19 +85,19 @@ module sideHolder() {
       }
 
       // screw holes
-      translate(v=[-railMountWidthDiff + 10,0,5])
+      translate(v=[-railMountWidthDiff + 11.5,0,5])
         rotate(a=[90,0,0])
-        cylinder(r=m3RadiusSlacked, h=10, center=true);
+        cylinder(r=m4RadiusSlacked, h=10, center=true);
 
-      translate(v=[-railMountWidthDiff + 10,0,25])
+      translate(v=[-railMountWidthDiff + 11.5,0,25])
         rotate(a=[90,0,0])
-        cylinder(r=m3RadiusSlacked, h=10, center=true);
+        cylinder(r=m4RadiusSlacked, h=10, center=true);
     }
     
   }
 
   module backFace() {
-    translate(v=[0,198.0-sideThickness,0])
+    translate(v=[0,200.0+faceThickness+1,0])
       frontFace();
       
   }
@@ -134,24 +137,24 @@ module sideHolder() {
   difference() {
     cube(size=[sideThickness, totalLength, totalHeight]);
 
-    translate(v=[-eps/2,5,5])
-      cube(size=[sideThickness+eps,totalLength-10+eps, totalHeight-10+eps]);
+    translate(v=[-eps/2,8,5])
+      cube(size=[sideThickness+eps,totalLength-17.5+eps, totalHeight-10+eps]);
   }
 
 
   // side support/hold for case
   difference() {
     translate(v=[sideSupportWidth-sideThickness,totalLength,0])
-    cube(size=[sideThickness, 198-totalLength, totalHeight]);
+    cube(size=[sideThickness, totalMountLength-totalLength, totalHeight]);
 
-    translate(v=[sideSupportWidth-sideThickness-eps/2,(198-totalLength)+15,5])
-      cube(size=[sideThickness+eps,(198-totalLength)-10+eps, totalHeight-10+eps]);
+    translate(v=[sideSupportWidth-sideThickness-eps/2,(200-totalLength)+20,5])
+      cube(size=[sideThickness+eps,(200-totalLength)-10+eps, totalHeight-10+eps]);
   }
 }
 
 
 module sideHolderAligned() {
-  translate(v=[19,0,0])
+  //translate(v=[19,0,0])
     sideHolder();
 }
 
@@ -163,6 +166,6 @@ module mSide() {
 
 sideHolderAligned();
 
-translate(v=[42 + boxWidth,0,0])
-*mSide();
+//translate(v=[42 + boxWidth,0,0])
+//mSide();
 

cases/rack/screwmount.scad

@@ -0,0 +1,62 @@
+/*  Contains screw mounts to be used to fix risers and whatnot into plastic */
+
+include <../common.scad>
+include <./screws.scad>
+
+
+
+// Heat set inserts:
+
+// Useful references:
+// https://hackaday.com/2019/02/28/threading-3d-printed-parts-how-to-use-heat-set-inserts/
+
+
+
+// My knurled brass nut dimensions
+
+
+m4NutDiameter = 6;
+m4NutLength1 = 6;
+
+m3NutDiameter = 4.9;
+m3NutLength1 = 6;
+
+
+module nut_N(diameter,length,edm,elm) {
+  cylinder(h=(length + length*edm), d=(diameter + diameter*edm));
+}
+
+difference() {
+  union() {
+    cube(size=[30,30,2.5]);
+
+    translate(v=[8,8,0])
+    cylinder(h=8,d=8);
+
+    translate(v=[22,8,0])
+    cylinder(h=10,d=8);
+
+    translate(v=[8,22,0])
+    cylinder(h=8,d=10);
+
+    translate(v=[22,22,0])
+    cylinder(h=10,d=10);
+  }
+
+  union() {
+    translate(v=[8,8,2])
+      cylinder(h=6, d=6);
+
+    translate(v=[22,8,4])
+      cylinder(h=6,d=6);
+
+    translate(v=[8,22,2])
+    cylinder(h=6,d=6);
+
+    translate(v=[22,22,3])
+    cylinder(h=8,d=6);
+  }
+
+}
+
+

cases/rack/screws.scad

@@ -63,7 +63,7 @@ module m4HexNutPocketNegative() {
 
 // TODO: remove test
 
-difference() {
+*difference() {
   translate(v=[0,1,0])
   cube(size=[10,12,6], center=true);
 

cases/rack/top1.scad

@@ -0,0 +1,79 @@
+include <../common.scad>
+include <./screws.scad>
+
+$fn=64;
+
+module baseFrame() {
+  difference() {
+    cube(size=[200,200,4], center=true);
+    cube(size=[180,180,4], center=true);
+  }
+
+  translate(v=[80,80,0])
+  cube(size=[20,20, 4],center=true);
+
+  translate(v=[-80,80,0])
+  cube(size=[20,20, 4],center=true);
+
+  translate(v=[80,-80,0])
+  cube(size=[20,20, 4],center=true);
+
+  translate(v=[-80,-80,0])
+  cube(size=[20,20, 4],center=true);
+}
+
+module lugBottom() {
+  difference() {
+    cube(size=[9.7,9.7,6], center=true);
+
+    translate(v=[2,2,0])
+    cube(size=[9.1,9.1,5+1], center=true);
+  }
+  
+}
+
+
+module base() {
+
+  difference() {
+    union() {
+      translate(v=[0,0,4/2])
+        baseFrame();
+
+
+      translate(v=[-90,-90,-6/2])
+        lugBottom();
+
+      mirror(v=[1,0,0])
+        translate(v=[-90,-90,-6/2])
+        lugBottom();
+
+      mirror(v=[0,1,0])
+        translate(v=[-90,-90,-6/2])
+        lugBottom();
+
+      mirror(v=[1,1,0])
+        translate(v=[-90,-90,-6/2])
+        lugBottom();
+    }
+
+    union() {
+      translate(v=[80,80,0]) 
+      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+      translate(v=[-80,80,0]) 
+      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+      translate(v=[80,-80,0]) 
+      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+
+      translate(v=[-80,-80,0]) 
+      cylinder(h = 100, r = m3ptr, $fn=32, center=true);
+      
+    }
+  }
+}
+
+base();
+
+