improve tray part

config/rackFrame.scad

@@ -10,10 +10,10 @@ _profileConfigs = [
       ["numRailScrews", 10]
     ]],
     */
-    ["default", [
+    ["default", [ // Default config. Will be overwritten by any other profiles
       ["maxUnitWidth", 180],
       ["maxUnitDepth", 180],
-      ["numRailScrews", 18],
+      ["numRailScrews", 12],
       ["screwDiff", 10],
       ["mainRailScrewType", "m4"],
       ["mainRailSideMountScrewType", "m4"],

helper/screws.scad

@@ -32,6 +32,10 @@ m4HoleRadiusSlack = 0.15;
 m4Diameter = 4.0;
 m4Radius = m4Diameter / 2.0;
 m4RadiusSlacked = m4Radius + m4HoleRadiusSlack;
+
+m4CounterSunkHeadRadius = 4;
+m4CounterSunkHeadLength = 2.3;
+
 m4HexNutWidthAcrossFlats = 6.89;
 m4HexNutWidthAcrossCorners = FtoG(m4HexNutWidthAcrossFlats);
 m4HexNutThickness = 3.07;
@@ -91,6 +95,17 @@ module counterSunkHead_N(screwType, screwExtension=0, headExtension=0) {
       translate(v = [0, 0, m3CounterSunkHeadLength])
       cylinder(r = m3CounterSunkHeadRadius, h = headExtension);
     }
+  } else if (screwType == "m4") {
+    translate(v = [0, 0, -m4CounterSunkHeadLength])
+    union() {
+      cylinder(r1 = m4RadiusSlacked, r2 = m4CounterSunkHeadRadius, h = m4CounterSunkHeadLength);
+
+      translate(v = [0, 0, -screwExtension])
+      cylinder(r = m4RadiusSlacked, h = screwExtension);
+
+      translate(v = [0, 0, m4CounterSunkHeadLength])
+      cylinder(r = m4CounterSunkHeadRadius, h = headExtension);
+    }
   } else {
     error("Unsupported screw type");
   }

rack-mount/dimensionHelper.scad

@@ -5,6 +5,8 @@ include <./common.scad>
 echo("Vertical distance between 2 main rail holes: ", screwDiff);
 echo("Horizontal distance between 2 opposing main rail holes: ", rackMountScrewWidth);
 
+echo("Distance between main rail screw, and main rail inner edge:", railScrewHoleToInnerEdge);
+
 echo("Max supported rack-mount width: ", maxUnitWidth);
 echo("Max recommended rack-mount depth: ", maxUnitDepth);
 

rack-mount/print/tray_P.scad

@@ -1,20 +1,55 @@
 use <../tray.scad>
 
-// Config variables
+/*
-trayWidth = 140;
+  Parametric rack-mount tray -
-trayDepth = 88;
+  Dimensions can be adjusted using the variables below. You can also add mounting holes to fasten things that have
-trayThickness = 3;
+  screw holes at the bottom.
-trayLipThickness = 3;
 
-pointHoleRadius = screwRadiusSlacked("m3");
+  !!! Please also make sure that the correct rack frame preset is set in rackFrame.scad !!!
-pointHoleThickness = 2;
+*/
-pointMountElevation = 1;
+
-mountPoints = [ // [x,y,elevation,holeRadius,holeThickness]
+// begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
-   [(27.5),34, pointMountElevation, pointHoleRadius, pointHoleThickness],
+
-   [(27.5)+79.5,34, pointMountElevation, pointHoleRadius, pointHoleThickness]
+trayU = 2;
+
+baseWidth = 145;
+baseDepth = 100;
+
+baseThickness = 3; // tray bottom thickness
+frontThickness = 3; // front plate thickness
+sideThickness = 3;
+
+backLipHeight = 2;
+frontLipHeight = 2;
+
+sideSupport = true;
+trayLeftPadding = 10; // extra space between the left rail and tray. configure this to move the tray left/right.
+
+mountPointType = "m3";
+mountPointElevation = 1; // basically standoff height
+
+// add/config standoff coordinates here. Format is [[x,y]]
+mountPoints = [
+    [30,10],
+    [30+75,10],
+    [30,10+75],
+    [30+75,10+75],
 ];
+// end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
 
-mountScrewType = "m3";
 
-// Rack mount tray that supports screws on the bottom of the rack-mount item
+bottomScrewTray(
-bottomScrewTray(u=1, trayWidth=trayWidth, trayDepth=trayDepth, trayThickness=trayThickness, mountPoints=mountPoints, mountScrewType=mountScrewType, lipThickness=trayLipThickness);
+  u=trayU,
+  trayWidth=baseWidth,
+  trayDepth=baseDepth,
+  trayThickness=baseThickness,
+  frontLipHeight=frontLipHeight,
+  backLipHeight=backLipHeight,
+  mountPoints=mountPoints,
+  frontThickness=frontThickness,
+  sideThickness=sideThickness,
+  mountPointElevation=mountPointElevation,
+  mountPointType=mountPointType,
+  sideSupport=sideSupport,
+  trayLeftPadding=trayLeftPadding
+);

rack-mount/rackEars.scad

@@ -3,9 +3,20 @@ include <./common.scad>
 // Rack ear modules.
 // To be used either by itself if the item supports it, or within another module
 
-rackEarModule(frontThickness=3,sideThickness=3,frontWidth=30, sideDepth=50, u=4, support=true);
+rackEarModule(u=4, frontThickness=3, sideThickness=3, frontWidth=20, sideDepth=50, backPlaneHeight, support=true);
 
-module rackEarModule(frontThickness, sideThickness, frontWidth, sideDepth, u, backPlaneHeight=3, support=true) {
+module rackEarModule(
+  u,
+  frontThickness,
+  sideThickness,
+  frontWidth,
+  sideDepth,
+  backPlaneHeight,
+  support=true
+) {
+
+  // check frontWidth is wide enough
+  assert(frontWidth-sideThickness >= rackMountScrewXDist+railScrewHoleToInnerEdge);
 
   earHeight = u*uDiff + 2*rackMountScrewZDist;
 
@@ -23,9 +34,13 @@ module rackEarModule(frontThickness, sideThickness, frontWidth, sideDepth, u, ba
       }
 
       if (support) {
+        defaultExtraSpacing = 1;
+        extraSpacing = frontWidth-(rackMountScrewXDist+railScrewHoleToInnerEdge+sideThickness) > defaultExtraSpacing
+          ? defaultExtraSpacing
+          : 0; // don't include extra spacing for support, if tray itself is too large
+
         hull() {
-          extraSpacing = 1;
+          translate(v= [rackMountScrewXDist+railScrewHoleToInnerEdge+extraSpacing,frontThickness,0])
-          translate(v= [rackMountScrewXDist+railScrewHoleToOuterEdge+extraSpacing,frontThickness,0])
             cube(size = [sideThickness, eps, earHeight]);
 
           backSegmentPlane();
@@ -43,10 +58,10 @@ module rackEarModule(frontThickness, sideThickness, frontWidth, sideDepth, u, ba
 
   module rackMountHoles() {
     rotate(a=[90,0,0])
-      cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
+      cylinder(r=screwRadiusSlacked(mainRailScrewType), h=inf, center=true);
 
     translate(v=[0,0,u*uDiff])
       rotate(a=[90,0,0])
-        cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
+        cylinder(r=screwRadiusSlacked(mainRailScrewType), h=inf, center=true);
   }
 }

rack-mount/tray.scad

@@ -1,14 +1,16 @@
 include <./common.scad>
 use <./rackEars.scad>
 
+/*
+  Parametric rack-mount tray -
+  Please see print/tray_P.scad for configuring/printing
 
-module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, mountScrewType, lipThickness=3) {
+  Please also make sure that the correct rack frame preset is set in rackFrame.scad.
+*/
 
-  frontLipHeight = 2;
+module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, mountPointElevation, mountPointType, frontThickness, sideThickness, frontLipHeight, backLipHeight, trayLeftPadding, sideSupport=true) {
-  backLipHeight = 1; // also applies to sides
 
-  rackEarSideThickness = 3;
+  lipThickness = sideThickness;
-  rackEarFrontThickness = 3;
 
   screwDx = rackMountScrewWidth; // x dist between the mount holes
   screwDz = uDiff * u;
@@ -16,82 +18,66 @@ module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, moun
   plateLength = screwDx + 2*rackMountScrewXDist;
   plateHeight = screwDz + 2*rackMountScrewZDist;
 
-  minScrewToTraySpacing = 8;
+  minScrewToTraySpacing = railScrewHoleToInnerEdge;
 
-  // TODO: toggle this based on left/right/middle alignment
+  leftScrewDistToTray = minScrewToTraySpacing + trayLeftPadding;
-  leftScrewDistToTray = minScrewToTraySpacing + 2 + 10;
 
   leftScrewGlobalX = -leftScrewDistToTray;
   rightScrewGlobalX = screwDx + leftScrewGlobalX;
 
-  points=mountPoints;
+  // check (tray width)+(configured extra space) fits within the rack
+  assert(trayWidth <= screwDx-(2*minScrewToTraySpacing + trayLeftPadding));
 
   difference() {
-    applyMountHoles(points)
+    applyMountHoles()
-    translate(v = [-rackEarSideThickness, -rackEarFrontThickness, -trayThickness])
+    translate(v = [-sideThickness, -frontThickness, -trayThickness])
     body();
-
-    // hack
-    *union() {
-      translate(v = [-20, 18, 15])
-      rotate(a = [0, 90, 0])
-      cylinder(r = 10, h = inf);
-
-      translate(v = [-20, 40, 13])
-      rotate(a = [0, 90, 0])
-      cylinder(r = 7, h = inf);
-    }
   }
 
   module body() {
 
+    // base
     cube(size = [trayWidth, trayDepth, trayThickness]);
 
+    // front lip
     translate(v = [0, 0, trayThickness])
     cube(size = [trayWidth, lipThickness, frontLipHeight]);
 
+    // back lip
     translate(v = [0, trayDepth-lipThickness, trayThickness])
     cube(size = [trayWidth, lipThickness, backLipHeight]);
 
-    translate(v = [0, 0, trayThickness])
-    cube(size = [lipThickness, trayDepth, backLipHeight]);
-
-    translate(v = [trayWidth-lipThickness, 0, trayThickness])
-    cube(size = [lipThickness, trayDepth, backLipHeight]);
-
     translate(v = [leftScrewGlobalX, 0, rackMountScrewZDist])
-    rackEarModule(frontThickness = rackEarFrontThickness, sideThickness = rackEarSideThickness, frontWidth =
+    rackEarModule(frontThickness = frontThickness, sideThickness = sideThickness, frontWidth =
-        leftScrewDistToTray+rackMountScrewXDist+rackEarSideThickness, sideDepth = trayDepth-lipThickness, u = u, backPlaneHeight=trayThickness+backLipHeight);
+        leftScrewDistToTray+rackMountScrewXDist+sideThickness, sideDepth = trayDepth-lipThickness, u = u, backPlaneHeight=trayThickness+backLipHeight, support=sideSupport);
 
     translate(v = [rightScrewGlobalX, 0, rackMountScrewZDist])
     mirror(v = [1, 0, 0])
-    rackEarModule(frontThickness = rackEarFrontThickness, sideThickness = rackEarSideThickness, frontWidth =
+    rackEarModule(frontThickness = frontThickness, sideThickness = sideThickness, frontWidth =
-       rightScrewGlobalX-trayWidth+rackMountScrewXDist+rackEarSideThickness, sideDepth = trayDepth-lipThickness, u = u, backPlaneHeight=trayThickness+backLipHeight);
+       rightScrewGlobalX-trayWidth+rackMountScrewXDist+sideThickness, sideDepth = trayDepth-lipThickness, u = u, backPlaneHeight=trayThickness+backLipHeight, support=sideSupport);
     }
 
 
-  module applyMountHoles(points) {
+  module applyMountHoles() {
 
+    mountPointPosThickness = 2;
 
     apply_pn() {
-      for (i = [0:len(points)-1]) {
+      for (i = [0:len(mountPoints)-1]) {
-        p = points[i];
+        x = mountPoints[i][0];
-        x = p[0];
+        y = mountPoints[i][1];
-        y = p[1];
+
-        elevation = p[2];
-        hR = p[3];
-        hT = p[4];
         translate(v=[x, y, 0])
-        cylinder(r=hR+hT, h=elevation);
+        cylinder(r=screwRadiusSlacked(mountPointType)+mountPointPosThickness, h=mountPointElevation);
       }
-      for (i = [0:len(points)-1]) {
+
-        p = points[i];
+      for (i = [0:len(mountPoints)-1]) {
-        x = p[0];
+        x = mountPoints[i][0];
-        y = p[1];
+        y = mountPoints[i][1];
-        hR = p[3];
+
-        hT = p[4];
+        translate(v=[x, y, -trayThickness])
-        translate(v=[x, y, 0])
+        mirror(v=[0,0,1])
-        cylinder(r=hR, h=inf50, center=true);
+        counterSunkHead_N(mountPointType, inf, inf);
       }
       children(0);
     }