add missing instructions

helper/common.scad

@@ -4,7 +4,7 @@
 
 $fn=64;
 // TODO move these to math
-eps=0.00001;
+eps=0.0001;
 
 inf10 = 10;
 inf50 = 50;

helper/screws.scad

@@ -58,6 +58,11 @@ function heatSetInsertSlotRadiusSlacked(screwType) =
   ? m3HeatSetInsertSlotRadiusSlacked
   : error("Unsupported screw type");
 
+function heatSetInsertSlotHeightSlacked(screwType) =
+  (screwType == "m3")
+  ? m3HeatSetInsertSlotHeightSlacked
+  : error("Unsupported screw type");
+
 function screwRadiusSlacked(screwType) =
   (screwType == "m3")
   ? m3RadiusSlacked

rack/assemblyGuide.scad

@@ -17,6 +17,10 @@ module assemblyInstructions () {
   // Instruction List (in order)
   // TODO: add steps to glue magnets and add heatset inserts
 
+  //render()
+  // addHeatSetInsertsYBar(at=$t);
+  // addMagnetsToMagnetModules(at=$t);
+  // addMagnetsToSideWall(at=$t);
   // attachXBarWithYBar(at=$t);
   // screwXBarAndYBar(at=$t);
   // attachSideConnectorModulesToYBars(at=$t);
@@ -32,16 +36,86 @@ module assemblyInstructions () {
   // end instructions
   final();
 
+
+  module addHeatSetInsertsYBar(at=0) {
+    t = lerp(a=10,b=0,t=at);
+
+    yBar();
+
+    heatSetHeight = heatSetInsertSlotHeightSlacked(rackFrameScrewType) * 0.95;
+
+    function sideModuleHeatSetTrans(t=0) =
+      translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,t-(heatSetHeight+sideWallConnLugDepression)]) *
+      yBarSideModuleConnectorTrans;
+
+    function mainRailHeatSetTrans(t=0) =
+      translate(v=[mainRailHeatSetOnYBarDx,mainRailHeatSetOnYBarDy,t-heatSetHeight]) *
+      yBarMainRailConnectorTrans;
+
+    function xBarHeatSetTrans(t=0) =
+      translate(v=[t-heatSetHeight,27,6]) *
+      yBarXBarConnectorTrans *
+      rotate(a=[0,90,0]);
+
+    module heatSetInsertsOneCorner(t=0) {
+      multmatrix(sideModuleHeatSetTrans(t = t))
+      heatSetInsert();
+
+      multmatrix(mainRailHeatSetTrans(t = t))
+      heatSetInsert();
+
+      multmatrix(xBarHeatSetTrans(t = t))
+      heatSetInsert();
+    }
+
+    heatSetInsertsOneCorner(t=t);
+
+    multmatrix(yBarMirrorOtherCornerTrans)
+    heatSetInsertsOneCorner(t=t);
+
+  }
+
+  module addMagnetsToMagnetModules(at=0) {
+    t = lerp(a=8,b=0,t=at);
+
+    magnetModule();
+
+    function insertMagnetTrans(t=0) =
+      translate(v=[sideWallConnW-(magnetFaceToSideWallConnOuterYEdge+magnetHSlacked) + t,
+                   magnetModuleMagnetMountDy,
+                   magnetModuleMagnetMountDz]) *
+      rotate(a=[0,90,0]);
+
+    multmatrix(insertMagnetTrans(t=t))
+    magnet();
+  }
+
+  module addMagnetsToSideWall(at=0) {
+    t = lerp(a=8,b=0,t=at);
+
+    sideWallLeft();
+
+    function insertMagnetTrans(t=0) =
+      translate(v=[sideWallThickness+t, magnetMountToYBarFront, magnetMountToYBarTop-sideWallZHingeTotalClearance]) *
+      rotate(a=[0,90,0]);
+
+    multmatrix(insertMagnetTrans(t=t))
+    magnet();
+
+    multmatrix(translate(v=[0,0,sideWallZ - 2*(magnetMountToYBarTop- sideWallZHingeTotalClearance)]) * insertMagnetTrans(t=t))
+    magnet();
+  }
+
   module attachXBarWithYBar(at=0) {
 
     t = lerp(a=20, b=0, t=at);
 
     // assemble x-y bar trays
     multmatrix(translate(v = [0, 0, t]))
-    yBar();
+    addHeatSetInsertsYBar(at=1);
 
     multmatrix(translate(v = [0, 0, t])*xBarSpaceToYBarSpace*xBarMirrorOtherCornerTrans*yBarSpaceToXBarSpace)
-    yBar();
+    addHeatSetInsertsYBar(at=1);
 
     multmatrix(xBarSpaceToYBarSpace)
     xBar();
@@ -58,10 +132,10 @@ module assemblyInstructions () {
       translate(v=[27,xBarSideThickness + extension,6]) * rotate(a=[270,0,0]);
 
     // screw to connect x and y bars
-    yBar();
+    addHeatSetInsertsYBar(at=1);
 
     multmatrix(xBarSpaceToYBarSpace*xBarMirrorOtherCornerTrans*yBarSpaceToXBarSpace)
-    yBar();
+    addHeatSetInsertsYBar(at=1);
 
     multmatrix(xBarSpaceToYBarSpace)
     union() {
@@ -99,7 +173,7 @@ module assemblyInstructions () {
 
     multmatrix(sideModuleTrans(elevation))
     union() {
-      magnetModule();
+      addMagnetsToMagnetModules(at=1);
 
       translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
       caseScrewA();
@@ -107,7 +181,7 @@ module assemblyInstructions () {
 
     multmatrix(xBarSpaceToYBarSpace * xBarMirrorOtherCornerTrans * yBarSpaceToXBarSpace * sideModuleTrans(elevation))
     union() {
-      magnetModule();
+      addMagnetsToMagnetModules(at=1);
 
       translate(v=[yBarScrewHoleToOuterYEdge,yBarScrewHoleToFrontXEdge,sideWallConnLugDepression + 2*elevation])
       caseScrewA();
@@ -164,7 +238,7 @@ module assemblyInstructions () {
 
     hingeHoleH = hingePoleH-sideWallConnLugDepression;
 
-    sideWallLeft();
+    addMagnetsToSideWall(at=1);
 
     translate(v=[hingePoleDx,hingePoleDy, (sideWallZ-hingeHoleH) + t])
     hingeDowel();
@@ -374,6 +448,17 @@ module assemblyInstructions () {
     cylinder(h=dowelPinH, r=dowelPinR);
   }
 
+  module heatSetInsert() {
+    color([1,0,1])
+    scale(v=[0.95,0.95,0.95])
+    heatSetInsertSlot_N(screwType=rackFrameScrewType, topExtension=0);
+  }
+
+  module magnet() {
+    color([1,0,1])
+    cylinder(r=magnetR, h=magnetH);
+  }
+
   module arrow(length) {
     color([1,0,1]) {
       translate(v = [0, 0, length-2])

rack/connector/mainRailYBarConnectors.scad

@@ -9,6 +9,8 @@ include <../sharedVariables.scad>
 
 include <../config.scad>
 
+mainRailHeatSetOnYBarDx = railSideMountThickness + 5;
+mainRailHeatSetOnYBarDy = railFrontThickness + 4;
 module onYBarToMainRailNegative() {
 
   slotSlack = xySlack;
@@ -18,7 +20,7 @@ module onYBarToMainRailNegative() {
     translate(v=[-slotZSlack/2, -slotSlack/2,0])
     cube(size = [railTotalWidth+slotZSlack, railTotalDepth + slotSlack, railFootThickness]);
 
-    translate(v = [railSideMountThickness + 5, railFrontThickness + 4 , -m3HeatSetInsertSlotHeightSlacked])
+    translate(v = [mainRailHeatSetOnYBarDx, mainRailHeatSetOnYBarDy, -m3HeatSetInsertSlotHeightSlacked])
     heatSetInsertSlot_N(rackFrameScrewType);
   }
 }
@@ -32,6 +34,6 @@ module onMainRailYBarConnectorPositive() {
 
 module onMainRailYBarConnectorNegative() {
 
-  translate(v = [5+railSideMountThickness, 4+railFrontThickness, railFootThickness])
+  translate(v = [mainRailHeatSetOnYBarDx, mainRailHeatSetOnYBarDy, railFootThickness])
   counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
 }

rack/side/hingeModule.scad

@@ -50,7 +50,7 @@ module hingeModule() {
         translate(v = [sideWallConnW/2.0, hingePoleR + radiusXYSlack, 0])
         cylinder(r = hingePoleR + radiusXYSlack, h = inf50);
 
-        translate(v = [sideWallConnW/2.0, , 0])
+        translate(v = [sideWallConnW/2.0, 0 , 0])
         cube(size=[2, 5, inf50], center=true);
       }
 

rack/side/magnetModule.scad

@@ -9,6 +9,9 @@ include <../../helper/screws.scad>
 translate(v=[10,-5,-(2+sideWallZHingeTotalClearance)])
 *magnetModule();
 
+magnetModuleMagnetMountDy = magnetMountToYBarFront - sideWallSlotToXZ;
+magnetModuleMagnetMountDz = magnetMountToYBarTop + sideWallConnLugDepression;
+
 module magnetModule() {
 
   applyYBarScrewMount()
@@ -42,11 +45,6 @@ module magnetModule() {
   }
 
   module applyMagnetMount() {
-
-    magnetMountDx = magnetMountShellRadius;
-    magnetMountDy = magnetMountToYBarFront - sideWallSlotToXZ;
-    magnetMountDz = magnetMountToYBarTop + sideWallConnLugDepression;
-
     apply_pn() {
       magnetMountShell();
       magnetMountHole();
@@ -55,7 +53,7 @@ module magnetModule() {
 
     module magnetMountShell() {
       hull() {
-        translate(v = [0, magnetMountDy, magnetMountDz])
+        translate(v = [0, magnetModuleMagnetMountDy, magnetModuleMagnetMountDz])
         rotate(a = [0, 90, 0])
         cylinder(r = magnetMountShellRadius, h = sideWallConnW-magnetFaceToSideWallConnOuterYEdge);
 
@@ -66,8 +64,8 @@ module magnetModule() {
 
     module magnetMountHole() {
       translate(v = [sideWallConnW-(magnetFaceToSideWallConnOuterYEdge+magnetHSlacked),
-        magnetMountDy,
+        magnetModuleMagnetMountDy,
-        magnetMountDz])
+        magnetModuleMagnetMountDz])
       rotate(a = [0, 90, 0])
       cylinder(r = magnetRSlacked, h = magnetHSlacked);
     }

rack/side/sideWallBase.scad

@@ -11,8 +11,8 @@ include <../sharedVariables.scad>
 include <./magnetModule.scad>
 include <./hingeModule.scad>
 
-echo("Side Wall Height", sideWallZ);
+//echo("Side Wall Height", sideWallZ);
-echo("Side Wall Depth", sideWallY);
+//echo("Side Wall Depth", sideWallY);
 
 //translate(v = [hingePoleDx ,hingePoleDy, 10])
 //rotate(a=[0,0,-120])

rack/xyPlate.scad

@@ -32,10 +32,6 @@ module xyPlate() {
 
   module applyYBarConnectors() {
 
-    // TODO ren
-    echo("connPosX", connPosX);
-    echo("connPosY", connPosY);
-
     apply_p() {
       union() {
         translate(v=[connPosX, connPosY, 0])