finalizing connectingBarDesign

rack2/assemble.scad

@@ -0,0 +1,8 @@
+include <../math.scad>
+include <./config.scad>
+include <./mainRail.scad>
+include <./connectingBar.scad>
+
+
+*mainRail();
+connectingBar();

rack2/config.scad

@@ -20,7 +20,7 @@ maxUnitDepth = 200;
 screwDiff = 10;
 
 // Number screw slots on the main rail. Affects build volume.
-numRailScrews = 20;
+numRailScrews = 3;
 
 // Screw type used for rackmount units. See screws.scad.
 mainRailScrewType = "m4";

rack2/connectingBar.scad

@@ -1,12 +1,12 @@
 include <../math.scad>
 include <./config.scad>
 include <./screws.scad>
+include <./misc/magnet.scad>
+
 include <./mainRail.scad>
 include <./helper/sphericalFilet.scad>
 include <./helper/cylindricalFilet.scad>
 
-// TODO remove support requirements
-// TODO add slack to top slots
 // TODO clean up
 // TODO: How do I nicely explain this?
 railSlotSpacing = 3;
@@ -22,6 +22,7 @@ barRoundness = 5;
 echo("Bar total depth: ", barDepth);
 echo("Bar total width: ", barWidth);
 
+
 module connectingBar() {
 
   module positive() {
@@ -35,11 +36,25 @@ module connectingBar() {
   }
 
   module stackConn_N() {
-    translate(v=[0,0,0])
-    cube(size = [10, 10, 5]);
+    taperH = 2;
 
-    translate(v=[5,5,5])
-    cylinder(r=2, h=2);
+    translate(v=[0,0,0])
+    cube(size = [10, 10, taperH]);
+
+
+    hull() {
+      translate(v = [0, 0, taperH])
+      linear_extrude(height=eps)
+      square(size = [10, 10]);
+
+      translate(v=[5,5,5])
+      linear_extrude(height=eps)
+      circle(r=magnetRSlacked);
+    }
+
+    // -1 is for male support
+    translate(v=[5,5,5 - 1])
+    cylinder(r=magnetRSlacked, h=magnetHSlacked);
   }
 
   // TODO move this to custom file
@@ -60,7 +75,8 @@ module connectingBar() {
 
     // TODO fix this up, no center=true
     translate(v=[-1, y1 + (y2 - y1)/2, 0])
-    cube(size=[2,10,5], center=true);
+    rotate(a=[0,45,0])
+    cube(size=[3,10,6], center=true);
   }
 
   // TODO move this in custom file, like for railFeetSlot_N
@@ -114,5 +130,3 @@ module connectingBar() {
   }
   connectingBar();
 }
-
-connectingBar();

rack2/mainRail.scad

@@ -29,8 +29,6 @@ frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
 railTotalWidth = frontFaceWidth;
 railTotalDepth = railFrontThickness+sideSupportDepth;
 
-*mainRail();
-
 echo("Total Rail Height: ", railTotalHeight);
 
 module mainRail() {
@@ -67,21 +65,11 @@ module mainRail() {
   module _sideSupportSegment() {
     difference() {
       cube(size = [sideSupportDepth, railSideMountThickness, railTotalHeight]);
-
-      union() {
-        for (i = [1:numRailScrews]) {
-          translate(v = [frontScrewSpacing, railFrontThickness/2, i*screwDiff+railFootThickness])
-          rotate(a = [90, 0, 0])
-          cylinder(r = screwRadiusSlacked(mainRailSideMountScrewType), h = inf10, $fn = 32);
-        }
-
-        translate(v = [4, 0, railFootThickness + 5])
-        rotate(a=[90,0,0])
-        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32, center = true);
-
-        translate(v = [4, 0, railTotalHeight- (railFootThickness + 5)])
-        rotate(a=[90,0,0])
-        cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf10, $fn = 32, center = true);
+      
+      for (i = [1:numRailScrews]) {
+        translate(v = [frontScrewSpacing, railFrontThickness/2, i*screwDiff+railFootThickness])
+        rotate(a = [90, 0, 0])
+        cylinder(r = screwRadiusSlacked(mainRailSideMountScrewType), h = inf10, $fn = 32);
       }
     }
   }
@@ -98,10 +86,12 @@ module mainRail() {
 
 module railFeetSlot_N() {
 
+  slotSlack = 0.2;
   union() {
-    cube(size = [railTotalWidth, railTotalDepth, railFootThickness]);
+    translate(v=[-slotSlack/2, -slotSlack/2,0])
+    cube(size = [railTotalWidth + slotSlack, railTotalDepth + slotSlack, railFootThickness]);
 
-    translate(v = [railSideMountThickness + 5, railFrontThickness + 4, -m3HeatSetInsertSlotHeightSlacked])
+    translate(v = [railSideMountThickness + 5, railFrontThickness + 4 , -m3HeatSetInsertSlotHeightSlacked])
     heatSetInsertSlot_N(rackFrameScrewType);
   }
 }

rack2/misc/magnet.scad

@@ -0,0 +1,11 @@
+
+
+// Dimensions for small cylindrical neodymium magnets that I bought off Amazon
+magnetR = 3;
+magnetH = 1.7;
+
+magnetRSlack = 0.1;
+magnetHSlack = 0.05;
+
+magnetRSlacked = magnetR + magnetRSlack;
+magnetHSlacked = magnetH + magnetHSlack;

rack2/screws.scad

@@ -5,7 +5,7 @@ include <../common.scad>
 
 /********************************************************************************/
 // M3 dimensions
-m3HoleRadiusSlack = 0.3;
+m3HoleRadiusSlack = 0.4; // higher slack for not-so straight heat set inserts
 m3Diameter = 3.0;
 m3Radius = m3Diameter / 2.0;
 m3RadiusSlacked = m3Radius + m3HoleRadiusSlack;