add to xBar, also refactor

helper/halfspace.scad

@@ -5,10 +5,7 @@ include <./common.scad>
 
 module halfspace(vpos, p) {
     translate(p)
-    align(a=[0,0,1], b=vpos)
+    align(a=[0,0,-1], b=vpos)
     translate(v=[0,0,-inf/2])
         cube(size=[inf, inf, inf], center=true);
-}
+}
-
-
-halfspace(vpos=[1,1,1], p=[10,10,10]);

helper/math.scad

@@ -13,9 +13,20 @@ function mirror4XY(midpoint, offsetX, offsetY)  =
 
 
 module align(a,b) {
+
+    echo("a", a);
+    echo("b", b);
     rot_axis = cross(a,b);
-    angle = acos(a*b/ (norm(a)*norm(b)));
+
+    if (rot_axis == 0) {
+        error("Can't align - provided vectors are parallel");
+    }
+
+    echo("rot_axis", rot_axis);
+
+    angle = acos(a*b/(norm(a)*norm(b)));
+    echo("angle", angle)
 
     rotate(v=rot_axis, a=angle)
         children(0);
-}
+}

rack/config.scad

@@ -32,3 +32,6 @@ mainRailSideMountScrewType = "m4";
 rackFrameScrewType = "m3";
 // Currently, only m3 screws are supported here (tolerance issues)
 assert(rackFrameScrewType == "m3");
+
+// Fillet radius
+baseRoundness = 5;

rack/derivedConfig.scad

@@ -1,4 +1,6 @@
 // Config file for derived variables. These variables are calculated from profile variables and are used by
 // multiple components.
 
-// TODO
+// TODO
+include <./config.scad>
+

rack/mainRail.scad

@@ -1,6 +1,7 @@
 include <./config.scad>
 include <../helper/screws.scad>
 include <../helper/math.scad>
+include <../helper/halfspace.scad>
 
 /* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
    Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
@@ -29,25 +30,43 @@ frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
 railTotalWidth = frontFaceWidth;
 railTotalDepth = railFrontThickness+sideSupportDepth;
 
+*mainRail();
+
 echo("Total Rail Height: ", railTotalHeight);
 
 // Also known as the z-bar :)
 module mainRail() {
 
-  union() {
+  mainRail();
-    _frontRailSegment();
 
-    translate(v = [railSideMountThickness, railFrontThickness, 0])
+  module mainRail() {
-    rotate(a = [0, 0, 90])
+    b = 0.75; // bevel value
-    _sideSupportSegment();
+    intersection() {
+      mainRailSharp();
+      halfspace(vpos=[1,1,0], p=[b,b,0]);
+      halfspace(vpos=[1,0,1], p=[b,0,b]);
+      halfspace(vpos=[1,0,-1], p=[b,0,railTotalHeight-b]);
 
-    translate(v = [0, railFrontThickness, 0]) {
+    }
+  }
 
-      translate(v=[railSideMountThickness,0,0])
-      _railFeet();
 
-      translate(v = [railSideMountThickness, 0, railTotalHeight - railFootThickness])
+  module mainRailSharp() {
-      _railFeet();
+    union() {
+      _frontRailSegment();
+
+      translate(v = [railSideMountThickness, railFrontThickness, 0])
+      rotate(a = [0, 0, 90])
+      _sideSupportSegment();
+
+      translate(v = [0, railFrontThickness, 0]) {
+
+        translate(v = [railSideMountThickness, 0, 0])
+        _railFeet();
+
+        translate(v = [railSideMountThickness, 0, railTotalHeight-railFootThickness])
+        _railFeet();
+      }
     }
   }
 

rack/xBar.scad

@@ -2,13 +2,24 @@ include <../helper/sphericalFilet.scad>
 include <../helper/cylindricalFilet.scad>
 include <../helper/screws.scad>
 include <./config.scad>
+include <./derivedConfig.scad>
+include <./xyBarConnector.scad>
+include <./xBarBasePlateConnector.scad>
+
+
+// Temporary
+include <./yBar.scad>
+include <./mainRail.scad>
+
+xBarDepth = maxUnitWidth - 2*(railSlotSpacing + railScrewHoleToInnerEdge);
 
-xBarDepth = 180;
 xBarWidth = 32;
 xBarHeight = 15;
 
-xBarWallThickness = 3;
+xBarWallThickness = 2;
-xBarRoundness = 5;
+xBarRoundness = baseRoundness;
+
+//echo(xBarDepth);
 
 module xBar() {
 
@@ -24,11 +35,55 @@ module xBar() {
   }
 
   module xBar() {
-    positive();
+
+    module mirrorOtherCorner() {
+      children(0);
+
+      // TODO rename xBarDepth to xBarLength/xBarWidth
+      translate(v = [xBarDepth, 0, 0])
+      mirror(v = [1, 0, 0]) {
+        children(0);
+      }
+    }
+
+    // TODO refactor - probably better off mirroring the side faces and hulling the shell
+    difference() {
+      union() {
+        intersection () {
+          positive();
+          halfspace(vpos = [1, 0, 1], p = [0.5, 0, 0]);
+
+          halfspace(vpos = [-1, 0, 1], p = [xBarDepth-0.5, 0, 0]);
+        }
+
+        yBarConnectorFromXLug();
+
+        mirrorOtherCorner()
+        yBarConnectorFromXLug();
+      }
+
+      union() {
+        yBarConnectorFromX_N();
+
+        mirrorOtherCorner()
+        yBarConnectorFromX_N();
+      }
+    }
+
+
+    // TODO change me?
+    translate(v=[0,xBarWidth,0])
+    basePlateMount();
+
+    translate(v=[xBarDepth,xBarWidth,0])
+    mirror(v=[1,0,0])
+    basePlateMount();
   }
 
   xBar();
 }
+translate(v=[-30,0,0])
+*yBar();
+xBar();
 
 
-//xBar();

rack/xBarBasePlateConnector.scad

@@ -0,0 +1,53 @@
+include <../helper/common.scad>
+include <../helper/screws.scad>
+include <./config.scad>
+
+module basePlateMount() {
+
+  screwHoleToBase = 6;
+  mountHeight = 10;
+  mountWidth = 10;
+  mountThickness = 2;
+
+  module support() {
+    r = 4;
+
+    difference () {
+      translate(v = [0, mountThickness, r/2])
+      rotate(a = [90, 0, 0])
+      rotate(a = [0, 0, 90])
+      cylinder(h = mountThickness, r = r, $fn = 3);
+
+      cube(size=[inf10, inf10, inf10]);
+    }
+
+    //translate([-r/2, -2,0])
+    //cube(size=[r/2, 0.1, 0.1]);
+  }
+
+  module positive() {
+    cube(size = [mountWidth, mountThickness, mountHeight]);
+
+    translate(v=[mountWidth,0,0])
+    mirror(v=[1,0,0])
+    hull() {
+      support();
+    }
+  }
+
+  module basePlateMount() {
+    translate(v=[0,-mountThickness,0])
+    difference() {
+      positive();
+
+      translate(v = [mountWidth/2, inf50/2, screwHoleToBase])
+      rotate(a = [90, 0, 0])
+      cylinder(h = inf50, r = screwRadiusSlacked(rackFrameScrewType));
+    }
+  }
+
+  basePlateMount();
+
+}
+
+

rack/xyBarConnector.scad

@@ -1,22 +1,54 @@
 include <../helper/screws.scad>
+include <../helper/halfspace.scad>
 include <./config.scad>
 
-module frontBarConnector_N() {
+module xBarConnectorFromY_N() {
-
     y1 = 6;
     y2 = 27;
     z = 6;
 
     translate(v = [-m3HeatSetInsertSlotHeightSlacked, y1, z])
-        rotate(a = [0, 90, 0])
+    rotate(a = [0, 90, 0])
-            heatSetInsertSlot_N(rackFrameScrewType);
+    heatSetInsertSlot_N(rackFrameScrewType);
 
     translate(v = [-m3HeatSetInsertSlotHeightSlacked, y2, z])
-        rotate(a = [0, 90, 0])
+    rotate(a = [0, 90, 0])
-            heatSetInsertSlot_N(rackFrameScrewType);
+    heatSetInsertSlot_N(rackFrameScrewType);
 
     // TODO fix this up, no center=true
     translate(v = [-1, y1+(y2-y1)/2, 0])
+    rotate(a = [0, 45, 0])
+    cube(size = [3, 10, 6], center = true);
+}
+
+
+module yBarConnectorFromX_N() {
+    y1 = 6;
+    y2 = 27;
+    z = 6;
+    translate(v = [-inf50/2, y1, z])
+    rotate(a = [0, 90, 0])
+    cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf50, $fn = 32);
+
+    translate(v = [-inf50/2, y2, z])
+    rotate(a = [0, 90, 0])
+    cylinder(r = screwRadiusSlacked(rackFrameScrewType), h = inf50, $fn = 32);
+}
+
+// TODO: figure out nice abstraction to apply both positive and negative mods
+module yBarConnectorFromXLug() {
+    y1 = 6;
+    y2 = 27;
+    z = 6;
+
+    intersection() {
+        // TODO fix this up, no center=true
+        translate(v = [-1, y1+(y2-y1)/2, 0])
         rotate(a = [0, 45, 0])
-            cube(size = [3, 10, 6], center = true);
+        scale(v=[0.90,0.90,0.95])
+        cube(size = [3, 10, 6], center = true);
+
+        mirror(v=[0,0,1])
+        halfspace(vpos=[0,0,1], p=[0,0,0]);
+    }
 }

rack/yBar.scad

@@ -22,7 +22,7 @@ yBarWidth = railSlotSpacing + railTotalWidth + sideSpacing;
 yBarHeight = 15;
 
 yBarWallThickness = 3;
-yBarRoundness = 5;
+yBarRoundness = baseRoundness;
 
 echo("Bar total depth: ", yBarDepth);
 echo("Bar total width: ", yBarWidth);
@@ -48,7 +48,7 @@ module yBar() {
       railFeetSlot_N();
 
       translate(v = [yBarWidth+eps, 0, 0])
-      frontBarConnector_N();
+      xBarConnectorFromY_N();
 
       translate(v = [yBarWidth-(railTotalWidth+railSlotSpacing)-9, railSlotSpacing, yBarHeight])
       sideWallConnector_N();