add xyPlate

rack/config.scad

@@ -11,7 +11,7 @@ include <./profiles.scad>
 profileName = "micro";
 profile = getProfile(profileName);
 
-echo("Profile:", profile);
+// echo("Profile:", profile);
 
 function getConfig(name) = getConfigValue(profile, name);
 

rack/print/xyPlate_P.scad

@@ -0,0 +1,5 @@
+include <../xyPlate.scad>
+
+// Oriented for 3d printing.
+// Supports generally not required.
+xyPlate();

rack/xBar.scad

@@ -7,9 +7,8 @@ include <./xyBarConnector.scad>
 include <./yBar.scad>
 
 // It's actually the railSlotToInnerYEdge of the yBar, it'll be nice to be able to refer to it like yBar.railSlotToInnerYEdge
-xBarDepth = maxUnitWidth - 2*railSlotToInnerYEdge;
-
-xBarWidth = 32;
+xBarX = maxUnitWidth - 2*railSlotToInnerYEdge;
+xBarY = 32;
 xBarHeight = 15;
 
 xBarWallThickness = 2;
@@ -24,27 +23,25 @@ module xBar() {
 
   module xBarBase() {
     intersection() {
-      mirror(v = [0, 1, 0])
-      rotate(a = [0, 0, -90])
+
       difference() {
-        cylindricalFiletEdge(xBarWidth, xBarDepth, xBarHeight, xBarRoundness);
+        cylindricalFiletEdge(xBarY, xBarX, xBarHeight, xBarRoundness);
 
         translate(v = [xBarWallThickness, xBarWallThickness, xBarWallThickness])
-        cylindricalFiletEdge(xBarWidth, xBarDepth-2*xBarWallThickness, xBarHeight, xBarRoundness);
+        cylindricalFiletEdge(xBarY, xBarX-2*xBarWallThickness, xBarHeight, xBarRoundness);
       }
 
       // Shave off bottom corners to reduce elephant's foot at where xBar and YBar join
-      halfspace(vpos = [1, 0, 1], p = [0.6, 0, 0]);
-      halfspace(vpos = [-1, 0, 1], p = [xBarDepth-0.6, 0, 0]);
+      halfspace(vpos = [0, 1, 1], p = [0, 0.6, 0]);
+      halfspace(vpos = [0, -1, 1], p = [0, xBarX-0.6, 0]);
     }
   }
 
   module mirrorOtherCorner() {
     children(0);
 
-    // TODO rename xBarDepth to xBarLength/xBarWidth
-    translate(v = [xBarDepth, 0, 0])
-    mirror(v = [1, 0, 0]) {
+    translate(v = [0, xBarX, 0])
+    mirror(v = [0, 1, 0]) {
       children(0);
     }
   }
@@ -53,9 +50,11 @@ module xBar() {
     apply_pn() {
 
       mirrorOtherCorner()
+      rotate(a=[0,0,-90])
       yBarConnectorFromXLug();
 
       mirrorOtherCorner()
+      rotate(a=[0,0,-90])
       yBarConnectorFromX_N();
 
       children(0);

rack/xyPlate.scad

@@ -0,0 +1,73 @@
+include <./yBar.scad>
+include <./xBar.scad>
+
+xyPlate();
+
+module xyPlate() {
+
+  applyYBarConnectors()
+  plateBody();
+
+  module plateBody() {
+    slack = 0.5;
+    plateBodyX = xBarX - slack;
+    plateBodyY = (yBarDepth - 2*xBarY) - slack;
+    plateBodyH = xBarWallThickness;
+
+    translate(v=[slack/2, slack/2, 0])
+    cube(size=[plateBodyX, plateBodyY, plateBodyH]);
+  }
+
+  module applyYBarConnectors() {
+    slack = 0.3;
+    // TODO rename _heatSetX to something more indicative of yBarBasePlateConnector
+    connDx = xBarX + 2*_heatSetX; // X distance between connectors
+    connDy = yBarDepth - 2*basePlateScrewMountToYBarXZFace; // Y distance between connectors
+
+    connYBarCornerDx = yBarWidth; // distance from a plate body corner and the nearest yBar corner
+    connYBarCornerDy = xBarY; // distance from a plate body corner and the nearest yBar corner
+
+    connPosX = basePlateScrewMountToYBarYZFace - connYBarCornerDx; // distance between plateBody corner at (0,0,0) and the related corner
+    connPosY = basePlateScrewMountToYBarXZFace - connYBarCornerDy;
+
+
+    apply_p() {
+      union() {
+        translate(v=[connPosX, connPosY, 0])
+        yBarConnector();
+
+        translate(v=[connPosX, connPosY+connDy, 0])
+        yBarConnector();
+
+        translate(v=[connPosX+connDx, connPosY, 0])
+        rotate(a=[0,0,180])
+        yBarConnector();
+
+        translate(v=[connPosX+connDx, connPosY+connDy, 0])
+        rotate(a=[0,0,180])
+        yBarConnector();
+
+      }
+
+      children(0);
+    }
+
+    module yBarConnector() {
+      difference() {
+        hull() {
+          cylinder(r = _baseConnY/2 - slack/2, h = _baseConnRecession);
+
+          translate(v = [1-connPosX, -_baseConnY/2, 0])
+          cube(size = [eps, _baseConnY-slack, _baseConnRecession]);
+
+          translate(v = [5-connPosX, -_baseConnY/2, 0])
+          cube(size = [eps, _baseConnY-slack, eps]);
+        }
+
+        cylinder(r=screwRadiusSlacked(rackFrameScrewType), h=inf, center=true);
+
+      }
+    }
+
+  }
+}

rack/yBarBasePlateConnector.scad

@@ -2,6 +2,7 @@ include <../helper/common.scad>
 include <../helper/halfspace.scad>
 include <../helper/screws.scad>
 include <./config.scad>
+include <./sharedVariables.scad>
 
 _mountX = 12;
 _mountY = 14;
@@ -18,6 +19,13 @@ _baseConnRecession = 3;
 _baseConnY = 8;
 _baseConnOuterXFaceToScrew = 2;
 
+_heatSetX = _mountX - _innerXFaceToScrew;
+_heatSetY = _mountY - _innerYFaceToScrew;
+
+// TODO refactor this entire file
+basePlateScrewMountToYBarXZFace = _heatSetY + joinCornerDepth; // Distance to the nearest YBar XZ face
+basePlateScrewMountToYBarYZFace =  (yBarWidth+_heatSetX) - yBarBasePlateConnectorWidth;
+
 module yBarBasePlateMount_P() {
   intersection() {
     cube(size = [_mountX, _mountY, _mountZ]);
@@ -27,32 +35,30 @@ module yBarBasePlateMount_P() {
 
 module yBarBasePlateMount_N() {
 
-  heatSetX = _mountX - _innerXFaceToScrew;
-  heatSetY = _mountY - _innerYFaceToScrew;
 
-  translate(v=[heatSetX, heatSetY, m3HeatSetInsertSlotHeightSlacked + _baseConnRecession])
+  translate(v=[_heatSetX, _heatSetY, m3HeatSetInsertSlotHeightSlacked + _baseConnRecession])
   mirror(v=[0,0,1])
     heatSetInsertSlot_N(rackFrameScrewType, topExtension=inf10);
 
   hull() {
-    translate(v = [heatSetX, heatSetY, 0])
+    translate(v = [_heatSetX, _heatSetY, 0])
     cylinder(r=_baseConnY/2, h=_baseConnRecession);
 
-    translate(v = [inf50, heatSetY-_baseConnY/2, 0])
+    translate(v = [inf50, _heatSetY-_baseConnY/2, 0])
     cube(size = [eps, _baseConnY, _baseConnRecession]);
   }
 
   hull() {
-    translate(v = [heatSetX, heatSetY, 0])
+    translate(v = [_heatSetX, _heatSetY, 0])
     cylinder(r=_baseConnY/2+0.25, h=eps);
 
-    translate(v = [inf50, heatSetY-_baseConnY/2, 0])
+    translate(v = [inf50, _heatSetY-_baseConnY/2, 0])
     cube(size = [eps, _baseConnY + 0.5, eps]);
 
-    translate(v = [heatSetX, heatSetY, 1])
+    translate(v = [_heatSetX, _heatSetY, 1])
     cylinder(r=_baseConnY/2, h=eps);
 
-    translate(v = [inf50, heatSetY-_baseConnY/2, 1])
+    translate(v = [inf50, _heatSetY-_baseConnY/2, 1])
     cube(size = [eps, _baseConnY, eps]);
   }
 }

stl/rack/print/mainRail_P.stl

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