further work on rack-mount refactor

rack-mount/enclosed-box/animate.scad

@@ -0,0 +1,21 @@
+use <./entry.scad>
+
+$vpt = [120,-30,63];
+$vpr = [74,0,25];
+$vpd = 550;
+$vpf = 22.50;
+
+animateEnclosedBoxSystem(at=$t);
+
+module animateEnclosedBoxSystem(at=$t) {
+
+  zOrientation = "middle";
+  x=150;
+  y=70;
+  z=20;
+  dx = abs(lerp(a=-20, b=20, t=at));
+  dy = abs(lerp(a=-50, b=50, t=at));
+  dz = abs(lerp(a=-15, b=15, t=at));
+
+  enclosedBoxSystem(visualize=true, zOrientation=zOrientation, boxWidth=x+dx, boxDepth=y+dy, boxHeight=z+dz);
+}

rack-mount/enclosed-box/entry.scad

@@ -11,55 +11,64 @@ use <./frontBoxHolder.scad>
   This system does not require any mounting holes on the enclosed box.
 
   !!! Please also make sure that the correct rack frame preset is set in rackFrame.scad !!!
-
-  TODO support full box (so for the micro profile it would be 180) this may require widening the main rail
 */
+module enclosedBoxSystem (
 
 // begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
 
 // Does not affect any part dimensions. Set this to true to visualize how a box would be mounted.
-visualize = false;
+visualize = false,
+zOrientation = "middle", // ["middle" | "bottom"]
+recessSideRail = false,
 
-boxWidth = 170;
+boxWidth = 170,
-boxHeight = 27.0;
+boxHeight = 27,
-boxDepth = 100;
+boxDepth = 100,
 
-railDefaultThickness = 1.5;
+railDefaultThickness = 1.5,
-railSideThickness = 3;
+railSideThickness = 3,
 
-frontPlateThickness = 3;
+frontPlateThickness = 3,
-frontPlateCutoutYSpace = 3;
+frontPlateCutoutYSpace = 3,
-frontPlateCutoutXSpace = 5;
+frontPlateCutoutXSpace = 5,
-
-zOrientation = "middle"; // or "bottom"
 
 // end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
 
+) {
+  leftRailTrans = identity;
+  rightRailTrans = visualize
+    ? translate(v = [boxWidth, 0, 0])*mirror(v = [1, 0, 0])
+    : translate(v = [sideRailBaseWidth*2, 0, 0])*mirror(v = [1, 0, 0]);
 
-leftRailTrans = identity;
+  u = findU(boxHeight, railDefaultThickness);
-rightRailTrans = visualize
+  railBottomThickness = railBottomThickness(u, boxHeight, railDefaultThickness, zOrientation);
-  ? translate(v=[boxWidth,0,0]) * mirror(v=[1,0,0])
+  frontBoxHolderTrans = visualize
-  : translate(v=[sideRailBaseWidth*2,0,0]) * mirror(v=[1,0,0]);
+    ? translate(v = [railSideThickness-(railSupportsDx-boxWidth)/2, 0, sideRailLowerMountPointToBottom-
+      railBottomThickness])*mirror(v = [0, 1, 0])*rotate(a = [90, 0, 0])
+    : mirror(v = [0, 1, 0])*translate(v = [0, uDiff, frontPlateThickness-railBottomThickness]);
 
-u = findU(boxHeight, railDefaultThickness);
+  if (visualize) {
-railBottomThickness = railBottomThickness(u, boxHeight, railDefaultThickness, zOrientation);
-frontBoxHolderTrans = visualize
-  ? translate(v=[railSideThickness-(railSupportsDx-boxWidth)/2,0, sideRailLowerMountPointToBottom-railBottomThickness]) * mirror(v=[0,1,0]) * rotate(a=[90,0,0])
-  : mirror(v=[0,1,0]) * translate(v=[0,uDiff,frontPlateThickness - railBottomThickness]);
-
-if (visualize) {
     %cube(size = [boxWidth, boxDepth, boxHeight]);
+  }
+
+  multmatrix(leftRailTrans)
+    sideSupportRailBase(top = true, recess = recessSideRail, defaultThickness = railDefaultThickness, supportedZ =
+    boxHeight, supportedY = boxDepth, supportedX = boxWidth, zOrientation = zOrientation, railSideThickness =
+    railSideThickness);
+
+  multmatrix(rightRailTrans)
+    sideSupportRailBase(top = true, recess = recessSideRail, defaultThickness = railDefaultThickness, supportedZ =
+    boxHeight, supportedY = boxDepth, supportedX = boxWidth, zOrientation = zOrientation, railSideThickness =
+    railSideThickness);
+
+  multmatrix(frontBoxHolderTrans)
+    frontBoxHolder(
+    cutoutOffsetX = (rackMountScrewWidth-(boxWidth-2*frontPlateCutoutXSpace))/2, cutoutOffsetY = railBottomThickness+
+      frontPlateCutoutYSpace,
+    cutoutX = boxWidth-2*frontPlateCutoutXSpace, cutoutY = boxHeight-2*frontPlateCutoutYSpace,
+    zOrientation = zOrientation, supportedZ = boxHeight, supportWidth = max(10, boxWidth-(sideRailBaseWidth+10)),
+    supportRailDefaultThickness = railDefaultThickness, plateThickness = frontPlateThickness
+    );
 }
 
-multmatrix(leftRailTrans)
+enclosedBoxSystem();
-sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation, railSideThickness=railSideThickness);
-
-multmatrix(rightRailTrans)
-sideSupportRailBase(top=true, defaultThickness=railDefaultThickness, supportedZ=boxHeight, supportedY=boxDepth, supportedX=boxWidth, zOrientation=zOrientation, railSideThickness=railSideThickness);
-
-multmatrix(frontBoxHolderTrans)
-frontBoxHolder(
-  cutoutOffsetX=(rackMountScrewWidth-(boxWidth-2*frontPlateCutoutXSpace))/2, cutoutOffsetY=railBottomThickness+frontPlateCutoutYSpace,
-  cutoutX=boxWidth-2*frontPlateCutoutXSpace, cutoutY=boxHeight-2*frontPlateCutoutYSpace,
-  zOrientation = zOrientation, supportedZ=boxHeight, supportWidth=max(10, boxWidth-(sideRailBaseWidth+10)), supportRailDefaultThickness = railDefaultThickness, plateThickness=frontPlateThickness
-);

rack-mount/enclosed-box/sideRail.scad

@@ -4,7 +4,7 @@ include <./helper.scad>
 //sideSupportRailBase(top=true, defaultThickness=1.5, supportedZ=27.2, supportedY=101.5, supportedX=159);
 
 
-module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrientation="middle", defaultThickness=2, railSideThickness=4) {
+module sideSupportRailBase(top=true, recess=false, supportedZ, supportedY, supportedX, zOrientation="middle", defaultThickness=2, railSideThickness=4) {
 
   mountBlockDepth = 10;
   screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
@@ -16,12 +16,14 @@ module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrient
   u = findU(supportedZ, railBaseThickness);
   railBottomThickness = railBottomThickness(u, supportedZ, railBaseThickness, zOrientation);
 
-  assert(supportedX <= maxUnitWidth);
+  assert(supportedX <= maxUnitWidth, "Configured supported width is too high for rack profile");
   assert (zOrientation == "middle" || zOrientation == "bottom", "Z-Orientation not supported");
   assert(railBottomThickness >= railBaseThickness);
+  // require recessed rail if supportedX is close to maxUnitWidth
+  assert(recess || (supportedX+2*railSideThickness <= maxUnitWidth), "Configured supported width requires recessed side rail.");
 
   railSideHeight = supportedZ + railBaseThickness + railBottomThickness + overhangSlack;
-  frontMountPad = (sideRailScrewToMainRailFrontDx-mountBlockDepth/2)-xySlack;
+  frontMountPad = (sideRailScrewToMainRailFrontDx-mountBlockDepth/2);
 
   translate(v=[-railSideThickness, 0, -railBottomThickness])
   applyMainRailMounts()
@@ -127,7 +129,12 @@ module sideSupportRailBase(top=true, supportedZ, supportedY, supportedX, zOrient
             }
         }
 
+        frontCutTrans = recess ? translate(v=[0,frontMountPad,0]): translate(v=[0,xySlack,0]);
+        multmatrix(frontCutTrans) {
           cylindricalFiletNegative(p0=[sideRailBaseWidth,0,0],p1=[sideRailBaseWidth,0,inf], n=[1,-1,0],r=r);
+          halfspace(vpos=[0,-1,0], p=[0,0,0]);
+        }
+
       }
     }
   }

rack-mount/patch-panel/animate.scad

@@ -0,0 +1,28 @@
+include <../common.scad>
+use <./entry.scad>
+
+$vpt = [110,-42,36];
+$vpr = [77,0,23];
+$vpd = 445;
+$vpf = 22.50;
+
+animatePatchPanel(at=$t);
+
+module animatePatchPanel(at=$t) {
+
+  plateThickness = 3;
+  keystoneSpacing = 19;
+  slots = max(1,ceil(at*8));
+
+  rotate(a=[90,0,0])
+  mirror(v=[0,0,1])
+  render()
+  patchPanelSystem(numSlots = slots, plateThickness=plateThickness, keystoneSpacing=keystoneSpacing);
+
+  // keystone visualization
+  for (i = [0:slots-1]) {
+    translate(v=[keystoneSpacing*i + 12, 0,0,]) // hardcoded offset
+    %rj45Keystone();
+  }
+
+}

rack-mount/patch-panel/entry.scad

@@ -1,18 +1,26 @@
 use <./patchPanel.scad>
 
 /*
-  Parametric patch panel -
+  Parametric patch panel for rj45 keystones
 
   Please also make sure that the correct rack frame preset is set in rackFrame.scad.
 
   TODO add support for 2d arrays
 */
 
+module patchPanelSystem (
+
 // begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
 
-numSlots = 8;
+numSlots = 8,
+plateThickness = 3,
+keystoneSpacing = 19
 
 // end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
 
-mirror(v=[0,0,1])
+) {
-patchPanel(slots=numSlots);
+  mirror(v = [0, 0, 1])
+    patchPanel(slots = numSlots);
+}
+
+patchPanelSystem();

rack-mount/patch-panel/patchPanel.scad

@@ -7,12 +7,9 @@ use <../plateBase.scad>
 
   Please also make sure that the correct rack frame preset is set in rackFrame.scad.
 */
-*patchPanel(slots=2);
 
-module patchPanel (slots=8) {
+module patchPanel (slots=8, plateThickness=3, keystoneSpacing=19) {
     difference() {
-        plateThickness = 3;
-        keystoneSpacing = 19;
         supportPlateThickness = 5.9;
         supportPlateHeight = 29;
         supportPlateEdgeSpacing = 3;

rack-mount/plateBase.scad

@@ -20,7 +20,7 @@ module plateBase(U, plateThickness, screwType, screwToXEdge=4.5, screwToYEdge=4.
 
         mirror4XY(p=[screwToXEdge, screwToYEdge], dx=screwDx, dy=screwDy)
         translate(v=[0,0,plateThickness])
-        cylinder(r=screwRadiusSlacked(screwType), h=plateThickness*2, center=true);
+        cylinder(r=screwRadiusSlacked(screwType), h=inf, center=true);
     }
 
     module base() {

rack-mount/tray/animate.scad

@@ -0,0 +1,20 @@
+include <../common.scad>
+use <./entry.scad>
+
+$vpt = [100,-42,36];
+$vpr = [70,0,27];
+$vpd = 445;
+$vpf = 22.50;
+
+animateTraySystem(at=$t);
+
+module animateTraySystem(at=$t) {
+
+  trayU = max(1, ceil(at*3));
+  x=100;
+  y=100;
+  dx = abs(lerp(a=-40, b=40, t=at));
+  dy = abs(lerp(a=-30, b=30, t=at));
+
+  traySystem(trayU=trayU, baseWidth=x+dx, baseDepth=y+dy, mountPoints=[]);
+}

rack-mount/tray/entry.scad

@@ -8,25 +8,27 @@ use <./tray.scad>
   !!! Please also make sure that the correct rack frame preset is set in rackFrame.scad !!!
 */
 
+module traySystem (
+
 // begin config ////////////////////////////////////////////////////////////////////////////////////////////////////////
 
-trayU = 2;
+trayU = 2,
 
-baseWidth = 145;
+baseWidth = 145,
-baseDepth = 100;
+baseDepth = 100,
 
-baseThickness = 3; // tray bottom thickness
+baseThickness = 3, // tray bottom thickness
-frontThickness = 3; // front plate thickness
+frontThickness = 3, // front plate thickness
-sideThickness = 3;
+sideThickness = 3,
 
-backLipHeight = 2;
+backLipHeight = 2,
-frontLipHeight = 2;
+frontLipHeight = 2,
 
-sideSupport = true;
+sideSupport = true,
-trayLeftPadding = 10; // extra space between the left rail and tray. configure this to move the tray left/right.
+trayLeftPadding = 10, // extra space between the left rail and tray. configure this to move the tray left/right.
 
-mountPointType = "m3";
+mountPointType = "m3",
-mountPointElevation = 1; // basically standoff height
+mountPointElevation = 1, // basically standoff height
 
 // add/config standoff coordinates here. Format is [[x,y]]
 mountPoints = [
@@ -34,22 +36,27 @@ mountPoints = [
     [30+75,10],
     [30,10+75],
     [30+75,10+75],
-];
+]
+
 // end config //////////////////////////////////////////////////////////////////////////////////////////////////////////
 
+) {
 
-bottomScrewTray(
+  bottomScrewTray (
-  u=trayU,
+    u = trayU,
-  trayWidth=baseWidth,
+    trayWidth = baseWidth,
-  trayDepth=baseDepth,
+    trayDepth = baseDepth,
-  trayThickness=baseThickness,
+    trayThickness = baseThickness,
-  frontLipHeight=frontLipHeight,
+    frontLipHeight = frontLipHeight,
-  backLipHeight=backLipHeight,
+    backLipHeight = backLipHeight,
-  mountPoints=mountPoints,
+    mountPoints = mountPoints,
-  frontThickness=frontThickness,
+    frontThickness = frontThickness,
-  sideThickness=sideThickness,
+    sideThickness = sideThickness,
-  mountPointElevation=mountPointElevation,
+    mountPointElevation = mountPointElevation,
-  mountPointType=mountPointType,
+    mountPointType = mountPointType,
-  sideSupport=sideSupport,
+    sideSupport = sideSupport,
-  trayLeftPadding=trayLeftPadding
+    trayLeftPadding = trayLeftPadding
-);
+  );
+}
+
+traySystem();

rack-mount/tray/tray.scad

@@ -62,23 +62,28 @@ module bottomScrewTray(u, trayWidth, trayDepth, trayThickness, mountPoints, moun
 
     mountPointPosThickness = 2;
 
+    if (len(mountPoints) > 0) {
       apply_pn() {
         for (i = [0:len(mountPoints)-1]) {
           x = mountPoints[i][0];
           y = mountPoints[i][1];
 
-        translate(v=[x, y, 0])
+          translate(v = [x, y, 0])
-        cylinder(r=screwRadiusSlacked(mountPointType)+mountPointPosThickness, h=mountPointElevation);
+          cylinder(r = screwRadiusSlacked(mountPointType)+mountPointPosThickness, h = mountPointElevation);
         }
 
         for (i = [0:len(mountPoints)-1]) {
           x = mountPoints[i][0];
           y = mountPoints[i][1];
 
-        translate(v=[x, y, -trayThickness])
+          translate(v = [x, y, -trayThickness])
-        mirror(v=[0,0,1])
+          mirror(v = [0, 0, 1])
           counterSunkHead_N(mountPointType, inf, inf);
         }
+
+        children(0);
+      }
+    } else {
       children(0);
     }