update readme and dovetail slacks

README.md

@@ -66,8 +66,8 @@ For generating a specific part:
 
 `python3 rbuild.py -b yBar --nightly -c micro -t custom`
 
-Generated stls are put into the `stl/` directories. The actual variable values for different profiles can be found in  
-[rack/profiles.scad](config/profiles.scad).
+Generated stls are put into the `stl/` directories. The actual variable values for different profiles can be found in 
+[rack/profiles.scad](config/rackFrame.scad).
 
 We recommend you start by printing the `eval_P.stl` file first, just to determine if the default slack/layer height
 configurations work for you. If parts are too tight/loose please take a look at

config/slack.scad

@@ -10,7 +10,7 @@
     - The general philosophy for slack applications in this project is to subtract space from sockets, while not
       modifying the plugs.
     - Values are signed. Positive values can be interpreted as how much to remove from the socket along some dimension.
-    - This shouldn't be used to compensate for serious part shrinkage
+    - These values depend on print orientation and it's assumed parts are printed in their recommended orientations.
 */
 
 xySlack = 0.3;

rack-mount/bottomScrewTray.scad

@@ -0,0 +1,42 @@
+include <./common.scad>
+use <./rackEars.scad>
+
+// Rack mount tray that supports screws on the bottom of the rack-mount item
+
+// Config variables
+//trayAlignment = "middle"; // middle, right, left
+trayWidth = 150;
+trayDepth = 100;
+trayThickness = 3;
+
+mountPoints = [];
+mountScrewType = "m3";
+
+
+bottomScrewTray(u=5);
+
+module bottomScrewTray(u) {
+
+  screwDx = rackMountScrewWidth;
+  echo(screwDx);
+  screwDz = uDiff * u;
+
+  plateLength = screwDx + 2*rackMountScrewXDist;
+  plateHeight = screwDz + 2*rackMountScrewZDist;
+
+  leftScrewDistToTray = 10+4+3;
+  assert(leftScrewDistToTray >= 5);
+
+  leftScrewGlobalX = -leftScrewDistToTray;
+  rightScrewGlobalX = screwDx + leftScrewGlobalX;
+
+  cube(size=[trayWidth, trayDepth, trayThickness]);
+
+  translate(v=[rackMountScrewXDist+leftScrewGlobalX+3,0,rackMountScrewZDist])
+  rackEarModule(frontThickness=3,sideThickness=3,frontWidth=leftScrewDistToTray, sideDepth=trayDepth-3, u=5);
+
+  translate(v=[rightScrewGlobalX,0,rackMountScrewZDist])
+  mirror(v=[1,0,0])
+  rackEarModule(frontThickness=3,sideThickness=3,frontWidth=30, sideDepth=trayDepth-3, u=5);
+
+}

rack-mount/common.scad

@@ -1,8 +1,7 @@
 
-include <../rack/config.scad>
 include <../rack/sharedVariables.scad>
-include <../helper/math.scad>
-include <../helper/screws.scad>
+include <../helper/common.scad>
+include <../config/common.scad>
 
 /*
   QoL redefinitions/variables/reimports for rack mount items
@@ -10,7 +9,8 @@ include <../helper/screws.scad>
 
 uDiff = screwDiff;
 
-// ...
+rackMountScrewXDist = 4;
+rackMountScrewZDist = 4;
 
 
 

rack-mount/rackEars.scad

@@ -0,0 +1,43 @@
+include <./common.scad>
+
+// Rack ear modules.
+// To be used either by itself if the mount-item supports it, or within another module
+
+module rackEarStandAlone(frontThickness, sideThickness, frontWidth, sideDepth, sideHoles) {
+  // TODO
+}
+
+module rackEarModule(frontThickness, sideThickness, frontWidth, sideDepth, u, triangular=true) {
+
+  earHeight = u*uDiff + 2*rackMountScrewZDist;
+
+  difference() {
+    translate(v = [-rackMountScrewXDist, 0, -rackMountScrewZDist]) {
+      cube(size = [frontWidth, frontThickness, earHeight]);
+
+      if (triangular) {
+        hull() {
+          translate(v = [frontWidth-sideThickness, 0, 0])
+          cube(size = [sideThickness, frontThickness, earHeight]);
+
+          translate(v = [frontWidth-sideThickness, sideDepth, 0])
+          cube(size = [sideThickness, frontThickness, 1]);
+        }
+      } else {
+        translate(v = [frontWidth-sideThickness, 0, 0])
+        cube(size = [sideThickness, sideDepth, earHeight]);
+      }
+    }
+
+    union() {
+      rotate(a=[90,0,0])
+      cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
+
+      translate(v=[0,0,u*uDiff])
+      rotate(a=[90,0,0])
+      cylinder(r=screwRadiusSlacked(mainRailScrewType), h=frontThickness*2, center=true);
+    }
+  }
+}
+
+rackEarModule(frontThickness=3,sideThickness=3,frontWidth=30, sideDepth=50, u=4);

rack/connector/xBarYBarConnectors.scad

@@ -8,17 +8,17 @@ module onXBarToYBarNegative() {
   z = 8;
   slack = xBarYBarDovetailSlack;
 
-  translate(v=[-slack,14,0])
+  translate(v=[-1,14,0])
   mirror(v=[1,0,0])
   rotate(a=[0,0,-90])
   dovetail(
       topWidth = 15+slack,
       bottomWidth = 12+slack,
-      height = 2+slack,
+      height = 2,
       length = yBarHeight,
-      headExtension = 1,
+      headExtension = 1+slack,
       baseExtension = 2,
-      frontFaceLength = 0.5,
+      frontFaceLength = 0.5, // elephant foot compensation
       frontFaceScale = 1.05,
       backFaceLength = 5,
       backFaceScale = 1.2
@@ -57,7 +57,7 @@ module onYBarToXBarNegative() {
 
 module onYBarToXBarPositive() {
 
-  translate(v=[xBarYBarDovetailSlack, 14,0]) // TODO: variable for the 14
+  translate(v=[1, 14,0]) // TODO: variable for the 14
   rotate(a=[0,0,-90])
   dovetail(
       topWidth = 15-xySlack, // figure out why we need this
@@ -67,7 +67,7 @@ module onYBarToXBarPositive() {
       headExtension = 1,
       baseExtension = 2,
       frontFaceLength = 2,
-      frontFaceScale = 0.95,
+      frontFaceScale = 0.95, // elephant foot compensation
       backFaceLength = 5,
       backFaceScale = 1.2
   );