update on slide nut-only design

helper/slack.scad

@@ -17,7 +17,7 @@ xySlack = 0.3;
 
 radiusXYSlack = xySlack/2;
 
-zSlack = 0.0; // TODO figure out nice default value for this. keep in mind z shrinkage
+zSlack = 0.2; // TODO figure out nice default value for this. keep in mind z shrinkage
 
 overhangSlack = 0.4;
 

rack/connector/connectors.scad

@@ -66,6 +66,8 @@ module connectorPositive(on, to) {
     onYBarToXBarPositive();
   } else if (on == "yBar" && to == "basePlate") {
     onYBarBasePlateConnectorPositive();
+  } else if (on == "xBar" && to == "yBar") {
+    onXBarToYBarPositive();
   } else if (on == "mainRail" && to == "yBar") {
     onMainRailYBarConnectorPositive();
   }

rack/connector/xBarYBarConnectors.scad

@@ -12,7 +12,7 @@ include <../config.scad>
 // On xBar
 module onXBarToYBarNegative() {
   y = 27;
-  z = 6;
+  z = 8;
   slack = xBarYBarDovetailSlack;
 
   translate(v=[-slack,14,0])
@@ -35,18 +35,40 @@ module onXBarToYBarNegative() {
   translate(v = [-xBarSideThickness, y, z])
   rotate(a = [0, -90, 0])
   counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
+
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,3,13.5])
+  lug();
+
+  translate(v=[-0.1,26,13.5])
+  lug();
+}
+
+module onXBarToYBarPositive() {
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,3,2])
+  lug();
+
+  translate(v=[-0.1,26,2])
+  lug();
 }
 
 
 // On yBar
 module onYBarToXBarNegative() {
   y = 27;
-  z = 6;
+  z = 8;
   translate(v = [-5, y, z])
   rotate(a = [180, 0, 0])
   rotate(a = [0, 90, 0])
   hexNutPocket_N("m3", openSide=false, backSpace=5);
 
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,3,2])
+  lug();
+
+  translate(v=[-0.1,26,2])
+  lug();
 }
 
 module onYBarToXBarPositive() {
@@ -65,8 +87,26 @@ module onYBarToXBarPositive() {
       backFaceLength = 5,
       backFaceScale = 1.2
   );
+
+  // lugs for snap fit and hold in place
+  translate(v=[-0.1,3,13.5])
+  lug();
+
+  translate(v=[-0.1,26,13.5])
+  lug();
 }
 
 
 xBarConnectorToYBarConnectorTrans = mirror(v=[1,0,0]);
-yBarConnectorToXBarConnectorTrans = mirror(v=[-1,0,0]);
+yBarConnectorToXBarConnectorTrans = mirror(v=[-1,0,0]);
+
+
+
+module lug() {
+  hull() {
+    sphere(r=0.5);
+
+    translate(v=[0,2,0])
+    sphere(r=0.5);
+  }
+}

rack/print/eval_P.scad

@@ -0,0 +1,35 @@
+include <../xBar.scad>
+include <../yBar.scad>
+include <../mainRail.scad>
+
+
+// Evaluation print for slack config
+
+intersection() {
+  yBar();
+  halfspace(vpos=[0,-1,0], p=[0,joinCornerDepth,0]);
+}
+
+translate(v=[35,0,0])
+intersection() {
+    translate(v=[0,-xBarX + xBarSideThickness + 5,0])
+    xBar();
+
+    halfspace(vpos=[0,1,0], p=[0,0,0]);
+  }
+
+translate(v=[60,20,0])
+rotate(a=[0,0,90])
+intersection() {
+  multmatrix(mainRailPrintOrientation)
+  mainRail();
+
+  halfspace(vpos=[-1,0,0], p=[19,0,0]);
+
+  mainRailPrintOrientation = [
+      [cos(-90), 0, sin(-90), railTotalHeight],
+      [0, 1, 0, 0],
+      [-sin(-90), 0, cos(-90), 0],
+      [0, 0, 0, 1]
+    ];
+}

rack/sharedVariables.scad

@@ -59,7 +59,7 @@ xBarX = maxUnitWidth - 2*railSlotToInnerYEdge;
 xBarY = 32;
 xBarHeight = 15;
 
-xBarWallThickness = 2;
+xBarWallThickness = 3;
 xBarSideThickness = 8;
 xBarRoundness = baseRoundness;
 

rack/xBar.scad

@@ -21,7 +21,7 @@ module xBar() {
         cylindricalFiletEdge(xBarY, xBarX, xBarHeight, xBarRoundness);
 
         translate(v = [xBarWallThickness, xBarSideThickness, xBarWallThickness])
-        cylindricalFiletEdge(xBarY, xBarX-2*xBarSideThickness, xBarHeight, xBarRoundness);
+        cylindricalFiletEdge(xBarY, xBarX-2*xBarSideThickness, xBarHeight, xBarRoundness-xBarWallThickness);
       }
 
       // Shave off bottom corners to reduce elephant's foot at where xBar and YBar join

rack/yBar.scad

@@ -27,7 +27,7 @@ module yBar() {
         sphericalFiletEdge(yBarWidth, yBarDepth, yBarHeight, yBarRoundness);
 
         translate(v = [yBarWallThickness, joinCornerDepth, yBarWallThickness])
-        cylindricalFiletEdge(yBarWidth, yBarDepth-2*joinCornerDepth, yBarHeight, yBarRoundness);
+        cylindricalFiletEdge(yBarWidth, yBarDepth-2*joinCornerDepth, yBarHeight, yBarRoundness-yBarWallThickness);
       }
 
       halfspace(vpos=[-1, 0, 1], p=[yBarWidth-1, 0,0]);

stl/rack/hingeModule_P1.stl

@@ -2883,20 +2883,6 @@ solid OpenSCAD_Model
       vertex 5.17565 15.1043 1.3
     endloop
   endfacet
-  facet normal 0.904035 -0.427459 0
-    outer loop
-      vertex 1.74463 16.7271 1.3
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-      vertex 1.74463 16.7271 0
-    endloop
-  endfacet
   facet normal 0.513872 -0.857867 0
     outer loop
       vertex 2.44442 17.5798 0
@@ -2953,6 +2939,20 @@ solid OpenSCAD_Model
       vertex 5.39085 15.8138 1.3
     endloop
   endfacet
+  facet normal 0.0488061 -0.998808 0
+    outer loop
+      vertex 3.31377 17.8909 0
+      vertex 3.5 17.9 1.3
+      vertex 3.31377 17.8909 1.3
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+  endfacet
+  facet normal 0.0488061 -0.998808 0
+    outer loop
+      vertex 3.5 17.9 1.3
+      vertex 3.31377 17.8909 0
+      vertex 3.5 17.9 0
+    endloop
+  endfacet
   facet normal 0.336812 -0.941572 0
     outer loop
       vertex 2.7729 17.7554 0
@@ -3051,20 +3051,6 @@ solid OpenSCAD_Model
       vertex 5.4 16 1.3
     endloop
   endfacet
-  facet normal -0.671524 0.740983 0
-    outer loop
-      vertex 4.8435 14.6565 0
-      vertex 4.70535 14.5313 1.3
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-    endloop
-  endfacet
   facet normal 0.671524 0.740983 -0
     outer loop
       vertex 2.29465 14.5313 0
@@ -3303,6 +3289,20 @@ solid OpenSCAD_Model
       vertex 1.92021 17.0556 0
     endloop
   endfacet
+  facet normal 0.904035 -0.427459 0
+    outer loop
+      vertex 1.74463 16.7271 1.3
+      vertex 1.82435 16.8957 0
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+  endfacet
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+    outer loop
+      vertex 1.82435 16.8957 0
+      vertex 1.74463 16.7271 1.3
+      vertex 1.74463 16.7271 0
+    endloop
+  endfacet
   facet normal 0.998795 -0.0490815 0
     outer loop
       vertex 1.6 16 1.3
@@ -3527,20 +3527,6 @@ solid OpenSCAD_Model
       vertex 2.1565 14.6565 0
     endloop
   endfacet
-  facet normal 0.0488061 -0.998808 0
-    outer loop
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     outer loop
       vertex 1.68181 16.5515 1.3
@@ -3653,6 +3639,20 @@ solid OpenSCAD_Model
       vertex 2.03128 17.2053 0
     endloop
   endfacet
+  facet normal -0.671524 0.740983 0
+    outer loop
+      vertex 4.8435 14.6565 0
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+      vertex 4.8435 14.6565 1.3
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+    endloop
+  endfacet
   facet normal 0.904035 0.427459 0
     outer loop
       vertex 1.82435 15.1043 1.3

stl/rack/stackConnectorBottom_P.stl

@@ -1665,6 +1665,34 @@ solid OpenSCAD_Model
       vertex 9.04879 6.86349 5.62933
     endloop
   endfacet
+  facet normal 0 -0.098023 0.995184
+    outer loop
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@@ -1973,6 +2001,34 @@ solid OpenSCAD_Model
       vertex 6.25 4.62933 4.13651
     endloop
   endfacet
+  facet normal 0 0.634394 0.77301
+    outer loop
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@@ -2169,34 +2225,6 @@ solid OpenSCAD_Model
       vertex 9.15063 6.75537 5.2729
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   endfacet
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@@ -2309,34 +2337,6 @@ solid OpenSCAD_Model
       vertex 6.25 3.42021 7.05558
     endloop
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stl/rack/stackConnectorDual_P.stl

@@ -1665,6 +1665,34 @@ solid OpenSCAD_Model
       vertex 9.04879 6.86349 5.87933
     endloop
   endfacet
+  facet normal 0 -0.098023 0.995184
+    outer loop
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@@ -2057,34 +2085,6 @@ solid OpenSCAD_Model
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@@ -2113,6 +2113,34 @@ solid OpenSCAD_Model
       vertex 8.64129 6.57979 7.30558
     endloop
   endfacet
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@@ -5151,6 +5151,34 @@ solid OpenSCAD_Model
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