update on slide nut-only design

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]);