rename and update print files for rack mount

2023-08-08 13:16:59 -04:00
parent 8fbd3aa573
commit cb7a5e559b
21 changed files with 31 additions and 35 deletions
--- a/rack-mount/sideRail.scad
+++ b/rack-mount/sideRail.scad
@ -0,0 +1,117 @@
+include <../helper/common.scad>
+include <../config/common.scad>
+include <../rack/sharedVariables.scad>
+include <./common.scad>
+
+sideSupportRailBase(u=2, double=true, top=true, baseThickness=1.5, sideThickness=4, backThickness=2, supportedZ=27.5, supportedY=101.5, supportedX=159);
+
+// distance between front and back main rail screw mounts
+sideRailScrewMountDist = yBarDepth - 2*(frontScrewSpacing + railFrontThickness + railSlotToXZ);
+
+module sideSupportRailBase(u=2, double=true, top=true, baseThickness=2, sideThickness=2, backThickness=2, supportedZ=26.5, supportedY=101.5, supportedX=159) {
+
+  mountBlockHeight = 10;
+  mountBlockDepth = 10;
+  screwMountGlobalDz = screwDiff / 2.0; // vertical distance between local origin and main rail screw mount
+  railLength = max(sideRailScrewMountDist + frontScrewSpacing + mountBlockDepth, supportedY+backThickness);
+  railBaseThickness = baseThickness;
+  railSideThickness = sideThickness;
+  railBaseWidth = 15;
+  railSideHeight = supportedZ + railBaseThickness*2;
+  frontMountPad = frontScrewSpacing;
+
+  applyMainRailMounts()
+  sideSupportRailBase();
+
+  module applyMainRailMounts() {
+
+    mountBlockExtension = (railSupportsDx - supportedX)/2 - railSideThickness;
+    assert(mountBlockExtension >= 10);
+
+    apply_p() {
+      union() {
+        translate(v = [0, frontMountPad, 0])
+        mountBlockColumn(mountBlockExtension=mountBlockExtension, u=u);
+        translate(v=[0,frontMountPad+sideRailScrewMountDist, 0])
+        mountBlockColumn(mountBlockExtension=mountBlockExtension, u=u);
+      }
+      children(0);
+    }
+  }
+
+  module mountBlockColumn(mountBlockExtension, u) {
+
+    difference() {
+      translate(v = [-mountBlockExtension, 0, 0])
+      cube(size = [mountBlockExtension, mountBlockDepth, railSideHeight]);
+
+      union() {
+        nutPocket();
+
+        if (double) {
+          translate(v=[0,0,uDiff * u]) // screwMountToGlobalZ
+          nutPocket();
+        }
+
+      }
+    }
+
+    module nutPocket() {
+      translate(v=[-mountBlockExtension/2,mountBlockDepth/2,mountBlockHeight/2]) // screwMountToGlobalZ
+      rotate(a=[90,0,0])
+      rotate(a=[0,90,0])
+      hexNutPocket_N(rackFrameScrewType, openSide=false);
+    }
+
+  }
+
+  module sideSupportRailBase() {
+    backThickness = 3;
+
+    difference () {
+      union() {
+        cube(size = [railBaseWidth, railLength, railBaseThickness]);
+
+        cube(size = [railSideThickness, railLength, railSideHeight]);
+
+        // back support
+        translate(v = [0, max(railLength-backThickness, supportedY), 0])
+        cube(size = [railBaseWidth, backThickness, railSideHeight]);
+
+        // back support for box
+        translate(v = [0, supportedY, 0])
+        cube(size = [railBaseWidth, backThickness, railSideHeight]);
+
+        // top support
+        if (top) {
+          translate(v = [0, 0, railSideHeight-baseThickness])
+          cube(size = [railBaseWidth, railLength, railBaseThickness]);
+        }
+
+      }
+      union() {
+        distanceFromSeparator = 3;
+        r = 5;
+
+        boxDy = frontMountPad+r+mountBlockDepth+distanceFromSeparator;
+        boxDz = baseThickness+distanceFromSeparator+r;
+        translate(v=[0,boxDy,boxDz])
+        minkowski() {
+          cube(size = [sideThickness, supportedY-(boxDy+distanceFromSeparator+r), railSideHeight-2*boxDz]);
+          sphere(r=r);
+        }
+        translate(v=[0,supportedY+distanceFromSeparator+r+backThickness,boxDz])
+        minkowski() {
+          cube(size = [sideThickness, 25, railSideHeight-2*boxDz]); // TODO calculate 22.5
+          sphere(r=r);
+        }
+
+        cylindricalFiletNegative(p0=[railBaseWidth,0,0],p1=[railBaseWidth,0,inf], n=[1,-1,0],r=4);
+      }
+    }
+  }
+
+}
+
+
+