update

cases/profiles/rockpro/case.scad

@@ -0,0 +1,197 @@
+// test for screw tolerances
+
+include <./rockpro.scad>;
+
+include <../power/src/base.scad>;
+$fn = 128;
+outerD = 4.65;
+
+innerD = 2.93;
+
+
+module caseOuter() {
+    rotate(a=[90,0,0])
+    minkowski() {
+        cube(size=[80,40,195], center=true);
+        cylinder(h=0.00000000001, r=10);
+    }
+}
+
+module caseInner() {
+    translate(v=[0,0,2])
+    rotate(a=[90,0,0])
+    minkowski() {
+        cube(size=[81.5,47,195+0.01], center=true);
+        *cylinder(h=0.00000000001, r=5);
+    }
+}
+
+
+module hgill(i) {
+  minkowski() {
+    *sphere(r=2);
+              translate(v=[0,i*10,5])
+              rotate(a=[30,0,0])
+              cube(size=[200, 4, 30], center=true);
+          }
+    }
+
+module caseShell() {
+    difference() {
+        caseOuter();
+
+        union() {
+          caseInner();
+
+          // side perforations
+          for (i=[-7:7]) {
+              hgill(i=i);
+          }
+
+          // top perforations
+          for (i=[-3:3]) {
+            translate(v=[0,i*20,50])
+            cube(size=[75,10,60], center=true);
+          }
+
+          // bottom perforations
+          for (i=[2:4]) {
+            translate(v=[0,i*20,-20])
+            cube(size=[60,8,50], center=true);
+          }
+
+          for (i=[-4:0]) {
+            translate(v=[0,i*20,-20])
+            cube(size=[60,8,50], center=true);
+          }
+          
+        }
+    }
+}
+
+
+module faceMountDiffs() {
+translate(v=[45,0,20])
+rotate(a=[90,0,0])
+cylinder(r=innerD/2,h=300, center=true);
+
+translate(v=[45,0,-20])
+rotate(a=[90,0,0])
+cylinder(r=innerD/2,h=300, center=true);
+
+translate(v=[-45,0,-20])
+rotate(a=[90,0,0])
+cylinder(r=innerD/2,h=300, center=true);
+
+translate(v=[-45,0,20])
+rotate(a=[90,0,0])
+cylinder(r=innerD/2,h=300, center=true);
+}
+
+
+module caseWithMountHoles() {
+  difference() {
+
+    union() {
+      caseShell();
+
+      translate(v=[-35, 25,-27.5])
+      rotate(a=[0,0,-90])
+      rockProMountPoints(6, 3.8, 64, false);
+    }
+
+    union() {
+      translate(v=[-35, 25,-27.5])
+      rotate(a=[0,0,-90])
+      rockProMountPoints(6, innerD/2, 64, false);
+
+      faceMountDiffs();
+    }
+  }
+}
+
+*caseWithMountHoles();
+
+
+module bottomTray() {
+difference() {
+
+union() {
+intersection() {
+  caseWithMountHoles();
+  translate(v=[0,0,-115])
+  cube(size=[500,500,200], center=true);
+}
+
+translate(v=[-45.5,0,-15])
+rotate(a=[90,90,0])
+joinTriangle(185);
+
+translate(v=[45.5,0,-15])
+rotate(a=[90,90,0])
+joinTriangle(185);
+}
+
+  // bottom lugs
+  union() {
+    translate(v=[-40,-90,-29])
+    cube(size=[10.2,10.2,2.5], center=true);
+
+    translate(v=[40,-90,-29])
+    cube(size=[10.2,10.2,2.5],center=true);
+
+    translate(v=[40,90,-29])
+    cube(size=[10.2,10.2,2.5],center=true);
+
+    translate(v=[-40,90,-29])
+    cube(size=[10.2,10.2,2.5],center=true);
+  }
+}
+}
+
+
+module topTray() {
+  difference () {
+    union() {
+      difference() {
+        caseWithMountHoles();
+        translate(v=[0,0,-115])
+          cube(size=[500,500,200], center=true);
+      }
+    }
+    // bottom lugs
+    union() {
+      translate(v=[-40,-90,29])
+        cube(size=[10.2,10.2,2.5], center=true);
+
+      translate(v=[40,-90,29])
+        cube(size=[10.2,10.2,2.5],center=true);
+
+      translate(v=[40,90,29])
+        cube(size=[10.2,10.2,2.5],center=true);
+
+      translate(v=[-40,90,29])
+        cube(size=[10.2,10.2,2.5],center=true);
+
+      
+      
+      translate(v=[-45.5,0,-15])
+        rotate(a=[90,90,0])
+        scale(v=[1,0.9,1])
+        joinTriangle(300);
+
+      translate(v=[45.5,0,-15])
+        rotate(a=[90,90,0])
+        scale(v=[1,0.9,1])
+        joinTriangle(300);
+    }
+  }
+}
+
+topTray();
+
+// TODO make sure rail works!!!
+
+
+scale(v=[1,0.9,1])
+*joinTriangle(10);

cases/profiles/rockpro/dual-tray-plate-part.scad

@@ -0,0 +1,125 @@
+include <../rack-tray/rack-tray.scad>
+include <../common.scad>
+include <../rack/screws.scad>
+include <./rockpro.scad>
+
+vU = 3;
+uHeight = 10;
+
+plateScrewDiffV = uHeight*vU;
+plateScrewDiffH = 180;
+
+plateScrewToHEdge = 4.5;
+plateScrewToVEdge = 5.5;
+
+frontPlateThickness = 3;
+
+frontPlateV = plateScrewDiffV + 2*plateScrewToHEdge;
+frontPlateH = plateScrewDiffH + 2*plateScrewToVEdge;
+
+
+plateScrewToBoxMin = 6;
+
+module _frontPlateBody() {
+    translate(v=[-plateScrewToVEdge,0,-plateScrewToHEdge])
+        cube(size=[frontPlateH,frontPlateThickness,frontPlateV]);
+}
+
+module _plateHole() {
+    rotate(a=[90,0,0])
+        cylinder(r=m4RadiusSlacked, h=inf, center=true);
+}
+
+
+module frontPlate() {
+
+    difference() {
+        _frontPlateBody();
+
+        union() {
+            // TODO: introduce helper modules for this pattern
+            _plateHole();
+
+            translate(v=[plateScrewDiffH,0,0])
+                _plateHole();
+
+            translate(v=[0,0,plateScrewDiffV])
+                _plateHole();
+
+            translate(v=[plateScrewDiffH,0,plateScrewDiffV])
+                _plateHole();
+        }
+    }
+}
+
+difference() {
+    frontPlate();
+    union() {
+        translate(v = [13, 0, - 10])
+            cube(size = [300, 100, 100]);
+
+        translate(v=[6,0,0])
+            cube(size=[5,5,5]);
+
+        translate(v=[6,0,20])
+            cube(size=[5,5,5]);
+    }
+}
+
+
+
+// todo use library constants
+module screwRiser(height) {
+    difference() {
+        cylinder(d=5, h=height, $fn=64);
+        cylinder(d=2.88, h=height, $fn=64);
+    }
+}
+
+module mountPoints_N(cylHeight, cylRad1, cylRad2, cylFn, center) {
+    for (i=[0:3]) {
+        p = mountPoints[i];
+        translate(v=[p[0], p[1], p[2]])
+            cylinder(r1=cylRad1, r2=cylRad2, h=cylHeight, $fn=cylFn, center=center);
+    }
+
+}
+
+module rockProScrewMounts() {
+    for (i=[0:3]) {
+        p = mountPoints[i];
+        translate(v=[p[0], p[1], p[2]])
+            screwRiser(5);
+    }
+}
+
+
+module rockProDualTray() {
+
+
+    trayBody();
+    translate(v=[9,8,trayBottomThickness])
+        rockProScrewMounts();
+
+    translate(v=[9 + pcbDimensions[0],8,trayBottomThickness])
+        rockProScrewMounts();
+
+}
+
+*difference() {
+    rockProDualTray();
+    // file specific bottom holes
+    union() {
+        translate(v = [10, 15, 0])
+            minkowski() {
+                cube(size = [69, 100, 5]);
+                cylinder(r = 1);
+            }
+
+        translate(v=[88,15,0])
+            minkowski() {
+                cube(size = [69, 100, 5]);
+                cylinder(r=1);
+            }
+    }
+}

cases/profiles/rockpro/dual-tray.scad

@@ -0,0 +1,125 @@
+include <../rack-tray/rack-tray.scad>
+include <../common.scad>
+include <../rack/screws.scad>
+include <./rockpro.scad>
+
+vU = 3;
+uHeight = 10;
+
+plateScrewDiffV = uHeight*vU;
+plateScrewDiffH = 180;
+
+plateScrewToHEdge = 4.5;
+plateScrewToVEdge = 5.5;
+
+frontPlateThickness = 2;
+
+frontPlateV = plateScrewDiffV + 2*plateScrewToHEdge;
+frontPlateH = plateScrewDiffH + 2*plateScrewToVEdge;
+
+
+plateScrewToBoxMin = 6;
+
+module _frontPlateBody() {
+    translate(v=[-plateScrewToVEdge,0,-plateScrewToHEdge])
+        cube(size=[frontPlateH,frontPlateThickness,frontPlateV]);
+}
+
+module _plateHole() {
+    rotate(a=[90,0,0])
+        cylinder(r=m4RadiusSlacked, h=inf, center=true);
+}
+
+
+module frontPlate() {
+
+    difference() {
+        _frontPlateBody();
+
+        union() {
+            // TODO: introduce helper modules for this pattern
+            _plateHole();
+
+            translate(v=[plateScrewDiffH,0,0])
+                _plateHole();
+
+            translate(v=[0,0,plateScrewDiffV])
+                _plateHole();
+
+            translate(v=[plateScrewDiffH,0,plateScrewDiffV])
+                _plateHole();
+        }
+    }
+}
+
+difference() {
+    frontPlate();
+    union() {
+        translate(v = [13, 0, - 10])
+            cube(size = [300, 100, 100]);
+
+        translate(v=[6,0,-2])
+            cube(size=[5.5,5.5,5.5]);
+
+        translate(v=[6,0,20-2])
+            cube(size=[5.5,5.5,5.5]);
+    }
+}
+
+
+
+// todo use library constants
+// TODO these risers are prone to snapping off
+module screwRiser(height) {
+    difference() {
+        cylinder(d=5, h=height, $fn=64);
+        cylinder(d=2.88, h=height, $fn=64);
+    }
+}
+
+module mountPoints_N(cylHeight, cylRad1, cylRad2, cylFn, center) {
+    for (i=[0:3]) {
+        p = mountPoints[i];
+        translate(v=[p[0], p[1], p[2]])
+            cylinder(r1=cylRad1, r2=cylRad2, h=cylHeight, $fn=cylFn, center=center);
+    }
+}
+
+module rockProScrewMounts() {
+    for (i=[0:3]) {
+        p = mountPoints[i];
+        translate(v=[p[0], p[1], p[2]])
+            screwRiser(5);
+    }
+}
+
+
+module rockProDualTray() {
+
+
+    trayBody();
+    translate(v=[9,8,trayBottomThickness])
+        rockProScrewMounts();
+
+    translate(v=[9 + pcbDimensions[0],8,trayBottomThickness])
+        rockProScrewMounts();
+
+}
+
+*difference() {
+    rockProDualTray();
+    // file specific bottom holes
+    union() {
+        translate(v = [10, 15, 0])
+            minkowski() {
+                cube(size = [69, 100, 5]);
+                cylinder(r = 1);
+            }
+
+        translate(v=[88,15,0])
+            minkowski() {
+                cube(size = [69, 100, 5]);
+                cylinder(r=1);
+            }
+    }
+}

cases/profiles/rockpro/newcase.scad

@@ -0,0 +1,201 @@
+
+include <./rockpro.scad>;
+
+include <../power/src/base.scad>;
+$fn = 128;
+outerD = 4.65;
+
+innerD = 2.93;
+
+
+
+
+
+module caseOuter() {
+    rotate(a=[90,0,0])
+    minkowski() {
+        //translate(v=[-35, -15, -32.5])
+        cube(size=[70,30,130], center=true);
+        cylinder(h=0.00000000001, r=15);
+    }
+}
+
+module caseInner() {
+    translate(v=[0,0,0])
+    rotate(a=[90,0,0])
+    minkowski() {
+        cube(size=[70,30,130+0.01], center=true);
+        cylinder(h=0.00000000001, r=12);
+    }
+}
+
+module hgill(i) {
+  minkowski() {
+    *sphere(r=2);
+              translate(v=[0,i*10,5])
+              rotate(a=[30,0,0])
+              cube(size=[200, 4, 30], center=true);
+          }
+    }
+
+module caseShell() {
+
+  union() {
+    
+
+    
+    difference() {
+      caseOuter();
+
+      union() {
+        caseInner();
+
+        // side perforations
+        for (i=[-7:7]) {
+          *hgill(i=i);
+        }
+
+        // top perforations
+        for (i=[-2:2]) {
+          translate(v=[0,i*20,50])
+            cube(size=[50,8,50], center=true);
+        }
+
+        for (i=[-2:2]) {
+          translate(v=[0,i*20,-20])
+            rotate(a=[0,0,25])
+            cube(size=[50,3,50], center=true);
+        }
+          
+      }
+    }
+  }
+}
+
+module caseWithMountHoles() {
+  difference() {
+
+    union() {
+      caseShell();
+
+      translate(v=[-35, 59,-28])
+      rotate(a=[0,0,-90])
+      rockProMountPoints(5.0, 5.5, 2.5, 64, false);
+      faceMountSupports();
+    }
+
+    union() {
+      translate(v=[-35, 59,-29.5])
+      rotate(a=[0,0,-90])
+      rockProMountPoints(6.5, innerD/2, innerD/2, 64, false);
+
+      faceMountDiffs();
+    }
+  }
+}
+
+module guideRail(x,y,z) {
+  // gross
+  cube(size=[y,z,x]);
+}
+
+
+module faceMountDiffs() {
+
+  for (i = [-1,1]) {
+    for (j = [-1,1]) {
+      translate(v=[i*47,0,j*15]) {                  
+
+        rotate(a=[90,0,0])
+          translate(v=[0,0,93])
+          *cylinder(r=innerD/2,h=12, center=true);
+          
+        rotate(a=[90,0,0])
+          translate(v=[0,0,-93])
+          *cylinder(r=innerD/2,h=12, center=true);
+
+                  
+          rotate(a=[90,0,0])
+          translate(v=[0,0,90])
+          cylinder(r=innerD/2,h=400, center=true);
+      }
+
+    }
+  }
+}
+
+module faceMountSupports() {
+
+  intersection() {
+    caseOuter();
+    for (i = [-1,1]) {
+      for (j = [-1,1]) {
+        translate(v=[i*47,0,j*15]) {
+
+          
+          rotate(a=[90,0,0])
+          translate(v=[0,0,90])
+          cylinder(r=innerD,h=400, center=true);
+
+        }
+      }
+    }
+  }
+}
+
+module bottomTray() {
+difference() {
+
+union() {
+  translate(v=[-48,0,-11])
+  cube(size=[4,130,4], center=true);
+
+  translate(v=[48,0,-11])
+  cube(size=[4,130,4], center=true);
+intersection() {
+  caseWithMountHoles();
+  translate(v=[0,0,-110])
+  cube(size=[500,500,200], center=true);
+}
+
+
+
+translate(v=[-50,65,-10+3])
+rotate(a=[90,90,0])
+guideRail(130,2,2);
+
+
+translate(v=[48, 65, -10+3])
+rotate(a=[90,90,0])
+guideRail(130,2,2);
+
+
+}
+
+// bottom lugs
+  union() {
+    translate(v=[-35,-56.5,-30])
+    *cube(size=[10.2,10.2,2.5], center=true);
+
+    translate(v=[35,-56.5,-30])
+    *cube(size=[10.2,10.2,2.5],center=true);
+
+    translate(v=[35,56.5,-30])
+    *cube(size=[10.2,10.2,2.5],center=true);
+
+    translate(v=[-35,56.5,-30])
+    *cube(size=[10.2,10.2,2.5],center=true);
+  }
+
+
+}
+
+}
+
+
+
+bottomTray();
+*caseWithMountHoles();
+
+
+*caseShell();

cases/profiles/rockpro/railTest.stl

@@ -0,0 +1,198 @@
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+      vertex 0 -4.05 -5
+      vertex 3.5 -4.05 -5
+    endloop
+  endfacet
+endsolid OpenSCAD_Model

cases/profiles/rockpro/rockpro.scad

@@ -0,0 +1,65 @@
+include <../common.scad>
+
+// All coordinates are in [x,y], or [x,y,z] format
+
+pcbDimensions = [79.41, 127.06]; // [x,y]
+pcbThickness = 1.22;
+
+// TODO move mount points
+mountPoints = [[0,0,0], [0,118,0], [71.0,118, 0], [71.0,0,0]];
+
+module mountPoints_N(cylHeight, cylRad1, cylRad2, cylFn, center) {
+  for (i=[0:3]) {
+    p = mountPoints[i];
+    translate(v=[p[0], p[1], p[2]])
+    cylinder(r1=cylRad1, r2=cylRad2, h=cylHeight, $fn=cylFn, center=center);
+  }
+  
+}
+
+module pcb() {
+  cube(size=[pcbDimensions[0], pcbDimensions[1], pcbThickness]);
+}
+
+// defined on x-z plane, start at top of pcb
+module frontFaceIOCutouts_N() {
+  translate(v=[9,0,0])
+    cube(size=[26.0,inf50,7.5]);
+
+  translate(v=[35,0,0])
+    cube(size=[35,inf50,17.9]);
+}
+module backFaceIOCutouts_N() {
+  translate(v=[9,0,0])
+    cube(size=[61,inf50,14]);
+}
+
+
+module cutoutProfile_N() {
+
+  color([1,0,1])
+  union() {
+  mirror(v=[0,1,0])
+    translate(v=[0,-1,pcbThickness])
+    frontFaceIOCutouts_N();
+
+  translate(v=[0,pcbDimensions[1]-1, pcbThickness])
+  backFaceIOCutouts_N();
+  }
+
+  color([0.3,0.8,0.1])
+  difference() {
+    pcb();
+    translate(v=[3.75, 3.75])
+      mountPoints_N(10,2,2,10,true);
+  }
+}
+
+//cutoutProfile_N();
+
+
+//mountPoints_N(10,2,2, true);
+
+
+
+