update

cases/rack2/mainRail.scad

@@ -0,0 +1,121 @@
+include <./config.scad>
+include <./screws.scad>
+
+// Distance between the middle of a screw mount and the rail's vertical edges
+railScrewHoleToInnerEdge = 5;
+railScrewHoleToOuterEdge = 5;
+
+// Distance between the midpoint of the rail screw holes.
+rackMountScrewWidth = maxUnitWidth + 2*railScrewHoleToInnerEdge;
+
+railFrontThickness = 6; // Make sure that the nuts for the chosen screw type can slot within the front face
+railSideMountThickness = 2.5;
+railOtherThickness = 2.5;
+
+
+// Extra spacing for the rack unit screws.
+frontScrewSpacing = 8;
+
+/* Small horizontal planes at the top and bottom of the main rails. Used so we can fasten the rail to the frame
+   Note that this value is also used for a depression at the bottom/top of the frame for aligning the rail */
+railFootThickness = 3;
+
+railTotalHeight = screwDiff * (numRailScrews+1) + 2*railFootThickness;
+
+
+sideSupportExtraSpace = 2;
+sideSupportScrewHoleToFrontEdge = 5;
+sideSupportScrewHoleToBackEdge = 4.5;
+sideSupportDepth = sideSupportScrewHoleToBackEdge + sideSupportScrewHoleToFrontEdge;
+
+frontFaceWidth = railScrewHoleToInnerEdge + railScrewHoleToOuterEdge;
+
+
+module _frontRailSegment() {
+    difference() {
+        cube(size=[frontFaceWidth, railFrontThickness, railTotalHeight]);
+
+        for (i=[1:numRailScrews]) {
+            translate(v=[railScrewHoleToOuterEdge, railFrontThickness/2, i*screwDiff + railFootThickness])
+                rotate(a=[90,0,0])
+                    m4HexNutPocketNegative();
+        }
+    }
+}
+
+module _connectingLBracketRailSegment() {
+
+    difference() {
+        cube(size = [railOtherThickness, frontScrewSpacing + railOtherThickness, railTotalHeight]);
+
+        union () {
+            translate(v=[0,4,railFootThickness + screwDiff / 2])
+                rotate(a=[0,90,0])
+                    cylinder(r=m3RadiusSlacked, h = 10, $fn=32, center=true);
+
+            translate(v=[0,4,railTotalHeight-(railFootThickness + screwDiff / 2)])
+                rotate(a=[0,90,0])
+                    cylinder(r=m3RadiusSlacked, h = 10, $fn=32, center=true);
+        }
+    }
+
+    translate(v=[0, frontScrewSpacing + railOtherThickness, 0])
+    rotate(a=[0,0,270])
+        cube(size=[railOtherThickness, frontFaceWidth - sideSupportExtraSpace, railTotalHeight]);
+}
+
+
+module _sideSupportSegment() {
+
+    difference() {
+        cube(size=[sideSupportDepth, railSideMountThickness, railTotalHeight]);
+
+        for (i=[1:numRailScrews]) {
+            translate(v=[sideSupportScrewHoleToFrontEdge, railFrontThickness/2, i*screwDiff + railFootThickness])
+            rotate(a=[90,0,0])
+                    cylinder(r=m4RadiusSlacked, h=10, $fn=32);
+        }
+    }
+
+}
+
+module _railFeet() {
+
+    difference() {
+        cube(size = [frontFaceWidth - sideSupportExtraSpace, sideSupportDepth, railFootThickness]);
+
+        hull() {
+            translate(v = [1.5, 5, 0])
+                cylinder(r = m3RadiusSlacked, h = 10, $fn = 32);
+
+            translate(v = [0, 5, 0])
+            cube(size=[0.1, m3RadiusSlacked*2, 10], center=true);
+        }
+    }
+}
+
+module mainRail() {
+    union() {
+
+        _frontRailSegment();
+
+        translate(v = [0, railFrontThickness, 0])
+            _connectingLBracketRailSegment();
+
+        translate(v = [frontFaceWidth-sideSupportExtraSpace, railFrontThickness + railOtherThickness + frontScrewSpacing, 0])
+            rotate(a = [0, 0, 90])
+                _sideSupportSegment();
+
+
+        translate(v = [0, railFrontThickness + railOtherThickness + frontScrewSpacing, 0]) {
+            _railFeet();
+
+            translate(v = [0, 0, railTotalHeight-railFootThickness])
+                _railFeet();
+        }
+    }
+}
+
+mainRail();
+
+echo("Total Rail Height = ", railTotalHeight);