wip on base connector

helper/common.scad

@@ -10,3 +10,38 @@ inf10 = 10;
 inf50 = 50;
 inf1000 = 1000;
 inf = inf1000;
+
+
+module apply_p() {
+  union() {
+    children(0);
+    children(1);
+  }
+}
+
+module apply_n() {
+  difference() {
+    children(1);
+    children(0);
+  }
+}
+
+module apply_pn() {
+  difference() {
+    union() {
+      children(0);
+      children(2);
+    }
+    children(1);
+  }
+}
+
+module apply_np() {
+  difference() {
+    union() {
+      children(1);
+      children(2);
+    }
+    children(0);
+  }
+}

helper/screws.scad

@@ -10,6 +10,9 @@ m3Diameter = 3.0;
 m3Radius = m3Diameter / 2.0;
 m3RadiusSlacked = m3Radius + m3HoleRadiusSlack;
 
+m3CounterSunkHeadRadius = 3;
+m3CounterSunkHeadLength = 1.7;
+
 m3HexNutWidthAcrossFlats = 5.41;
 m3HexNutWidthAcrossCorners = FtoG(m3HexNutWidthAcrossFlats);
 m3HexNutThickness = 2.18;
@@ -35,7 +38,7 @@ m4HexNutThickness = 3.07;
 
 /********************************************************************************/
 
-module heatSetInsertSlot_N(screwType) {
+module heatSetInsertSlot_N(screwType, topExtension=inf50) {
   if (screwType == "m3") {
     union() {
       // actual slot for insert
@@ -43,7 +46,7 @@ module heatSetInsertSlot_N(screwType) {
 
       // extra space above slot to help with insertion
       translate(v=[0, 0, m3HeatSetInsertSlotHeightSlacked])
-      cylinder(h = inf50, r = 1.3*m3HeatSetInsertSlotRadiusSlacked);
+      cylinder(h = topExtension, r = m3HeatSetInsertSlotRadiusSlacked);
     }
   } else {
     error("Unsupported screw type");
@@ -57,6 +60,24 @@ function screwRadiusSlacked(screwType) =
   ? m4RadiusSlacked
   : error("Unsupported screw type");
 
+
+module counterSunkHead_N(screwType, screwExtension=0, headExtension=0) {
+
+  if (screwType == "m3") {
+    cylinder(r1=m3RadiusSlacked, r2=m3CounterSunkHeadRadius, h=m3CounterSunkHeadLength);
+
+    translate(v=[0,0,-screwExtension])
+    cylinder(r=m3RadiusSlacked, h=screwExtension);
+
+    translate(v=[0,0,m3CounterSunkHeadLength])
+    cylinder(r=m3CounterSunkHeadRadius, h=headExtension);
+
+  } else {
+    error("Unsupported screw type");
+  }
+}
+
+
 module hexNutPocket_N(screwType) {
   if (screwType == "m3") {
     hexNutPocketHelper_N(m3RadiusSlacked, m3HexNutWidthAcrossCorners / 2 + 0.1, m3HexNutThickness + 0.2);

rack/xBar.scad

@@ -4,8 +4,6 @@ include <../helper/screws.scad>
 include <./config.scad>
 include <./derivedConfig.scad>
 include <./xyBarConnector.scad>
-include <./xBarBasePlateConnector.scad>
-
 
 // Temporary
 include <./yBar.scad>
@@ -49,7 +47,7 @@ module xBar() {
     // TODO refactor - probably better off mirroring the side faces and hulling the shell
     difference() {
       union() {
-        intersection () {
+        intersection() {
           positive();
           halfspace(vpos = [1, 0, 1], p = [0.5, 0, 0]);
 
@@ -69,21 +67,10 @@ module xBar() {
         yBarConnectorFromX_N();
       }
     }
-
-
-    // TODO change me?
-    translate(v=[0,xBarWidth,0])
-    basePlateMount();
-
-    translate(v=[xBarDepth,xBarWidth,0])
-    mirror(v=[1,0,0])
-    basePlateMount();
   }
-
   xBar();
 }
-translate(v=[-30,0,0])
+
-*yBar();
 xBar();
 
 

rack/xBarBasePlateConnector.scad

@@ -1,53 +0,0 @@
-include <../helper/common.scad>
-include <../helper/screws.scad>
-include <./config.scad>
-
-module basePlateMount() {
-
-  screwHoleToBase = 6;
-  mountHeight = 10;
-  mountWidth = 10;
-  mountThickness = 2;
-
-  module support() {
-    r = 4;
-
-    difference () {
-      translate(v = [0, mountThickness, r/2])
-      rotate(a = [90, 0, 0])
-      rotate(a = [0, 0, 90])
-      cylinder(h = mountThickness, r = r, $fn = 3);
-
-      cube(size=[inf10, inf10, inf10]);
-    }
-
-    //translate([-r/2, -2,0])
-    //cube(size=[r/2, 0.1, 0.1]);
-  }
-
-  module positive() {
-    cube(size = [mountWidth, mountThickness, mountHeight]);
-
-    translate(v=[mountWidth,0,0])
-    mirror(v=[1,0,0])
-    hull() {
-      support();
-    }
-  }
-
-  module basePlateMount() {
-    translate(v=[0,-mountThickness,0])
-    difference() {
-      positive();
-
-      translate(v = [mountWidth/2, inf50/2, screwHoleToBase])
-      rotate(a = [90, 0, 0])
-      cylinder(h = inf50, r = screwRadiusSlacked(rackFrameScrewType));
-    }
-  }
-
-  basePlateMount();
-
-}
-
-

rack/xyBarConnector.scad

@@ -45,10 +45,12 @@ module yBarConnectorFromXLug() {
         // TODO fix this up, no center=true
         translate(v = [-1, y1+(y2-y1)/2, 0])
         rotate(a = [0, 45, 0])
-        scale(v=[0.90,0.90,0.95])
+        scale(v=[0.90,0.95,0.90])
         cube(size = [3, 10, 6], center = true);
 
         mirror(v=[0,0,1])
         halfspace(vpos=[0,0,1], p=[0,0,0]);
+
+        halfspace(vpos=[1,0,0], p=[-2,0,0]);
     }
 }

rack/yBar.scad

@@ -11,6 +11,7 @@ include <./mainRail.scad>
 include <./stackConnector.scad>
 include <./xyBarConnector.scad>
 include <./sideWallConnector.scad>
+include <./yBarBasePlateConnector.scad>
 
 // TODO clean up
 // TODO: How do I nicely explain this?
@@ -24,6 +25,8 @@ yBarHeight = 15;
 yBarWallThickness = 3;
 yBarRoundness = baseRoundness;
 
+joinCornerDepth = 32;
+
 echo("Bar total depth: ", yBarDepth);
 echo("Bar total width: ", yBarWidth);
 
@@ -34,8 +37,8 @@ module yBar() {
     difference() {
       sphericalFiletEdge(yBarWidth, yBarDepth, yBarHeight, yBarRoundness);
 
-      translate(v = [yBarWallThickness, 32, yBarWallThickness])
+      translate(v = [yBarWallThickness, joinCornerDepth, yBarWallThickness])
-      cylindricalFiletEdge(yBarWidth, yBarDepth-32*2, yBarHeight, yBarRoundness);
+      cylindricalFiletEdge(yBarWidth, yBarDepth-2*joinCornerDepth, yBarHeight, yBarRoundness);
     }
   }
 
@@ -55,7 +58,7 @@ module yBar() {
     }
   }
 
-  module sideBar() {
+    module yBar() {
 
     module mirrorOtherCorner() {
       children(0);
@@ -67,12 +70,30 @@ module yBar() {
     }
 
     difference() {
+
+      union() {
         positive();
 
+        mirrorOtherCorner()
+        translate(v=[yBarWidth-12, joinCornerDepth,0.01])
+        yBarBasePlateMount_P(mountX=12, mountZ=yBarHeight);
+      }
+      union() {
         mirrorOtherCorner()
         singleCornerNoStackConnector_N();
+
+        mirrorOtherCorner()
+        translate(v=[yBarWidth-12, joinCornerDepth, 0])
+        yBarBasePlateMount_N();
+      }
     }
   }
 
-  sideBar();
+  yBar();
 }
+
+translate(v=[yBarWidth-12, joinCornerDepth, m3CounterSunkHeadLength])
+*yBarBasePlateMount_N();
+yBar();
+
+//counterSunkHead_N("m3", 1, 1);

rack/yBarBasePlateConnector.scad

@@ -0,0 +1,28 @@
+include <../helper/common.scad>
+include <../helper/screws.scad>
+include <./config.scad>
+
+module yBarBasePlateMount_P(mountX=12, mountY=12, mountZ=12) {
+  cube(size=[mountX, mountY, mountZ]);
+}
+
+module yBarBasePlateMount_N(innerEdgeToScrew=6, baseConnectorRecession = 2) {
+
+  translate(v=[innerEdgeToScrew,innerEdgeToScrew, m3HeatSetInsertSlotHeightSlacked + baseConnectorRecession])
+  mirror(v=[0,0,1])
+  heatSetInsertSlot_N(rackFrameScrewType, topExtension=inf10);
+
+  translate(v=[2,2,0])
+  cube(size=[inf50,8,baseConnectorRecession]);
+
+  translate(v=[innerEdgeToScrew,innerEdgeToScrew, baseConnectorRecession+m3CounterSunkHeadLength])
+  mirror(v=[0,0,1])
+  *counterSunkHead_N(rackFrameScrewType, screwExtension=0, headExtension=eps);
+}
+
+*difference() {
+  yBarBasePlateMount_P();
+  yBarBasePlateMount_N(innerEdgeToScrew=6,wallThickness=3);
+}
+
+*yBarBasePlateMount_N(innerEdgeToScrew=6);