wip - add matrix transformations

rack/connector/basePlateYBarConnectors.scad

@@ -0,0 +1,68 @@
+include <../../helper/screws.scad>
+include <../../helper/common.scad>
+include <../../helper/matrix.scad>
+include <../../helper/slack.scad>
+include <../../helper/dovetail.scad>
+include <../../helper/halfspace.scad>
+
+include <../sharedVariables.scad>
+
+include <../config.scad>
+
+_mountX = 12;
+_mountY = 14;
+_mountZ = 10;
+
+// Needed for yBar to align this connector to its inner Y edge
+yBarBasePlateConnectorWidth = _mountX;
+
+// x and y faces of the yBarBasePlateMount_P block
+_innerXFaceToScrew = 6;
+_innerYFaceToScrew = 8;
+
+_baseConnRecession = 3;
+_baseConnY = 8;
+_baseConnOuterXFaceToScrew = 2;
+
+_heatSetX = _mountX - _innerXFaceToScrew;
+_heatSetY = _mountY - _innerYFaceToScrew;
+
+// TODO refactor this entire file
+basePlateScrewMountToYBarXZFace = _heatSetY + joinCornerDepth; // Distance to the nearest YBar XZ face
+basePlateScrewMountToYBarYZFace =  (yBarWidth+_heatSetX) - yBarBasePlateConnectorWidth;
+
+module onYBarBasePlateConnectorPositive() {
+  translate(v=[0,0,yBarWallThickness])
+  intersection() {
+    cube(size = [_mountX, _mountY, _mountZ]);
+    halfspace(vpos=[0, -1, -1], p=[0, _mountY-1, _mountZ-1]);
+  }
+}
+
+module onYBarBasePlateConnectorNegative() {
+
+  translate(v=[_heatSetX, _heatSetY, m3HeatSetInsertSlotHeightSlacked + _baseConnRecession])
+  mirror(v=[0,0,1])
+  heatSetInsertSlot_N(rackFrameScrewType, topExtension=inf10);
+
+  hull() {
+    translate(v = [_heatSetX, _heatSetY, _baseConnRecession+overhangSlack])
+    roundCutSlice(radius = heatSetInsertSlotRadiusSlacked(rackFrameScrewType)+radiusXYSlack);
+
+    translate(v = [_heatSetX, _heatSetY, 0])
+    roundCutSlice(radius = _baseConnY/2 + radiusXYSlack);
+  }
+
+
+
+  module roundCutSlice(radius, length=inf50) {
+
+    hull() {
+      cylinder(r = radius, h = eps);
+
+      translate(v = [length, -radius, 0])
+      cube(size = [eps, radius*2, eps]);
+    }
+  }
+
+}

rack/connector/connectors.scad

@@ -1,46 +1,77 @@
 /*
   Connector factory
 */
-include <../helper/screws.scad>
-include <../helper/slack.scad>
-include <../helper/dovetail.scad>
-include <../helper/halfspace.scad>
-include <./config.scad>
+include <../../helper/screws.scad>
+include <../../helper/common.scad>
+include <../../helper/matrix.scad>
+include <../../helper/slack.scad>
+include <../../helper/dovetail.scad>
+include <../../helper/halfspace.scad>
+include <../config.scad>
+
+include <./xBarYBarConnectors.scad>
+include <./mainRailYBarConnectors.scad>
+include <./sideModuleYBarConnectors.scad>
+include <./stackYBarConnectors.scad>
+include <./basePlateYBarConnectors.scad>
 
 // WIP
-
 partList = ["yBar", "xBar", "mainRail", "xyPlate", "sideModule"];
 
+mirror(v=[1,0,0])
+*connectorDebug(on="xBar", to="yBar", trans=identity);
+
+*connectorDebug(on="yBar", to="xBar", trans=identity);
+
 // Default is to apply the positive first
-module applyConnector(on,to, trans) {
+module applyConnector(on, to, trans) {
 
-  //apply_pn() {
+  apply_pn() {
+    multmatrix(trans)
+    connectorPositive(on=on, to=to);
 
-  //}
+    multmatrix(trans)
+    connectorNegative(on=on, to=to);
+
+    children(0);
+  }
+}
+
+
+module connectorDebug(on, to, trans) {
+
+  color([0,1,0])
+  multmatrix(trans)
+  connectorPositive(on=on, to=to);
+
+  color([1,0,0])
+  multmatrix(trans)
+  connectorNegative(on=on, to=to);
+
+}
+
+
+module applyConnectorDebug(on,to,trans) {
+
+  echo("on: ", on, "-- to:", to);
+
+  apply_p() {
+    multmatrix(trans)
+    connectorDebug(on=on,to=to,trans=trans);
+
+    children(0);
+  }
 }
 
 module connectorPositive(on, to) {
 
   if (on == "yBar" && to == "xBar") {
     onYBarToXBarPositive();
+  } else if (on == "yBar" && to == "basePlate") {
+    onYBarBasePlateConnectorPositive();
+  } else if (on == "mainRail" && to == "yBar") {
+    onMainRailYBarConnectorPositive();
   }
-
-
-  module onYBarToXBarPositive() {
-    rotate(a=[0,0,-90])
-    dovetail(
-    topWidth = 15,
-    bottomWidth = 12,
-    height = 2,
-    length = yBarHeight,
-    headExtension = 1,
-    baseExtension = 2,
-    frontFaceLength = 2,
-    frontFaceScale = 0.95,
-    backFaceLength = 5,
-    backFaceScale = 1.2);
-  }
-
 }
 
 module connectorNegative(on, to) {
@@ -51,44 +82,14 @@ module connectorNegative(on, to) {
     onXBarToYBarNegative();
   } else if (on == "yBar" && to == "sideModule") {
     onYBarSideModuleNegative();
+  } else if (on == "yBar" && to == "mainRail") {
+    onYBarToMainRailNegative();
+  } else if (on == "yBar" && to == "stackConnector") {
+    onYBarStackConnectorNegative();
+  } else if (on == "yBar" && to == "basePlate") {
+    onYBarBasePlateConnectorNegative();
+  } else if (on == "mainRail" && to == "yBar") {
+    onMainRailYBarConnectorNegative();
   }
 
-
-  module onYBarToXBarNegative() {
-    y = 27;
-    z = 6;
-    translate(v = [-m3HeatSetInsertSlotHeightSlacked, y, z])
-    rotate(a = [0, 90, 0])
-    heatSetInsertSlot_N(rackFrameScrewType);
-
-  }
-
-  module onXBarToYBarNegative() {
-    y = 27;
-    z = 6;
-    slack = xySlack;
-
-    translate(v=[-0.5,14,0])
-    mirror(v=[1,0,0])
-    rotate(a=[0,0,-90])
-    dovetail(topWidth = 15+slack, bottomWidth = 12+slack, height = 2+slack, length = yBarHeight,
-             headExtension = 1, baseExtension = 2, frontFaceLength = 0.5, frontFaceScale = 1.05,
-             backFaceLength = 5, backFaceScale = 1.2);
-
-    // TODO clean this up
-    translate(v = [-6, y, z])
-    rotate(a = [0, -90, 0])
-    counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
-  }
-
-  module onYBarSideModuleNegative() {
-    translate(v = [-xySlack/2, -xySlack/2, -sideWallConnLugDepression])
-    cube(size = [sideWallConnW+xySlack, sideWallConnD+xySlack, sideWallConnLugDepression]);
-
-    translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, -(m3HeatSetInsertSlotHeightSlacked+sideWallConnLugDepression)])
-    heatSetInsertSlot_N(rackFrameScrewType);
-  }
-
-
 }
-

rack/connector/mainRailYBarConnectors.scad

@@ -0,0 +1,37 @@
+include <../../helper/screws.scad>
+include <../../helper/common.scad>
+include <../../helper/matrix.scad>
+include <../../helper/slack.scad>
+include <../../helper/dovetail.scad>
+include <../../helper/halfspace.scad>
+
+include <../sharedVariables.scad>
+
+include <../config.scad>
+
+module onYBarToMainRailNegative() {
+
+  slotSlack = xySlack;
+  slotZSlack = zSlack;
+
+  union() {
+    translate(v=[-slotZSlack/2, -slotSlack/2,0])
+    cube(size = [railTotalWidth+slotZSlack, railTotalDepth + slotSlack, railFootThickness]);
+
+    translate(v = [railSideMountThickness + 5, railFrontThickness + 4 , -m3HeatSetInsertSlotHeightSlacked])
+    heatSetInsertSlot_N(rackFrameScrewType);
+  }
+}
+
+
+module onMainRailYBarConnectorPositive() {
+
+  cube(size = [frontFaceWidth, sideSupportDepth+railFrontThickness, railFootThickness]);
+}
+
+
+module onMainRailYBarConnectorNegative() {
+
+  translate(v = [5+railSideMountThickness, 4+railFrontThickness, railFootThickness])
+  counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
+}

rack/connector/sideModuleYBarConnectors.scad

@@ -0,0 +1,19 @@
+include <../../helper/screws.scad>
+include <../../helper/common.scad>
+include <../../helper/matrix.scad>
+include <../../helper/slack.scad>
+include <../../helper/dovetail.scad>
+include <../../helper/halfspace.scad>
+
+include <../sharedVariables.scad>
+
+include <../config.scad>
+
+module onYBarSideModuleNegative() {
+
+  translate(v = [-xySlack/2, -xySlack/2, -sideWallConnLugDepression])
+  cube(size = [sideWallConnW+xySlack, sideWallConnD+xySlack, sideWallConnLugDepression]);
+
+  translate(v = [yBarScrewHoleToOuterYEdge, yBarScrewHoleToFrontXEdge, -(m3HeatSetInsertSlotHeightSlacked+sideWallConnLugDepression)])
+  heatSetInsertSlot_N(rackFrameScrewType);
+}

rack/connector/stackYBarConnectors.scad

@@ -0,0 +1,128 @@
+include <../../helper/screws.scad>
+include <../../helper/common.scad>
+include <../../helper/matrix.scad>
+include <../../helper/slack.scad>
+include <../../helper/dovetail.scad>
+include <../../helper/halfspace.scad>
+
+include <../sharedVariables.scad>
+
+include <../config.scad>
+
+connectorYEdgeToYBarYEdge = 5;
+connectorXEdgeToYBarXEdge = 5;
+
+connectorRectWidth = 10;
+connectorRectDepth = 10;
+connectorTotalHeight = 10;
+connectorSocketMagnetExtrudeHeight = 1;
+connectorTaperStartHeight = 3;
+
+connectorTopR = 3;
+
+connectorRectPlugSlack = -0.2;
+connectorRectSocketSlack = 0.2;
+
+connectorBottomToScrew = 6;
+
+module stackConnectorBase(rectSlack, topSlack=0.0) {
+
+  wSlacked = connectorRectWidth + rectSlack;
+  dSlacked = connectorRectDepth + rectSlack;
+  topRSlacked = connectorTopR + rectSlack/2;
+
+  module connRect() {
+    linear_extrude(height=eps)
+    square(size = [wSlacked, dSlacked]);
+  }
+
+  module connTop() {
+    linear_extrude(height=eps)
+    circle(r=topRSlacked);
+  }
+
+  hull() {
+    connRect();
+
+    translate(v=[0,0,connectorTaperStartHeight])
+    connRect();
+  }
+
+  hull() {
+    translate(v = [0, 0, connectorTaperStartHeight])
+    connRect();
+
+    translate(v=[wSlacked/2, dSlacked/2, connectorTotalHeight+topSlack])
+    connTop();
+  }
+}
+
+
+module onYBarStackConnectorNegative() {
+
+  wSlacked = connectorRectWidth + connectorRectSocketSlack;
+  dSlacked = connectorRectDepth + connectorRectSocketSlack;
+
+  bevelSlack = 0.6;
+  bevelR = wSlacked + bevelSlack;
+  bevelW = dSlacked + bevelSlack;
+  bevelH = 0.6;
+
+  screwExtension = 4;
+
+
+  union() {
+    stackConnectorBase(connectorRectSocketSlack, topSlack=0.4);
+
+    translate(v = [-screwExtension, connectorRectDepth/2, connectorBottomToScrew])
+    rotate(a = [0, -90, 0])
+    counterSunkHead_N(rackFrameScrewType, screwExtension = 5, headExtension = 10);
+
+    // bevel at the lip of the socket to guide the plug, as well as mitigate elephant foot during 3d printing
+    hull() {
+      translate(v = [0, 0, bevelH])
+      linear_extrude(height = eps)
+      square(size = [wSlacked, dSlacked]);
+
+      translate(v = [-bevelSlack/2, -bevelSlack/2, 0])
+      linear_extrude(height = eps)
+      square(size = [bevelR, bevelW]);
+    }
+  }
+}
+
+
+module stackConnectorPlug() {
+
+  difference() {
+    stackConnectorBase(connectorRectPlugSlack);
+
+    translate(v=[connectorRectWidth/2,connectorRectDepth/2,connectorBottomToScrew])
+    rotate(a=[0,0,90])
+    rotate(a=[90,0,0])
+    hexNutPocket_N(rackFrameScrewType, openSide=false);
+  }
+}
+
+module stackConnectorDual() {
+
+  space = 0.5; // extra space inbetween
+
+  translate(v=[0,0,space])
+  stackConnectorPlug();
+
+  mirror(v=[0,0,1])
+  stackConnectorPlug();
+
+  cube(size=[connectorRectWidth+connectorRectPlugSlack, connectorRectDepth+connectorRectPlugSlack, space]);
+}
+
+
+module stackConnectorBottom() {
+
+  height = 2; // space between bottom and floor
+
+  stackConnectorPlug();
+  translate(v=[0,0,-height])
+  cube(size=[connectorRectWidth+connectorRectPlugSlack, connectorRectDepth+connectorRectPlugSlack, height]);
+}

rack/connector/transformations.scad

@@ -0,0 +1,10 @@
+// Spatial transformations between various parts' local spaces
+include <./connectors.scad>
+
+
+function transform(from, to) =
+  (from == "yBar" && to == "xBar")
+  ? identity
+  : (from == "xBar" && to == "yBar")
+  ? identity
+  : identity;

rack/connector/xBarYBarConnectors.scad

@@ -0,0 +1,71 @@
+include <../../helper/screws.scad>
+include <../../helper/common.scad>
+include <../../helper/matrix.scad>
+include <../../helper/slack.scad>
+include <../../helper/dovetail.scad>
+include <../../helper/halfspace.scad>
+
+include <../sharedVariables.scad>
+
+include <../config.scad>
+
+// On xBar
+module onXBarToYBarNegative() {
+  y = 27;
+  z = 6;
+  slack = xBarYBarDovetailSlack;
+
+  translate(v=[-slack,14,0])
+  mirror(v=[1,0,0])
+  rotate(a=[0,0,-90])
+  dovetail(
+      topWidth = 15+slack,
+      bottomWidth = 12+slack,
+      height = 2+slack,
+      length = yBarHeight,
+      headExtension = 1,
+      baseExtension = 2,
+      frontFaceLength = 0.5,
+      frontFaceScale = 1.05,
+      backFaceLength = 5,
+      backFaceScale = 1.2
+  );
+
+  // TODO clean this up
+  translate(v = [-xBarSideThickness, y, z])
+  rotate(a = [0, -90, 0])
+  counterSunkHead_N(rackFrameScrewType, screwExtension=inf10, headExtension=inf10);
+}
+
+
+// On yBar
+module onYBarToXBarNegative() {
+  y = 27;
+  z = 6;
+  translate(v = [-m3HeatSetInsertSlotHeightSlacked, y, z])
+  rotate(a = [0, 90, 0])
+  heatSetInsertSlot_N(rackFrameScrewType);
+
+}
+
+module onYBarToXBarPositive() {
+
+  translate(v=[xBarYBarDovetailSlack, 14,0]) // TODO: variable for the 14
+  rotate(a=[0,0,-90])
+  dovetail(
+      topWidth = 15-xySlack, // figure out why we need this
+      bottomWidth = 12,
+      height = 2,
+      length = yBarHeight,
+      headExtension = 1,
+      baseExtension = 2,
+      frontFaceLength = 2,
+      frontFaceScale = 0.95,
+      backFaceLength = 5,
+      backFaceScale = 1.2
+  );
+}
+
+
+xBarConnectorToYBarConnectorTrans = mirror(v=[1,0,0]);
+yBarConnectorToXBarConnectorTrans = mirror(v=[-1,0,0]);