finished rail-laser

rail-laser/rail-laser.scad

@@ -2,18 +2,93 @@ include <roundedcube.scad>
 
 $fn = 50;
 
-rail_width = 21.0 + 0.2;
-rail_height = 6.0 + 0.2 + 2;
-rail_lip_width_small = 1.5 - 0.2;
-rail_lip_width_big = 3.5 - 0.2;
-rail_lip_height = 1.1 - 0.1;
+bodies_gap = 0.05;
+
+laser_dia = 6.5;
+laser_len = 14.0;
+
+bat_width = 18.0;
+bat_length = 30.0;
+bat_height = 9.0;
+bat_case_add = 1.0;
+
+switch_hole_dia = 2.2;
+switch_hole_dist = 15.0;
+switch_length = 19.6;
+switch_length_body = 10.6;
+switch_width = 5.7;
+switch_height = 12.0 + 2.0;
+switch_nub = 3.0;
+
+body_width = 25.0;
+body_length = 50.0;
+body_height = 42.0;
+body_frame_offset = 2.5;
+body_frame_gap = 0.5;
+body_cube_rounding = 1.0;
+body_bat_off = 5.5;
+body_switch_off_x = bat_height + 6.0;
+body_switch_off_y = 4.0;
+body_switch_add = 0.5;
+body_hole_dia_left = 2.5;
+body_hole_dia_right = 2.2;
+body_hole_off_x = 2.2;
+body_hole_off_z = body_hole_off_x;
+body_rail_lock_off_x = 10.0;
+body_rail_lock_off_z = 4.0;
+
+rail_width = 21.2;
+rail_height = 8.2;
+rail_lip_width_small = 1.3;
+rail_lip_width_big = 3.3;
+rail_lip_height = 1.0;
+
+rail_lock_width = 20.0;
+rail_lock_depth = 10.0;
+rail_lock_base_height = 3.0;
+rail_lock_pin_size = 5.0;
+rail_lock_pin_width = 10.0;
+rail_lock_pin_height = 5.0;
+rail_lock_tab_len = 1.0;
+rail_lock_tab_depth = 2.0;
+rail_lock_whole_width = body_width + (2 * rail_lock_tab_len);
+rail_lock_tab_width = (rail_lock_whole_width - rail_lock_width) / 2;
+rail_lock_travel = 5.0;
+rail_lock_spring_dia = 7.0;
+rail_lock_spring_hole = 1.0;
+
+frame_gap = 0.25;
+frame_sphere = 20;
+frame_add_touch = 4.0;
+frame_wall = 1.5;
+frame_mount_hole = 3.0;
+frame_mount_hole_off = 6.0;
+frame_mid_len = (frame_mount_hole / 4) + (2 * frame_wall);
+frame_mid_dia = laser_dia + (2 * frame_wall);
+frame_tail_len = 8.0;
+frame_tail_width = frame_mid_dia + 0.5;
+frame_negative_width = frame_sphere * 2 / 3 + 7;
+frame_hole_dia = 2.9;
+frame_hole_dia_arch = 3.3;
+frame_hole_off = 1.8;
+frame_hole_neg_off = 10;
+frame_hole_neg_len = 15;
+frame_hole_neg_deg_a = 9;
+frame_hole_neg_deg_b = frame_hole_neg_deg_a;
+
+frame_hole_neg_rad_small = frame_mid_len + ((frame_sphere + frame_tail_len) / 2) - frame_hole_off;
+frame_hole_neg_rad_large = frame_mid_len + ((frame_sphere + frame_tail_len) / 2) + frame_hole_off;
+frame_len = frame_sphere + frame_mid_len + frame_tail_len;
+
+//body_frame_off = body_height - rail_height - (frame_sphere / 2) - body_frame_offset;
+body_frame_off = (frame_sphere / 2) + body_frame_offset;
 
 module rail_lip(l) {
     hull() {
-        translate([-1, -0.1, 0])
+        translate([-1, -0.001, 0])
         cube([l + 2, 0.2, rail_lip_width_big]);
-        translate([-1, rail_lip_height - 0.1, (rail_lip_width_big - rail_lip_width_small) / 2])
-        cube([l + 2, 0.1, rail_lip_width_small]);
+        translate([-1, rail_lip_height - 0.001, (rail_lip_width_big - rail_lip_width_small) / 2])
+        cube([l + 2, 0.001, rail_lip_width_small]);
     }
 }
 
@@ -31,53 +106,80 @@ module rail(l) {
     }
 }
 
-laser_dia = 6.5;
-laser_len = 14.0;
+module rail_lock_internal(add = 0.0) {
+    if (add == 0) {
+        cube([rail_lock_width + add, rail_lock_depth + add, rail_lock_base_height + add], center = true);
+    
+        translate([(rail_lock_width + add + rail_lock_tab_width + add) / 2, 0, 0])
+        cube([rail_lock_tab_width + add, rail_lock_tab_depth + add, rail_lock_base_height + add], center = true);
+        
+        translate([-(rail_lock_width + add + rail_lock_tab_width + add) / 2, 0, 0])
+        cube([rail_lock_tab_width + add, rail_lock_tab_depth + add, rail_lock_base_height + add], center = true);
+    } else {
+        translate([0, 0, -rail_lock_travel / 2]) {
+            cube([rail_lock_width + add + 0.001, rail_lock_depth + add, rail_lock_base_height + add + rail_lock_travel + 0.001], center = true);
+        
+            translate([(rail_lock_width + add + rail_lock_tab_width + add) / 2, 0, 0])
+            cube([rail_lock_tab_width + add, rail_lock_tab_depth + add, rail_lock_base_height + add + rail_lock_travel], center = true);
+            
+            translate([-(rail_lock_width + add + rail_lock_tab_width + add) / 2, 0, 0])
+            cube([rail_lock_tab_width + add, rail_lock_tab_depth + add, rail_lock_base_height + add + rail_lock_travel], center = true);
+        }
+    }
+    
+    translate([0, 0, (rail_lock_base_height + add + rail_lock_pin_height + add) / 2])
+    cube([rail_lock_pin_width + add, rail_lock_pin_size + add, rail_lock_pin_height + add], center = true);
+}
+
+module rail_lock(add = 0.0) {
+    if (add == 0) {
+        difference() {
+            rail_lock_internal(add);
+            
+            translate([0, 0, -rail_lock_spring_hole - rail_lock_base_height / 2])
+            cylinder(d = rail_lock_spring_dia, h = rail_lock_spring_hole + 1);
+            
+            translate([0, -rail_lock_pin_size / 2, (rail_lock_base_height + add + rail_lock_pin_height + add) / 2 - -rail_lock_pin_size / 2])
+            rotate([45, 0, 0])
+            cube([rail_lock_pin_width + 2, rail_lock_pin_size, rail_lock_pin_height], center = true);
+        }
+    } else {
+        rail_lock_internal(add);
+    
+        translate([0, 0, -rail_lock_spring_hole - (rail_lock_base_height + add) / 2 - rail_lock_travel])
+        cylinder(d = rail_lock_spring_dia, h = rail_lock_spring_hole);
+    }
+}
 
 module laser() {
     cylinder(d = laser_dia, h = laser_len);
 }
 
-frame_gap = 0.2;
-frame_sphere = 20;
-frame_add_touch = 4.0;
-frame_wall = 1.5;
-frame_mount_hole = 2.0;
-frame_mid_len = frame_mount_hole + (2 * frame_wall);
-frame_mid_dia = laser_dia + (2 * frame_wall);
-frame_tail_len = 8.0;
-frame_tail_width = frame_mid_dia + 0.5;
-frame_negative_width = frame_sphere * 2 / 3 + 7;
-frame_hole_dia = 2.9;
-frame_hole_off = 1.8;
-frame_hole_neg_off = 10;
-frame_hole_neg_len = 15;
-frame_hole_neg_deg_a = 9;
-frame_hole_neg_deg_b = frame_hole_neg_deg_a;
-frame_hole_neg_rad_small = frame_mid_len + ((frame_sphere + frame_tail_len) / 2) - frame_hole_off;
-frame_hole_neg_rad_large = frame_mid_len + ((frame_sphere + frame_tail_len) / 2) + frame_hole_off;
-frame_len = frame_sphere + frame_mid_len + frame_tail_len;
-
 module laser_frame_screw_arc(radius, deg) {
     for (r = [-deg : 1 : deg])
     translate([radius, 0, 0])
     rotate([0, 0, r])
     translate([-radius, 0, 0])
-    cylinder(d = frame_hole_dia, h = frame_negative_width + frame_hole_neg_len);
+    cylinder(d = frame_hole_dia_arch, h = frame_negative_width + frame_hole_neg_len);
 }
 
 module laser_frame(added_gap = 0, negative = 0) {
     difference() {
         union() {
+            // top sphere
             translate([0, 0, (frame_sphere / 2) + (frame_len - frame_sphere)])
             sphere(d = frame_sphere + added_gap);
             
             if (negative == 0) {
+                // mid section
                 translate([0, 0, frame_len - frame_sphere - frame_mid_len - 0.5])
                 cylinder(d = frame_mid_dia + added_gap, h = frame_mid_len + frame_add_touch + 1.0);
                 
-                translate([-(frame_tail_width + added_gap) / 2, -(frame_tail_width + added_gap) / 2, frame_len - frame_sphere - frame_mid_len - frame_tail_len])
-                roundedcube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len]);
+                // bottom cube
+                translate([-(frame_tail_width + added_gap) / 2, -(frame_tail_width + added_gap) / 2, frame_len - frame_sphere - frame_mid_len - frame_tail_len]) {
+                    cube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len]);
+                    //roundedcube([frame_tail_width + added_gap, frame_tail_width + added_gap, frame_tail_len]);
+                }
             } else {
                 translate([0, 0, frame_len - frame_add_touch])
                 cylinder(d = laser_dia + added_gap, h = frame_mid_len + frame_add_touch);
@@ -96,21 +198,25 @@ module laser_frame(added_gap = 0, negative = 0) {
         }
         
         if (negative == 0) {
+            // cutout for laser itself
             translate([0, 0, -1])
             cylinder(d = laser_dia + (2 * frame_gap), h = frame_len + 2);
         
-            translate([0, 0, (frame_len - frame_sphere - frame_mid_len) + (frame_mid_len / 2)])
-            rotate([0, 90, 0]) {
-                cylinder(d = frame_mount_hole, h = frame_mid_dia);
+            // holding screws for laser
+            translate([0, 0, frame_len - (frame_mount_hole / 2) - frame_mount_hole_off])
+            rotate([0, 90, 45]) {
+                cylinder(d = frame_mount_hole, h = frame_sphere);
             
                 rotate([-90, 0, 0])
-                cylinder(d = frame_mount_hole, h = frame_mid_dia);
+                cylinder(d = frame_mount_hole, h = frame_sphere);
             }
             
+            // x-axis holes
             translate([-frame_tail_width / 2 - 1, 0, frame_len - frame_sphere - frame_mid_len - frame_tail_len + (frame_tail_len / 2) - frame_hole_off])
             rotate([0, 90, 0])
             cylinder(d = frame_hole_dia, h = frame_tail_width + 2);
             
+            // y-axis holes
             translate([0, -frame_tail_width / 2 - 1, frame_len - frame_sphere - frame_mid_len - frame_tail_len + (frame_tail_len / 2) + frame_hole_off])
             rotate([-90, 0, 0])
             cylinder(d = frame_hole_dia, h = frame_tail_width + 2);
@@ -118,55 +224,91 @@ module laser_frame(added_gap = 0, negative = 0) {
     }
 }
 
-body_width = 25.0;
-body_length = 45.0;
-body_height = 35.0;
-body_frame_gap = 0.5;
-body_frame_off = 15;
-body_cube_rounding = 1.0;
+module battery(add = 0.0) {
+    translate([-add / 2, -add / 2, -add / 2])
+    cube([bat_height + add, bat_width + add, bat_length + add]);
+}
 
-body_hole_dia = 2.2;
-body_hole_off_x = 2.2;
-body_hole_off_z = body_hole_off_x;
+module switch(add = 0.0) {
+    translate([(switch_length - (switch_length_body + add * 2)) / 2, -add, 0])
+    cube([(switch_length_body + add * 2), switch_width + add * 2, switch_height]);
+    
+    translate([(switch_length - switch_nub) / 2, (switch_width - switch_nub) / 2, switch_height])
+    cube([switch_nub, switch_nub, switch_nub]);
+    
+    translate([(switch_length - switch_length_body) / 4, switch_width / 2, 0]) {
+        cylinder(d = switch_hole_dia, h = switch_height + (switch_nub * 4));
+        translate([switch_hole_dist, 0, 0])
+        cylinder(d = switch_hole_dia, h = switch_height + (switch_nub * 4));
+    }
+}
 
-module body() {
+module body(hole_dia) {
     difference() {
-        //cube([body_length, body_width, body_height]);
-        roundedcube([body_length, body_width, body_height], false, body_cube_rounding);
+        // main body part
+        cube([body_length, body_width, body_height]);
+        //roundedcube([body_length, body_width, body_height], false, body_cube_rounding);
         
-        translate([-1, (body_width - rail_width) / 2, body_height - rail_height + 0.1])
+        // cutout for rail
+        translate([-1, (body_width - rail_width) / 2, body_height - rail_height + 0.001])
         rail(body_length + 2);
         
+        // cutout and preview for laser frame
         translate([body_length - frame_len, body_width / 2, body_frame_off])
         rotate([0, 90, 0]) {
             laser_frame(body_frame_gap, 1);
             %laser_frame();
         }
         
+        // cutout and preview for battery
+        translate([body_bat_off, (body_width - bat_width) / 2, (body_height - rail_height - bat_length) / 2]) {
+            battery(bat_case_add);
+            %battery();
+        }
+        
+        // cutout and preview for switch
+        translate([body_switch_off_x, body_width - switch_height + 0.001, body_height - rail_height - body_switch_off_y])
+        rotate([-90, 0, 0]) {
+            switch(body_switch_add);
+            %switch(0);
+            
+            // cutout for cabling
+            // TODO not very nice,
+            // with hardcoded values
+            translate([-0.001, -2.5, -8])
+            cube([18.5, 30, 9.5]);
+        }
+        
+        // cutout and preview for rail locking mechanism
+        translate([body_length - body_rail_lock_off_x, body_width / 2, rail_lock_base_height / 2 + body_height - rail_height - body_rail_lock_off_z])
+        rotate([0, 0, 90]) {
+            rail_lock(0.5);
+            %rail_lock();
+        }
+        
+        // outside screw holes
         translate([body_hole_off_x, -1, body_hole_off_z])
         rotate([-90, 0, 0])
-        cylinder(d = body_hole_dia, h = body_width + 2);
+        cylinder(d = hole_dia, h = body_width + 2);
         translate([body_length - body_hole_off_x, -1, body_hole_off_z])
         rotate([-90, 0, 0])
-        cylinder(d = body_hole_dia, h = body_width + 2);
+        cylinder(d = hole_dia, h = body_width + 2);
         translate([body_hole_off_x, -1, body_height - rail_height - body_hole_off_z])
         rotate([-90, 0, 0])
-        cylinder(d = body_hole_dia, h = body_width + 2);
+        cylinder(d = hole_dia, h = body_width + 2);
         translate([body_length - body_hole_off_x, -1, body_height - rail_height - body_hole_off_z])
         rotate([-90, 0, 0])
-        cylinder(d = body_hole_dia, h = body_width + 2);
-        
-        translate([-1, body_width / 2, body_height / 2.35])
-        rotate([0, 90, 0])
-        cylinder(d = 10, h = 20);
+        cylinder(d = hole_dia, h = body_width + 2);
     }
 }
 
-bodies_gap = 0.05;
-
-module body_half(half = 0) {
+module body_half(half) {
     difference() {
-        body();
+        if (half == 0) {
+            body(body_hole_dia_left);
+        } else {
+            body(body_hole_dia_right);
+        }
         
         if (half == 0) {
             translate([-1, (bodies_gap - body_width) / 2, -1])
@@ -190,13 +332,20 @@ module print() {
     
     translate([body_length + 10, body_height + 2, 0])
     laser_frame(0, 0);
+    
+    translate([body_length + 10, 20, rail_lock_base_height / 2])
+    rotate([0, 0, 90])
+    rail_lock(0);
+    
+    // simple brim
+    //translate([-10, -10, 0])
+    //cube([80, 95, 0.2]);
 }
 
-//laser_frame(0, 0);
-//laser_frame(0.5, 1);
+//laser_frame();
+rail_lock();
 
 //body_half(0);
 //body_half(1);
-//body();
 
-print();
+//print();