From: Jan "Yenya" Kasprzak <kas@fi.muni.cz>
Date: Sun, 27 Oct 2013 09:25:24 +0000 (+0100)
Subject: rearlight.scad: first printed version
X-Git-Url: https://www.fi.muni.cz/~kas/git//home/kas/public_html/git/?a=commitdiff_plain;h=f4fa8e4d280179849f99cd51686fb12301a9e3b1;p=bike-lights.git

rearlight.scad: first printed version

BUGS:
- make rear spring a bit stronger
- wall_thickness could probably be lowered to 1.5mm
- fraen_h should be lowered about 0.5-1mm
- side barriers are too high
- clip_angle is too big - about 18 degrees should be enough

TO CHECK:
- bolt sizes
- side LED hole size
- cable hole

TODO:
we use elliptical beam lens, so for two lenses it could make sense
to not have the clip and lens axis parallel, but instead to make
it shine more to the side.
---

diff --git a/parts/rearlight.scad b/parts/rearlight.scad
index 2c8e7a9..ecc53dd 100644
--- a/parts/rearlight.scad
+++ b/parts/rearlight.scad
@@ -13,11 +13,14 @@ pin_offset = 10.35*1.4142;
 pin_len = 9.2;
 front_add = 4;
 
+rear_pin_dist = 9.1;
+rear_pin_diam = 3.25;
+
 side_barrier_x_offset = 13;
 side_barrier_pin_z_offset = 4.2;
 side_barrier_thickness = 2;
 
-heatsink_thickness = 2.5;
+heatsink_thickness = 2;
 
 clip_h1 = 27; // front height (on the heatsink side)
 clip_h2 = 20; // rear height (on the lens side)
@@ -113,7 +116,7 @@ module round_part() {
 				rotate([0, 0, angle+45])
 					translate([pin_offset, 0, -epsilon])
 						cylinder(r=pin_diam/2,
-							h=epsilon, $fn=32);
+							h=epsilon);
 			};
 		}
 
@@ -127,7 +130,7 @@ module round_part() {
 			rotate([0, 0, angle+45])
 				translate([pin_offset, 0, epsilon])
 					cylinder(r=pin_diam/2,
-						h=pin_len+epsilon, $fn=32);
+						h=pin_len+epsilon);
 		};
 	};
 
@@ -150,7 +153,7 @@ module square_cone() {
 					h = epsilon);
 			for (angle = [0, 90, 180, 270])
 				rotate([0, 0, angle])
-					translate([9.1, 9.1, 0])
+					translate([rear_pin_dist, rear_pin_dist, 0])
 						cylinder(r=wall_thickness+3.75/2, h = epsilon);
 		}
 		hull() {
@@ -159,36 +162,52 @@ module square_cone() {
 					h = epsilon);
 			for (angle = [0, 90, 180, 270]) {
 				rotate([0, 0, angle]) 
-					translate([9.1, 9.1, -epsilon])
+					translate([rear_pin_dist, rear_pin_dist, -epsilon])
 						cylinder(r=3.75/2, h = epsilon);
 				rotate([0, 0, angle+45])
 					translate([pin_offset, 0, fraen_h - pin_len + epsilon])
 						cylinder(r=pin_diam/2,
-							h=epsilon, $fn=32);
+							h=epsilon);
 			}
 		}
 	}
 }
 
-rear_spring_w = 4;
+rear_spring_w = 2*rear_pin_dist-rear_pin_diam-0.5;
+rear_spring_h = 1;
+rear_spring_center_w = 4;
+led_zoff = 6;
 
 module rear_spring() {
 	translate([0, 0, wall_thickness/2])
-		cube([18+2*wall_thickness+3.5, rear_spring_w, wall_thickness], center=true);
-	difference() {
-		rotate([90, 0, 0])
-			translate([0, 0, -rear_spring_w/2])
-			cylinder(r=6-heatsink_thickness, h = rear_spring_w);
-		translate([0, 0, -infty/2+epsilon])
-			cube(infty, center=true);
-	};
-};
+		cube([rear_spring_center_w, rear_spring_w, wall_thickness],
+			center=true);
+	translate([0, rear_spring_w/2-wall_thickness/2,
+		(led_zoff-heatsink_thickness)/2])
+		cube([rear_spring_center_w,
+			wall_thickness, led_zoff-heatsink_thickness],
+			center=true);
+	translate([0, -rear_spring_w/2+wall_thickness/2,
+		(led_zoff-heatsink_thickness)/2])
+		cube([rear_spring_center_w,
+			wall_thickness, led_zoff-heatsink_thickness],
+			center=true);
+
+	for (angle=[0, 180]) {
+		rotate([0, 0, angle])
+		translate([5.5, 0, rear_spring_h/2])
+			rotate([0, 0, 45]) {
+				cube([wall_thickness, 14, rear_spring_h],
+					center=true);
+		}
+	}
+}
 
 module heatsink_holder() {
 	for (angle = [0, 180]) {
 		rotate([0, 0, angle])
-			translate([9.1+wall_thickness, 0, 6/2])
-			cube([3.5/2+wall_thickness, 2*9.1-3.5-0.5, 6], center=true);
+			translate([rear_pin_dist+wall_thickness, 0, led_zoff/2])
+			cube([rear_pin_diam/2+wall_thickness, 2*rear_pin_dist-rear_pin_diam-0.5, led_zoff], center=true);
 	}
 }
 
@@ -206,49 +225,123 @@ module lens_holder() {
 			cube([infty, 0.5, infty]);
 
 		// cable hole, 2*3mm
-		translate([9.1, 0, 6+3])
+		translate([rear_pin_dist, 0, 6+3])
 			rotate([0, 0, 60])
 				cube([infty, 2, 3]);
 
 		// side LED hole, 3mm
 		translate([0, 0, fraen_h - pin_len])
 			rotate([90, 0, 0])
-				cylinder(r=3.5/2, h=infty, $fn=6);
+				cylinder(r=rear_pin_diam/2, h=infty, $fn=6);
 	};
 		
 	rear_spring();
 	heatsink_holder();
 };
 
-union() {
-	lens_holder($fn = 128);
-	translate([clip_x_off, clip_y_off, 0])
-		seat_clip();
-/*
-hull() {
-	translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
-		cube([9.1, epsilon, wall_thickness], center=true);
-	translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
-		cube([9.1, epsilon/2, wall_thickness], center=true);
-};
+module xy_joint() {
+	hull() {
+		intersection() {
+			lens_holder();
+			translate([-infty-0.5*rear_pin_dist,
+				rear_pin_dist+rear_pin_diam/2+0.35*wall_thickness,
+				0])
+				cube([infty, infty, clip_wall]);
+		};
+
+		translate([clip_x_off, clip_y_off, 0])
+			intersection() {
+				seat_clip();
+				translate([-infty+clip_wall+0.20*clip_h1, -infty-clip_space, 0])
+					cube([infty, infty, clip_wall]);
+			};
+	};
+	hull() {
+		intersection() {
+			lens_holder();
+			translate([0.5*rear_pin_dist,
+				rear_pin_dist+rear_pin_diam/2+0.35*wall_thickness,
+				0])
+				cube([infty, infty, clip_wall]);
+		};
 
-hull() {
-	translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
-		cube([2*.259+3.5, epsilon, wall_thickness], center=true);
-	translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
-		cube([clip_h1+clip_wall, epsilon/2, wall_thickness], center=true);
+		translate([clip_x_off, clip_y_off, 0])
+			intersection() {
+				seat_clip();
+				translate([0.8*clip_h1-clip_wall, -infty-clip_space, 0])
+					cube([infty, infty, clip_wall]);
+			};
+	};
 };
 
-translate([7.5, 13.3, 0])
-	cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);
+module yz_joint() {
+	difference() {
+		hull() {
+			translate([clip_x_off, clip_y_off, 0])
+				intersection() {
+					seat_clip();
+					translate([-1.5*clip_wall+(fraen_h-pin_len)*tan(clip_angle), -clip_space/2-clip_wall+epsilon, 0])
+					cube([clip_wall, epsilon, fraen_h - pin_len]);
+				};
+			translate([clip_x_off - 1.5*clip_wall+(fraen_h-pin_len)*tan(clip_angle), 0, 0])
+		   
+				cube([clip_wall, epsilon, (fraen_h - pin_len)]);
+		};
+		hull() {
+			translate([0, 0, fraen_h - pin_len + epsilon])
+				cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness/2,
+					h = epsilon);
+			for (angle = [0, 90, 180, 270])
+				rotate([0, 0, angle])
+					translate([rear_pin_dist, rear_pin_dist, -epsilon])
+						cylinder(r=wall_thickness/2+3.75/2, h = epsilon);
+		};
+	};
+};
 
+module full_joint() {
+	difference() {
+		hull() {
+				intersection() {
+					rotate([-90, 0, 0])
+					scale([0.30, 1, 1])
+						cylinder(r = fraen_h-pin_len, h = rear_pin_dist + wall_thickness+rear_pin_diam/2);
+					translate([-infty/2, rear_pin_dist + wall_thickness + rear_pin_diam/2 - epsilon, 0])
+						cube(infty);
+				};
+			translate([clip_x_off, clip_y_off, 0])
+				intersection() {
+					seat_clip();
+					translate([(fraen_h-pin_len)*tan(clip_angle)-clip_wall, -clip_space/2-clip_wall+epsilon, 0])
+						rotate([90, 0, 0])
+						scale([0.45, 1, 1])
+							cylinder(r = fraen_h-pin_len, h = epsilon);
+				};
+		};
+		hull() {
+			translate([0, 0, fraen_h - pin_len + epsilon])
+				cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness/2,
+					h = epsilon);
+			for (angle = [0, 90, 180, 270])
+				rotate([0, 0, angle])
+					translate([rear_pin_dist, rear_pin_dist, -epsilon])
+						cylinder(r=wall_thickness/2+3.75/2, h = epsilon);
+		};
 	}
-	//translate([-infty/2, -infty/2, 8])
-	//	cube(infty);
-*/
+};
+
+module main() {
+	lens_holder();
+	translate([clip_x_off, clip_y_off, 0])
+		seat_clip();
+	// xy_joint();
+	// yz_joint();
+	full_joint();
 };
 
 
+scale([1, -1, 1]) main($fn=128);
+// main($fn = 128);
 	// vnitrni prumer kruhu by mel byt 30.75mm
 	// vnejsi prumer aspon 35 mm
 	// pin od stredu 10.35mm na x a y