Merge pull request #9 from matushorvath/cassette-cover

Cassette cover mounting features

Author: matushorvath

model/Makefile

@@ -4,7 +4,7 @@ PREVIEWS=$(TARGETS:.stl=.png)
 all: $(TARGETS)
 preview: $(PREVIEWS)
 
-include $(wildcard *.deps)
+-include $(wildcard *.deps)
 
 # Detect OpenSCAD location
 ifneq ($(shell wslinfo --version),)

model/cassette_cover.scad

@@ -3,9 +3,6 @@ include <common.scad>
 include <cassette_dimensions.scad>
 include <BOSL2/std.scad>
 
-// TODO locating features on cover
-// TODO mounting tabs on cover
-
 module cc_cover_handle() {
     move([
         -CC_VISIBLE_DEPTH + DELTA,
@@ -40,6 +37,9 @@ function cc_cover_plane(dist) =
     )
     round_corners(shape, radius = radii, $fn=fn_where_needed);
 
+//%polygon(cc_cover_plane(CC_VISIBLE_DEPTH));
+//polygon(cc_cover_plane(0));
+
 module cc_bottom_corner_mask() {
     // Rounding for bottom corners
     // Needs to be applied after skin(), because it causes different
@@ -69,7 +69,78 @@ module cc_bottom_corner_mask() {
         }
 }
 
-// cc_bottom_corner_mask();
+//cc_bottom_corner_mask();
+
+module cc_cover_top_bezel() {
+    move([
+        DELTA,
+        scr_fwd_height - CC_BEZEL_WIDTH - CC_COVER_FIT,
+        CC_BEZEL_POSITION
+    ])
+        cuboid([
+                BODY_WALL + CC_BEZEL_EXTRA_DEPTH,
+                CC_BEZEL_WIDTH,
+                cc_mask_width - 2 * CC_BEZEL_POSITION
+            ],
+            anchor = LEFT + BOTTOM + FRONT
+        );
+}
+
+module cc_cover_side_bezel() {
+    move([
+        DELTA,
+        CC_BEZEL_POSITION,
+        CC_COVER_FIT
+    ])
+        // Use diff, not difference, so we can position the gaps and the ball with the same operation
+        diff() {
+            bezel_side_height = scr_fwd_height - 2 * CC_BEZEL_POSITION;
+
+            // Bezel side body
+            cuboid([
+                    BODY_WALL + CC_BEZEL_EXTRA_DEPTH,
+                    bezel_side_height,
+                    CC_BEZEL_WIDTH
+                ],
+                anchor = LEFT + BOTTOM + FRONT
+            );
+
+            // Mounting points (two sets of two gaps and and a ball)
+            move([DELTA, bezel_side_height / 2, -DELTA]) // move mount points relative to bezel body
+                ycopies(CC_MOUNT_DISTANCE + CC_MOUNT_LENGTH + CC_MOUNT_GAP) { // two pairs of mounting points per bezel side
+                    ycopies(CC_MOUNT_LENGTH + CC_MOUNT_GAP) // two gaps around each mounting point
+                        // Gaps around mounting points, to make them flexible
+                        tag("remove") cuboid([
+                                BODY_WALL + CC_BEZEL_EXTRA_DEPTH + 2 * DELTA,
+                                CC_MOUNT_GAP,
+                                CC_BEZEL_WIDTH + 2 * DELTA
+                            ],
+                            anchor = LEFT + BOTTOM
+                        );
+
+                    // Mounting point ball
+                    move([
+                        BODY_WALL - CC_MOUNT_BALL_FIT, // ball starts right behind the wall, with a small delta to make the fit tight
+                        0,
+                        CC_MOUNT_BALL_R - CC_COVER_INTERFERENCE // 
+                    ])
+                        bottom_half(z = CC_COVER_INTERFERENCE - CC_MOUNT_BALL_R + DELTA)
+                            sphere(
+                                r = CC_MOUNT_BALL_R,
+                                anchor = LEFT
+                            );
+                }
+        }
+}
+
+module cc_cover_mounts() {
+    cc_cover_top_bezel();
+
+    zflip_copy(z = cc_mask_width / 2)
+        cc_cover_side_bezel();
+}
+
+//cc_cover_mounts();
 
 module cc_cover_object() {
     // Position the forward face
@@ -96,23 +167,23 @@ module cc_cover_object() {
     skin(faces, slices = 10);
 }
 
+//cc_cover_object();
+
 module cc_cover() {
     // Angle and move the cover together with the corner mask
     move([kbd_back_x, kbd_back_y, CC_MASK_LEFT_Z]) // move to position relative to the model
         zrot(-SCR_FWD_A) // angle relative to the model
             difference() {
                 union() {
                     cc_cover_object();
+                    cc_cover_mounts();
                     cc_cover_handle();
                 }
 
                 cc_bottom_corner_mask();
             }
 }
 
-// %polygon(cc_cover_plane(CC_VISIBLE_DEPTH));
-// polygon(cc_cover_plane(0));
-
 // use <body.scad>
 // xrot(90) {
 //     %body(true);

model/cassette_dimensions.scad

@@ -95,3 +95,24 @@ CC_B_R = SCR_FWD_BR_R;
 CC_MASK_LEFT_Z = 63;
 CC_MASK_RIGHT_Z = 222.5;
 cc_mask_width = CC_MASK_RIGHT_Z - CC_MASK_LEFT_Z;
+
+// Cover mounting features
+
+// Depth of the mounting bezel (in addition to BODY_WALL to clear the wall)
+CC_BEZEL_EXTRA_DEPTH = 4;
+
+// Mounting bezel width, needs to be thin enough to be flexible
+CC_BEZEL_WIDTH = 1.5;
+
+// Mounting features on the bezel
+CC_MOUNT_DISTANCE = 140;
+CC_MOUNT_LENGTH = 4;
+CC_MOUNT_GAP = 1;
+
+CC_COVER_FIT = 0.1; // gap around the bezel
+CC_COVER_INTERFERENCE = 0.5; // how much the ball extends past the bezel; should be at least CC_COVER_FIT
+CC_MOUNT_BALL_R = 2;
+CC_MOUNT_BALL_FIT = 0.2;
+
+// Bezel position; relative to cover edges
+CC_BEZEL_POSITION = 20;

model/vt52.scad

@@ -5,7 +5,6 @@ include <BOSL2/std.scad>
 use <cassette_cover.scad>
 use <shell.scad>
 
-// TODO finish right side dark cover
 // TODO bottom cover
 // TODO keyboard plate
 // TODO try to put "DIGITAL decscope" near the backspace