lasercut enclosure design, triggers a bug in openscad 2011.12.13

enclosure.scad

/**
 * Rough box measurements (based on the electronics board size)
 *
 * Height 15cm -> 10cm should be enough
 * Width 30cm
 * Depth 20cm
 *
 * Coilforms:
 *   4.0” DIA
 *   3.22” DIA
 *   Torus thickness 72mm
 *
 * Fans:
 *   60mm*60mm (4mm mounting holes)
 *
 * Holes for the power and interrupter signal wires will be drilled/milled afterwards
 */


/**************************
 * Basic units.
 * 
 * Originally by Hans Häggström, 2010.
 * Dual licenced under Creative Commons Attribution-Share Alike 3.0 and LGPL2 or later
 */

mm = 1;
cm = 10 * mm;
dm = 100 * mm;
m = 1000 * mm;
inch = 25.4 * mm;

M3 = 3*mm;
M4 = 4*mm;
M5 = 5*mm;
M6 = 6*mm;
M8 = 8*mm;

// When a small distance is needed to overlap shapes for boolean cutting, etc.
epsilon = 0.01*mm;

TAU = 6.2831853071; //2*PI, see http://tauday.com/
PI = TAU/2;

/************************/

/***********************
 * Some globally needed variables
 */
material_z = 8*mm;
box_z = 10*cm + 2*material_z; // We need the 10cm on the *inside*
box_x = 30*cm;
box_y = 20*cm;
secondary_coil_r = (3.22*inch)/2;
primary_coil_r = (4.0*inch)/2;

front_top_slot_offset = 20;
front_left_slot_offset = 20;
front_leg_z=13;

/************************/

/***********************
 * Coilforms for visually checking the design
 */
module coilform_3d(cr,ch)
{
    $fa=0.5;
    $fs=0.1;
    difference()
    {
        cylinder(r=cr, h=ch);
        translate([0,0,-1])
        {
            cylinder(r=cr-2, h=ch+2);
        }
    }
}

module secondary_coilform_3d()
{
    cr=secondary_coil_r;
    ch=11*inch;
    coilform_3d(cr, ch);
    translate([0,0,11*inch])
    {
        coilform_torus_3d(cr);
    }
}

module coilform_torus_3d(cr)
{
    th=72/2;
    ri=cr;
    $fn=50;
    translate([0,0,th])
    {
        rotate_extrude(convexity = 10)
        {
            translate([ri, 0, 0])
            {
                circle(r = th);
            }
        }
    }
}

module primary_coilform_3d()
{
    cr=primary_coil_r;
    ch=62;
    coilform_3d(cr, ch);
}

module coilforms_3d()
{
    primary_coilform_3d();
    secondary_coilform_3d();
}
//coilforms_3d();
/************************/


module slot_2d(w,d=material_z*1.1)
{
    $fa=0.5;
    $fs=0.1;
    slot_corner_r=0.25;
    union()
    {
        // These cylinders are to avoid weak points in the acrylic, see http://blog.ponoko.com/2010/06/17/how-to-make-snug-joints-in-acrylic/
        square([w,d]);
        circle(r=slot_corner_r);
        translate([0,d,0])
        {
            circle(r=slot_corner_r);
        }
        translate([w,0,0])
        {
            circle(r=slot_corner_r);
            translate([0,d,0])
            {
                circle(r=slot_corner_r);
            }
        }
    }
}
//slot_2d(30);

module span(r_inner, width, tan_angle)
{
    $fa=0.5;
    $fs=0.1;
    cr = width/2;
    a_len = r_inner+width;
    mirror([1,0,0])
    {
        union()
        {
            intersection()
            {
                // Full circle
                difference()
                {
                    circle(r=r_inner+width);
                    circle(r=r_inner);
                }
                // right-angled triagle
                translate([0,a_len,0])
                {
                    mirror([1,1,0])
                    {
                        polygon(points=[[0,0],[a_len,0],[0,tan(tan_angle) * a_len]], paths=[[0,1,2]]);
                    }
                }
            }
            translate([0,r_inner+cr,0])
            {
                circle(r=cr, center=false);
            }
            rotate([0,0,tan_angle])
            {
                translate([0,r_inner+cr,0])
                {
                    circle(r=cr, center=false);
                }
            }
        }
    }
}

//span(primary_coil_r*2+2, 5, 30);

module multi_span_test(tan_angle)
{
    for(i=[0:(360/tan_angle)-1])
    {
        rotate([0,0,i*tan_angle])
        {
            span(primary_coil_r*2+2, 5, tan_angle);
        }
    }
}
//multi_span_test(30);

module slot_tight_2d(w,d=material_z*1.1)
{
    $fa=0.5;
    $fs=0.1;
    tf=d/20;
    difference()
    {
        slot_2d(w,d);
        translate([-d+tf,d/2,0])
        {
            circle(r=d);
        }
        translate([w+d-tf,d/2,0])
        {
            circle(r=d);
        }
    }
}
//slot_tight_2d(30);

module front_back_top_bottom_slots()
{
    translate([front_top_slot_offset,0])
    {
        slot_tight_2d(box_x-front_top_slot_offset*2);
    }
}

module front_back_left_right_slots()
{
    translate([0,front_left_slot_offset])
    {
        rotate([0,0,90])
        {
            slot_tight_2d(box_z-front_top_slot_offset*2);
        }
    }
}

module back_et_front_2d()
{
    leg_w=25;
    difference()
    {
        translate([0,-front_leg_z])
        {
            // Main face with "legs"
            difference()
            {
                square([box_x, box_z+front_leg_z]);
                translate([leg_w,-epsilon])
                {
                    square([box_x-2*leg_w, front_leg_z-material_z/2]);
                }
            }
        }
        // Slot for top plate
        translate([0,box_z-material_z+epsilon])
        {
            front_back_top_bottom_slots();
        }
        // Slot for bottom plate
        translate([0,0])
        {
            front_back_top_bottom_slots();
        }
        // Slot for left plate
        translate([material_z-epsilon,0])
        {
            front_back_left_right_slots();
        }
        // Slot for right plate
        translate([box_x+epsilon,0])
        {
            front_back_left_right_slots();
        }
    }
}
//back_et_front_2d();

module back_2d()
{
    lightning_holes = 5;
    difference()
    {
        back_et_front_2d();
        // 5 HV lightning shaped ventilation holes
        for(i=[0:lightning_holes-1])
        {
            translate([((box_x-2*material_z)/lightning_holes)*i+6*material_z,20,0])
            {
                mirror([1,0,0])
                {
                    scale([2,2,2])
                    {
                       hv_lightning();
                    }
                }
            }
        }
    }
    // ventilation holes ?
}

module back_3d()
{
    color([(34/255), (232/255), (234/255), 0.75])
    {
        translate([0,box_y,0])
        {
            rotate([90,0,0])
            {
                linear_extrude(height=material_z)
                {
                    back_2d();
                }
            }
        }
    }
}
//back_3d();

module front_2d()
{
    back_et_front_2d();
    // ventilation holes ?
}

module front_3d()
{
    color([(34/255), (232/255), (234/255), 0.75])
    {
        translate([0,material_z,0])
        {
            rotate([90,0,0])
            {
                linear_extrude(height=material_z)
                {
                    front_2d();
                }
            }
        }
    }
}
//front_3d();

module top_bottom_front_back_slots()
{
    translate([-epsilon,0])
    {
        slot_2d(front_top_slot_offset+2*epsilon);
    }
    translate([box_x-front_top_slot_offset,0])
    {
        slot_2d(front_top_slot_offset+epsilon);
    }
}

module top_bottom_plate_2d()
{
    difference()
    {
        square([box_x, box_y]);
        translate([-epsilon,-epsilon])
        {
            top_bottom_front_back_slots();
        }
        translate([-epsilon, box_y-material_z+epsilon])
        {
            top_bottom_front_back_slots();
        }
    }
}

module top_2d()
{
    $fa=0.5;
    $fs=0.1;
    primary_hole_width = 5; // mm
    primary_hole_size = 10; // degrees
    primary_hole_count = 8;
    difference()
    {
        top_bottom_plate_2d();
        translate([box_x/2, box_y/2]) // center
        {
            // Hole for securing the coilforms
            circle(r=M5);
            // Holes for passing through the primary coil wires (for various tunings)
            for(i=[0:primary_hole_count-1])
            {
                rotate([0,0,i*(360/primary_hole_count)])
                {
                    span(primary_coil_r+3, primary_hole_width, primary_hole_size);
                }
            }
        }
    }
}

//top_2d();

module top_3d()
{
    color([(71/255), (48/255), (212/255), 0.75])
    {
        translate([0,0,box_z-material_z])
        {
            linear_extrude(height=material_z)
            {
                top_2d();
            }
        }
    }
}
//top_3d();

module bottom_2d()
{
    top_bottom_plate_2d();
    // TODO: Add ventilation holes/slots ?
}
//bottom_2d();

module bottom_3d()
{
    color([(71/255), (48/255), (212/255), 0.75])
    {
        linear_extrude(height=material_z)
        {
            bottom_2d();
        }
    }
}
//bottom_3d();

module left_right_front_back_slots()
{
    //front_left_slot_offset
    translate([-epsilon,0])
    {
        slot_2d(front_left_slot_offset-material_z);
    }
    translate([box_z-material_z-front_left_slot_offset+epsilon,0])
    {
        slot_2d(front_left_slot_offset-material_z);
    }
}


module left_right_plate()
{
    difference()
    {
        square([box_z-(2*material_z),box_y]);
        translate([0,0])
        {
            left_right_front_back_slots();
        }
        translate([0,box_y-material_z+epsilon])
        {
            left_right_front_back_slots();
        }
        
    }    
}

module left_2d()
{
    lightning_holes = 3;
    difference()
    {
        left_right_plate();
        // 3 HV lightning shaped ventilation holes
        for(i=[0:lightning_holes-1])
        {
            translate([40,((box_y-2*material_z)/lightning_holes)*i+5.5*material_z,0])
            {
                mirror([0,0,0])
                {
                    rotate([0,0,-90])
                    {
                       hv_lightning();
                    }
                }
            }
        }
        // Ventilation hole, the leftover doubles as stiffener bottom plate
        translate([material_z, 3*material_z,0])
        {
            square([front_leg_z, box_y-6*material_z]);
        }
    }
}

//left_2d();

module left_3d()
{
    color([(34/255), (222/255), (52/255), 0.75])
    {
        translate([material_z,0,material_z])
        {
            rotate([0,-90,0])
            {
                linear_extrude(height=material_z)
                {
                    left_2d();
                }
            }
        }
    }
}
//left_3d();

module right_2d()
{
    lightning_holes = 3;
    difference()
    {
        left_right_plate();
        // 3 HV lightning shaped ventilation holes
        for(i=[0:lightning_holes-1])
        {
            translate([40,((box_y-2*material_z)/lightning_holes)*i+4*material_z,0])
            {
                mirror([0,1,0])
                {
                    rotate([0,0,-90])
                    {
                       hv_lightning();
                    }
                }
            }
        }
        // Ventilation hole, the leftover doubles as stiffener bottom plate
        translate([material_z, 3*material_z,0])
        {
            square([front_leg_z, box_y-6*material_z]);
        }
    }
}
//right_2d();

module right_3d()
{
    color([(34/255), (222/255), (52/255), 0.75])
    {
        translate([box_x,0,material_z])
        {
            rotate([0,-90,0])
            {
                linear_extrude(height=material_z)
                {
                    right_2d();
                }
            }
        }
    }
}
//right_3d();

module box_3d()
{
    bottom_3d();
    top_3d();
    back_3d();
    front_3d();
    left_3d();
    right_3d();
}
//box_3d();

module rendering()
{
    box_3d();
    translate([box_x/2,box_y/2,box_z])
    {
        coilforms_3d();
    }
}
//rendering();


module hv_lightning()
{
    translate([-15,-148,0])
    {
        import(file="high_voltage_lightningonly.dxf");
    }
}
//hv_lightning();

/**
 * Seems front_2d module triggers some sort of infinite-loop (ran out of swapspace once because of that...)
 * but only when used alone (the 3D extrusion [and cutting a projection from that] works fine...)
 */
module front_2d_fromprojection()
{
    projection(cut=false)
    {
        rotate([90,0,0])
        {
            front_3d();
        }
    }
}
//front_2d_fromprojection();
/**
 * Ditto for back_2d
 */
module back_2d_fromprojection()
{
    projection(cut=false)
    {
        rotate([90,0,0])
        {
            back_3d();
        }
    }
}
//back_2d_fromprojection();


// Trigger bug
front_2d();


/**
 * Calls to the 2D modules in single place for easier exporting
 *
bottom_2d();
top_2d();
front_2d();
back_2d();
left_2d();
right_2d();
 */

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