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OpenSCAD source code: Hard drive platter base and drilling fixture
// Vacuum Tube LED Lights
// Ed Nisley KE4ZNU February ... September 2016
Layout = "PlatterBase"; // Cap LampBase USBPort Bushings
// Socket(s) (Build)FinCap Platter[Base|Fixture]
DefaultSocket = "Noval";
Section = false; // cross-section the object
Support = true;
//- Extrusion parameters must match reality!
ThreadThick = 0.25;
ThreadWidth = 0.40;
HoleWindage = 0.2;
Protrusion = 0.1; // make holes end cleanly
inch = 25.4;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
//----------------------
// Dimensions
// https://en.wikipedia.org/wiki/Tube_socket#Summary_of_Base_Details
// punch & screw OC modified for drive platter chassis plate
// platter = 25 mm ID
// CD = 15 mm ID with raised ring at 37 mm, needs screw head clearance
T_NAME = 0; // common name
T_NUMPINS = 1; // total, with no allowance for keying
T_PINBCD = 2; // tube pin circle diameter
T_PINOD = 3; // ... diameter
T_PINLEN = 4; // ... length (must also clear evacuation tip / spigot)
T_HOLEOD = 5; // nominal panel hole from various sources
T_PUNCHOD = 6; // panel hole optimized for inch-size Greenlee punches
T_TUBEOD = 7; // envelope or base diameter
T_PIPEOD = 8; // light pipe from LED to tube base (clear evac tip / spigot)
T_SCREWOC = 9; // mounting screw holes
// Name pins BCD dia length hole punch tube pipe screw
TubeData = [
["Mini7", 8, 9.53, 1.016, 7.0, 16.0, 25.0, 18.0, 5.0, 35.0], // punch 11/16, screw 22.5 OC
["Octal", 8, 17.45, 2.36, 10.0, 36.2, (8 + 1)/8 * inch, 32.0, 11.5, 47.0], // screw 39.0 OC
["Noval", 10, 11.89, 1.1016, 7.0, 22.0, 25.0 , 21.0, 7.5, 35.0], // punch 7/8, screw 28.0 OC
["Magnoval", 10, 17.45, 1.27, 9.0, 29.7, (4 + 1)/4 * inch, 46.0, 12.4, 38.2], // similar to Novar
["Duodecar", 13, 19.10, 1.05, 9.0, 32.0, (4 + 1)/4 * inch, 38.0, 12.5, 47.0], // screw 39.0 OC
];
ID = 0;
OD = 1;
LENGTH = 2;
Pixel = [7.0,10.0,3.0]; // ID = contact patch, OD = PCB dia, LENGTH = overall thickness
SocketNut = // socket mounting: threaded insert or nut recess
// [3.5,5.2,7.2] // 6-32 insert
[4.0,6.0,5.9] // 4 mm short insert
;
NutSides = 8;
SocketShim = 2*ThreadThick; // between pin holes and pixel top
SocketFlange = 1.5; // rim around socket below punchout
PanelThick = 1.5; // socket extension through punchout
FinCutterOD = 1/8 * inch;
FinCapSize = [(Pixel[OD] + 2*FinCutterOD),30.0,(10.0 + 2*Pixel[LENGTH])];
USBPCB =
// [28,16,6.5] // small Sparkfun knockoff
[36,18 + 1,5.8 + 0.4] // Deek-Robot fake FTDI with ISP header
;
Platter = [25.0,95.0,1.26]; // hard drive platter dimensions
//----------------------
// Useful routines
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(d=(FixDia + HoleWindage),h=Height,$fn=Sides);
}
//----------------------
// Tube cap
CapTube = [4.0,3/16 * inch,10.0]; // brass tube for flying lead to cap LED
CapSize = [Pixel[ID],(Pixel[OD] + 2.0),(CapTube[OD] + 2*Pixel[LENGTH])];
CapSides = 8*4;
module Cap() {
difference() {
union() {
cylinder(d=CapSize[OD],h=(CapSize[LENGTH]),$fn=CapSides); // main cap body
translate([0,0,CapSize[LENGTH]]) // rounded top
scale([1.0,1.0,0.65])
sphere(d=CapSize[OD]/cos(180/CapSides),$fn=CapSides); // cos() fixes slight undersize vs cylinder
cylinder(d1=(CapSize[OD] + 2*3*ThreadWidth),d2=CapSize[OD],h=1.5*Pixel[LENGTH],$fn=CapSides); // skirt
}
translate([0,0,-Protrusion]) // bore for wiring to LED
PolyCyl(CapSize[ID],(CapSize[LENGTH] + 3*ThreadThick + Protrusion),CapSides);
translate([0,0,-Protrusion]) // PCB recess with clearance for tube dome
PolyCyl(Pixel[OD],(1.5*Pixel[LENGTH] + Protrusion),CapSides);
translate([0,0,(1.5*Pixel[LENGTH] - Protrusion)]) // small step + cone to retain PCB
cylinder(d1=(Pixel[OD]/cos(180/CapSides) + HoleWindage),d2=Pixel[ID],h=(Pixel[LENGTH] + Protrusion),$fn=CapSides);
translate([0,0,(CapSize[LENGTH] - CapTube[OD]/(2*cos(180/8)))]) // hole for brass tube holding wire loom
rotate([90,0,0]) rotate(180/8)
PolyCyl(CapTube[OD],CapSize[OD],8);
}
}
//----------------------
// Heatsink tube cap
module FinCap() {
CableOD = 3.5; // cable + braid diameter
BulbOD = 3.75 * inch; // bulb OD; use 10 inches for flat
echo(str("Fin Cutter: ",FinCutterOD));
FinSides = 2*4;
BulbRadius = BulbOD / 2;
BulbDepth = BulbRadius - sqrt(pow(BulbRadius,2) - pow(FinCapSize[OD],2)/4);
echo(str("Bulb OD: ",BulbOD," recess: ",BulbDepth));
NumFins = floor(PI*FinCapSize[ID] / (2*FinCutterOD));
FinAngle = 360 / NumFins;
echo(str("NumFins: ",NumFins," angle: ",FinAngle," deg"));
difference() {
union() {
cylinder(d=FinCapSize[ID],h=FinCapSize[LENGTH],$fn=2*NumFins); // main body
for (i = [0:NumFins - 1]) // fins
rotate(i * FinAngle)
hull() {
translate([FinCapSize[ID]/2,0,0])
rotate(180/FinSides)
cylinder(d=FinCutterOD,h=FinCapSize[LENGTH],$fn=FinSides);
translate([(FinCapSize[OD] - FinCutterOD)/2,0,0])
rotate(180/FinSides)
cylinder(d=FinCutterOD,h=FinCapSize[LENGTH],$fn=FinSides);
}
rotate(FinAngle/2) // cable entry boss
translate([FinCapSize[ID]/2,0,FinCapSize[LENGTH]/2])
cube([FinCapSize[OD]/4,FinCapSize[OD]/4,FinCapSize[LENGTH]],center=true);
}
for (i = [1:NumFins - 1]) // fin inner gullets, omit cable entry side
rotate(i * FinAngle + FinAngle/2) // joint isn't quite perfect, but OK
translate([FinCapSize[ID]/2,0,-Protrusion])
rotate(0*180/FinSides)
cylinder(d=FinCutterOD/cos(180/FinSides),h=(FinCapSize[LENGTH] + 2*Protrusion),$fn=FinSides);
translate([0,0,-Protrusion]) // PCB recess
PolyCyl(Pixel[OD],(1.5*Pixel[LENGTH] + Protrusion),FinSides);
PolyCyl(Pixel[ID],(FinCapSize[LENGTH] - 3*ThreadThick),FinSides); // bore for LED wiring
translate([0,0,(FinCapSize[LENGTH] - 3*ThreadThick - 2*CableOD/(2*cos(180/8)))]) // cable inlet
rotate(FinAngle/2) rotate([0,90,0]) rotate(180/8)
PolyCyl(CableOD,FinCapSize[OD],8);
if (BulbOD <= 10.0 * inch) // curve for top of bulb
translate([0,0,-(BulbRadius - BulbDepth + 2*ThreadThick)]) // ... slightly flatten tips
sphere(d=BulbOD,$fn=16*FinSides);
}
}
//----------------------
// Aperture for USB-to-serial adapter snout
// These are all magic numbers, of course
module USBPort() {
translate([0,USBPCB[0]])
rotate([90,0,0])
linear_extrude(height=USBPCB[0])
polygon(points=[
[0,0],
[USBPCB[1]/2,0],
[USBPCB[1]/2,0.5*USBPCB[2]],
[USBPCB[1]/3,USBPCB[2]],
[-USBPCB[1]/3,USBPCB[2]],
[-USBPCB[1]/2,0.5*USBPCB[2]],
[-USBPCB[1]/2,0],
]);
}
//----------------------
// Box for Leviton ceramic lamp base
module LampBase() {
Insert = [3.5,5.2,7.2]; // 6-32 brass insert to match standard electrical screws
Bottom = 3.0;
Base = [4.0*inch,4.5*inch,20.0 + Bottom];
Sides = 12*4;
Retainer = [3.5,11.0,1.0]; // flat fiber washer holding lamp base screws in place
StudSides = 8;
StudOC = 3.5 * inch;
Stud = [Insert[OD], // insert for socket screws
min(15.0,1.5*(Base[ID] - StudOC)/cos(180/StudSides)), // OD = big enough to merge with walls
(Base[LENGTH] - Retainer[LENGTH])]; // leave room for retainer
union() {
difference() {
rotate(180/Sides)
cylinder(d=Base[OD],h=Base[LENGTH],$fn=Sides);
rotate(180/Sides)
translate([0,0,Bottom])
cylinder(d=Base[ID],h=Base[LENGTH],$fn=Sides);
translate([0,-Base[OD]/2,Bottom + 1.2]) // mount on double-sided foam tape
rotate(0)
USBPort();
}
for (i = [-1,1])
translate([i*StudOC/2,0,0])
rotate(180/StudSides)
difference() {
cylinder(d=Stud[OD],h=Stud[LENGTH],$fn=StudSides);
translate([0,0,Bottom])
PolyCyl(Stud[ID],(Stud[LENGTH] - (Bottom - Protrusion)),6);
}
}
}
//----------------------
// Base for hard drive platters
module PlatterBase(TubeName = DefaultSocket) {
PCB =
[36,18,3] // Arduino Pro Mini
;
Tube = search([TubeName],TubeData,1,0)[0];
SocketHeight = Pixel[LENGTH] + SocketShim + TubeData[Tube][T_PINLEN] - PanelThick;
echo(str("Base for ",TubeData[Tube][0]," socket"));
Overhang = 5.5; // platter overhangs base by this much
Bottom = 4*ThreadThick;
Base = [(Platter[OD] - 3*Overhang), // smaller than 3.5 inch Sch 40 PVC pipe...
(Platter[OD] - 2*Overhang),
2.0 + max(PCB[1],(2.0 + SocketHeight + USBPCB[2])) + Bottom];
Sides = 24*4;
echo(str(" Height: ",Base[2]," mm"));
Insert = // platter mounting: threaded insert or nut recess
// [3.5,5.2,7.2] // 6-32 insert
[3.9,5.0,8.0] // 3 mm - long insert
;
NumStuds = 4;
StudSides = 8;
Stud = [Insert[OD], // insert for socket screws
2*Insert[OD], // OD = big enough to merge with walls
Base[LENGTH]]; // leave room for retainer
StudBCD = floor(Base[ID] - Stud[OD] + (Stud[OD] - Stud[ID])/2);
echo(str("Platter screw BCD: ",StudBCD," mm"));
PCBInset = Base[ID]/2 - sqrt(pow(Base[ID]/2,2) - pow(PCB[0],2)/4);
union() {
difference() {
rotate(180/Sides)
cylinder(d=Base[OD],h=Base[LENGTH],$fn=Sides);
rotate(180/Sides)
translate([0,0,Bottom])
cylinder(d=Base[ID],h=Base[LENGTH],$fn=Sides);
translate([0,-Base[OD]/2,Bottom + 1.2]) // mount PCB on foam tape
rotate(0)
USBPort();
}
for (a = [0:(NumStuds - 1)]) // platter mounting studs
rotate(180/NumStuds + a*360/(NumStuds))
translate([StudBCD/2,0,0])
rotate(180/StudSides)
difference() {
cylinder(d=Stud[OD],h=Stud[LENGTH],$fn=2*StudSides);
translate([0,0,Bottom])
PolyCyl(Stud[ID],(Stud[LENGTH] - (Bottom - Protrusion)),StudSides);
}
intersection() { // microcontroller PCB mounting plate
rotate(180/Sides)
cylinder(d=Base[OD],h=Base[LENGTH],$fn=Sides);
translate([-PCB[0]/2,(Base[ID]/2 - PCBInset),0])
cube([PCB[0],Base[OD]/2,Base[LENGTH]],center=false);
}
difference() {
intersection() { // totally ad-hoc bridge around USB opening
rotate(180/Sides)
cylinder(d=Base[OD],h=Base[LENGTH],$fn=Sides);
translate([-1.25*USBPCB[1]/2,-(Base[ID]/2),0])
cube([1.25*USBPCB[1],2.0,Base[LENGTH]],center=false);
}
translate([0,-Base[OD]/2,Bottom + 1.2]) // mount PCB on foam tape
rotate(0)
USBPort();
}
}
}
//----------------------
// Drilling fixture for disk platters
module PlatterFixture() {
StudOC = [1.16*inch,1.16*inch]; // Sherline tooling plate screw spacing
StudClear = 5.0;
BasePlate = [(20 + StudOC[0]*ceil(Platter[OD] / StudOC[0])),(Platter[OD] + 10),7.0];
PlateRound = 10.0; // corner radius
difference() {
hull() // basic block
for (i=[-1,1], j=[-1,1])
translate([i*(BasePlate[0]/2 - PlateRound),j*(BasePlate[1]/2 - PlateRound),0])
cylinder(r=PlateRound,h=BasePlate[2],$fn=4*4);
for (i=[-1:1], j=[-1:1]) // index marks
translate([i*100/2,j*100/2,BasePlate[2] - 2*ThreadThick])
cylinder(d=1.5,h=1,$fn=6);
for (i=[-1,1], j=[-1,0,1]) // holes for tooling plate studs
translate([i*StudOC[0]*ceil(Platter[OD] / StudOC[0])/2,j*StudOC[0],-Protrusion])
PolyCyl(StudClear,BasePlate[2] + 2*Protrusion,6);
translate([0,0,-Protrusion]) // center clamp hole
PolyCyl(StudClear,BasePlate[2] + 2*Protrusion,6);
translate([0,0,BasePlate[2] - Platter[LENGTH]]) // disk locating recess
linear_extrude(height=(Platter[LENGTH] + Protrusion),convexity=2)
difference() {
circle(d=(Platter[OD] + 1),$fn=8*4);
circle(d=Platter[ID],$fn=8*4);
}
translate([0,0,BasePlate[2] - 4.0]) // drilling recess
linear_extrude(height=(4.0 + Protrusion),convexity=2)
difference() {
circle(d=(Platter[OD] - 10),$fn=8*4);
circle(d=(Platter[ID] + 10),$fn=8*4);
}
}
}
//----------------------
// Tube Socket
module Socket(Name = DefaultSocket) {
NumSides = 6*4;
Tube = search([Name],TubeData,1,0)[0];
echo(str("Building ",TubeData[Tube][0]," socket"));
echo(str(" Punch: ",TubeData[Tube][T_PUNCHOD]," mm = ",TubeData[Tube][T_PUNCHOD]/inch," inch"));
echo(str(" Screws: ",TubeData[Tube][T_SCREWOC]," mm =",TubeData[Tube][T_SCREWOC]/inch," inch OC"));
OAH = Pixel[LENGTH] + SocketShim + TubeData[Tube][T_PINLEN];
BaseHeight = OAH - PanelThick;
difference() {
union() {
linear_extrude(height=BaseHeight) // base outline
hull() {
circle(d=(TubeData[Tube][T_PUNCHOD] + 2*SocketFlange),$fn=NumSides);
for (i=[-1,1])
translate([i*TubeData[Tube][T_SCREWOC]/2,0])
circle(d=2.0*SocketNut[OD],$fn=NumSides);
}
cylinder(d=TubeData[Tube][T_PUNCHOD],h=OAH,$fn=NumSides); // boss in chassis punch hole
}
for (i=[0:(TubeData[Tube][T_NUMPINS] - 1)]) // tube pins
rotate(i*360/TubeData[Tube][T_NUMPINS])
translate([TubeData[Tube][T_PINBCD]/2,0,(OAH - TubeData[Tube][T_PINLEN])])
rotate(180/4)
PolyCyl(TubeData[Tube][T_PINOD],(TubeData[Tube][T_PINLEN] + Protrusion),4);
for (i=[-1,1]) // mounting screw holes & nut traps / threaded inserts
translate([i*TubeData[Tube][T_SCREWOC]/2,0,-Protrusion]) {
PolyCyl(SocketNut[OD],(SocketNut[LENGTH] + Protrusion),NutSides);
PolyCyl(SocketNut[ID],(OAH + 2*Protrusion),NutSides);
}
translate([0,0,-Protrusion]) { // LED recess
PolyCyl(Pixel[OD],(Pixel[LENGTH] + Protrusion),8);
}
translate([0,0,(Pixel[LENGTH] - Protrusion)]) { // light pipe
rotate(180/TubeData[Tube][T_NUMPINS])
PolyCyl(TubeData[Tube][T_PIPEOD],(OAH + 2*Protrusion),TubeData[Tube][T_NUMPINS]);
}
}
// Totally ad-hoc support structures ...
if (Support) {
color("Yellow") {
for (i=[-1,1]) // nut traps
translate([i*TubeData[Tube][T_SCREWOC]/2,0,(SocketNut[LENGTH] - ThreadThick)/2])
for (a=[0:5])
rotate(a*30 + 15)
cube([2*ThreadWidth,0.9*SocketNut[OD],(SocketNut[LENGTH] - ThreadThick)],center=true);
if (Pixel[OD] > TubeData[Tube][T_PIPEOD]) // support pipe only if needed
translate([0,0,(Pixel[LENGTH] - ThreadThick)/2])
for (a=[0:7])
rotate(a*22.5)
cube([2*ThreadWidth,0.9*Pixel[OD],(Pixel[LENGTH] - ThreadThick)],center=true);
}
}
}
//----------------------
// Greenlee punch bushings
module PunchBushing(Name = DefaultSocket) {
PunchScrew = 9.5;
BushingThick = 3.0;
Tube = search([Name],TubeData,1,0)[0];
echo(str("Building ",TubeData[Tube][0]," bushing"));
NumSides = 6*4;
difference() {
union() {
cylinder(d=Platter[ID],h=BushingThick,$fn=NumSides);
cylinder(d=TubeData[Tube][T_PUNCHOD],h=(BushingThick - Platter[LENGTH]),$fn=NumSides);
}
translate([0,0,-Protrusion])
PolyCyl(PunchScrew,5.0,8);
}
}
//----------------------
// Build it
if (Layout == "Cap") {
if (Section)
difference() {
Cap();
translate([-CapSize[OD],0,CapSize[LENGTH]])
cube([2*CapSize[OD],2*CapSize[OD],3*CapSize[LENGTH]],center=true);
}
else
Cap();
}
if (Layout == "FinCap") {
if (Section) render(convexity=5)
difference() {
FinCap();
// translate([0,-FinCapSize[OD],FinCapSize[LENGTH]])
// cube([2*FinCapSize[OD],2*FinCapSize[OD],3*FinCapSize[LENGTH]],center=true);
translate([-FinCapSize[OD],0,FinCapSize[LENGTH]])
cube([2*FinCapSize[OD],2*FinCapSize[OD],3*FinCapSize[LENGTH]],center=true);
}
else
FinCap();
}
if (Layout == "BuildFinCap")
translate([0,0,FinCapSize[LENGTH]])
rotate([180,0,0])
FinCap();
if (Layout == "LampBase")
LampBase();
if (Layout == "PlatterBase")
PlatterBase();
if (Layout == "PlatterFixture")
PlatterFixture();
if (Layout == "USBPort")
USBPort();
if (Layout == "Bushings")
PunchBushing();
if (Layout == "Socket")
if (Section) {
difference() {
Socket();
translate([-100/2,0,-Protrusion])
cube([100,50,50],center=false);
}
}
else
Socket();
if (Layout == "Sockets") {
translate([0,50,0])
Socket("Mini7");
translate([0,20,0])
Socket("Octal");
translate([0,-15,0])
Socket("Duodecar");
translate([0,-50,0])
Socket("Noval");
translate([0,-85,0])
Socket("Magnoval");}
Owner

ednisley commented Sep 2, 2016

More detail on my blog at http://wp.me/poZKh-69F

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