OpenSCAD Source Code: Vacuum Tube LEDs -- Ersatz Heatsink Plate Cap

Vacuum Tube Lights.scad

// Vacuum Tube LED Lights
// Ed Nisley KE4ZNU January 2016

Layout = "FinCap";						// Cap LampBase USBPort Socket(s) (Build)FinCap

Section = true;							// 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

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 (overestimate)
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
T_SCREWOC = 9;											// mounting screw holes

//    Name      pins     BCD   dia  length   hole            punch       env  pipe screw
TubeData = [
	["Mini7",     8,    9.53, 1.016,   7.0,  16.0,        11/16 * inch,  18.0,  5.0, 22.5],
	["Octal",     8,   17.45, 2.36,   10.0,  36.2,    (8 + 1)/8 * inch,  32.0, 11.5, 39.0],
	["Noval",    10,   11.89, 1.1016,  7.0,  22.0,          7/8 * inch,  21.0,  5.0, 28.0],
	["Duodecar", 13,   19.10, 1.05,    9.0,  32.0,         1.25 * inch,  38.0, 12.5, 39.0],
];

ID = 0;
OD = 1;
LENGTH = 2;

Pixel = [7.0,10.0,3.0];								// ID = contact patch, OD = PCB dia, LENGTH = overall thickness

Nut = [3.5,8.0,3.0];								// socket mounting nut recess

BaseShim = 2*ThreadThick;							// between pin holes and pixel top
SocketFlange = 2.0;									// rim around socket below punchout
PanelThick = 2.0;									// socket extension through punchout

//----------------------
// 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(r=(FixDia + HoleWindage)/2,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] + 3.0),(CapTube[OD] + 2*Pixel[LENGTH])];

CapSides = 6*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)),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

CableOD = 3.5;											// cable + braid diameter
BulbOD = 3.75 * inch;									// bulb OD; use 10 inches for flat

FinCutterOD = 1/8 * inch;
echo(str("Fin Cutter: ",FinCutterOD));
FinSides = 2*4;

FinCapSize = [(Pixel[OD] + 2*FinCutterOD),30.0,(10.0 + 2*Pixel[LENGTH])];

BulbRadius = BulbOD / 2;
BulbDepth = BulbRadius - sqrt(pow(BulbRadius,2) - pow(FinCapSize[OD],2)/4);
echo(str("Bulb OD: ",BulbOD," recess: ",BulbDepth));

module FinCap() {
	
	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([0,28.0])
	rotate([90,0,0])
		linear_extrude(height=28.0)
			polygon(points=[
				[0,0],
				[8.0,0],
				[8.0,4.0],
//				[4.0,4.0],
				[4.0,6.5],
				[-4.0,6.5],
//				[-4.0,4.0],
				[-8.0,4.0],
				[-8.0,0],
			]);
}


//----------------------
// Box for Leviton ceramic lamp base

module LampBase() {
	
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 = [0.107 * inch,												// 6-32 mounting 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);
					}
	}
}

//----------------------
// Tube Socket

module Socket(Name = "Mini7") {
	
	NumSides = 6*4;
	
	Tube = search([Name],TubeData,1,0)[0];
	echo(str("Building ",TubeData[Tube][0]," socket"));
	echo(str(" Punch: ",TubeData[ID][T_PUNCHOD]," mm = ",TubeData[ID][T_PUNCHOD]/inch," inch"));
	echo(str(" Screws: ",TubeData[ID][T_SCREWOC]," mm =",TubeData[ID][T_SCREWOC]/inch," inch OC"));
	
	OAH = Pixel[LENGTH] + BaseShim + TubeData[Tube][T_PINLEN];
	BaseHeight = OAH - PanelThick;

	difference() {
		union() {
			linear_extrude(height=BaseHeight)
				hull() {
					circle(d=(TubeData[Tube][T_PUNCHOD] + 2*SocketFlange),$fn=NumSides);
					for (i=[-1,1])
						translate([i*TubeData[Tube][T_SCREWOC]/2,0])
							circle(d=2*Nut[OD],$fn=NumSides);
				}
			cylinder(d=TubeData[Tube][T_PUNCHOD],h=OAH,$fn=NumSides);
		}
			
		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
			translate([i*TubeData[Tube][T_SCREWOC]/2,0,-Protrusion]) {
				PolyCyl(Nut[OD],(Nut[LENGTH] + Protrusion),6);
				PolyCyl(Nut[ID],(OAH + 2*Protrusion),6);
			}
		
		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,(Nut[LENGTH] - ThreadThick)/2])
					for (a=[0:5])
						rotate(a*30 + 15)
							cube([2*ThreadWidth,0.9*Nut[OD],(Nut[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);

		}
	}

}

//----------------------
// 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 == "USBPort")
	USBPort();

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");
}

More details on my blog at http://wp.me/poZKh-5BN