parts/rearlight-dual.scad

   1 // Holder for two Fraen FHS-HEB1-LB01-x lenses for Luxeon LEDs.
   2
   3 eps = 0.01;
   4 infty = 100;
   5
   6 wall = 1.5;
   7 lens_dist = 45;
   8 fraen_diam = 30.90 + 0.3;
   9 fraen_h = 29.3;
  10 pin_diam = 4 + 0.2;
  11 pin_offset = 10.35*1.4142;
  12 pin_len = 9.2;
  13 front_add = 4;
  14
  15 rear_pin_dist = 9.1;
  16 rear_pin_diam = 3.25 + 0.5;
  17
  18 side_barrier_x_offset = 13;
  19 side_barrier_pin_z_offset = 4.2;
  20 side_barrier_thickness = 2;
  21
  22 heatsink_thickness = 2;
  23 heatsink_w = 15 + 0.5;
  24 heatsink_l = lens_dist + 1.5*heatsink_w;
  25 heatsink_z = 1 + wall;
  26 heatsink_hole_sep = 2*wall;
  27
  28 clip_h1 = 27; // front height (on the heatsink side)
  29 clip_h2 = 20; // rear height (on the lens side)
  30 clip_l  = 28;
  31 clip_wall = wall;
  32 clip_space = 3.5;
  33 clip_bolt1_z = 6;
  34 clip_bolt1_x = 19.5;
  35 clip_bolt2_z = 22;
  36 clip_bolt2_x = 21;
  37 clip_angle = 18;
  38 clip_top_xoff = clip_l*tan(clip_angle);
  39
  40 clip_y_off = 34;
  41 clip_x_off = 2;
  42 clip_x_rot = -3;
  43
  44 screw_yoff = 12;
  45 screw_d = 4;
  46 screw_d2 = 12;
  47 screw_h = 8;
  48 screw_wall = 3*wall;
  49
  50         // vnitrni prumer kruhu by mel byt 30.75mm
  51         // vnejsi prumer aspon 35 mm
  52         // pin od stredu 10.35mm na x a y
  53         // prumer pinu 4 mm
  54         // pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm
  55
  56         // piny by mely pokracovat jeste tak 4mm pod nulu,
  57         // a pak uz muze jit konv.obal do ctverce
  58         // vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
  59         // vrch chladice (s LEDkou) -18.5
  60         // konec nozicek -24.5
  61
  62 front_len = fraen_h + wall;
  63 rear_mount_depth = 10;
  64 rear_sep = 0.3;
  65
  66 module front_body() {
  67         hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 0]) {
  68                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall,
  69                         h = front_len + wall);
  70         }
  71 }
  72
  73 module front_part() {
  74         difference() {
  75                 front_body();
  76                 for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 0]) {
  77                         // front narower ring
  78                         translate([0, 0, -eps])
  79                                 cylinder(r = fraen_diam/2 - wall, h = wall+2*eps);
  80                         // main holes
  81                         translate([0, 0, wall])
  82                                 cylinder(r = fraen_diam/2 , h = front_len + eps);
  83                         // pin holes
  84                         for (angle = [0, 90, 180, 270]) {
  85                                 rotate([0, 0, angle+45])
  86                                         translate([pin_offset, 0, wall])
  87                                                 cylinder(r=pin_diam/2,
  88                                                         h=front_len + eps);
  89                         };
  90                 }
  91                 // rear mount
  92                 difference() {
  93                 hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, front_len - rear_mount_depth] ) {
  94                         cylinder(r = fraen_diam/2 + pin_diam/2,
  95                                 h = wall + rear_mount_depth + eps);
  96                 }
  97                 for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, front_len])
  98                 for (angle = [0, 90, 180, 270]) rotate([0, 0, angle])
  99                         translate([rear_pin_dist, rear_pin_dist, 0])
 100                                 cylinder(r=rear_pin_diam/2, h = wall);
 101                 }
 102                 // screw holes
 103                 for (y = [-1, 1]) translate([0, y*screw_yoff, -eps])
 104                         cylinder(r = screw_d/2,
 105                                 h = front_len + wall + 2*eps);
 106         }
 107 }
 108
 109 module rear_body() {
 110         hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 0] ) {
 111                 cylinder(r = fraen_diam/2 + pin_diam/2 - rear_sep,
 112                         h = wall + rear_mount_depth);
 113         }
 114 }
 115
 116 module rear_part() {
 117         difference() {
 118                 rear_body();
 119                 // pins
 120                 for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, wall])
 121                 for (angle = [0, 90, 180, 270]) rotate([0, 0, angle])
 122                         translate([rear_pin_dist, rear_pin_dist, 0])
 123                                 cylinder(r=rear_pin_diam/2, h = rear_mount_depth+wall+eps);
 124                 // pins hull
 125                 // for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 2*wall]) hull()
 126                 // for (angle = [0, 90, 180, 270]) rotate([0, 0, angle])
 127                 //      translate([rear_pin_dist, rear_pin_dist, 0])
 128                 //              cylinder(r=rear_pin_diam/2, h = rear_mount_depth);
 129                 difference() {
 130                         // outer wall
 131                         hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, heatsink_z + heatsink_thickness] ) {
 132                                 cylinder(r = fraen_diam/2 + pin_diam/2 - rear_sep - wall,
 133                                         h = rear_mount_depth + wall + eps);
 134                         }
 135                         // minus screw mounts
 136                         for (y = [-1, 1]) translate([0, y*screw_yoff, 0])
 137                                 cylinder(r = screw_d/2 + screw_wall,
 138                                         h = rear_mount_depth + wall + eps);
 139                 }
 140                 // screw holes
 141                 for (y = [-1, 1]) translate([0, y*screw_yoff, -eps])
 142                         cylinder(r = screw_d/2,
 143                                 h = rear_mount_depth + wall + 2*eps);
 144                 // heatsink
 145                 translate([-heatsink_l/2, -heatsink_w/2, heatsink_z])
 146                         cube([heatsink_l, heatsink_w, rear_mount_depth]);
 147                 // heatsink back hole
 148                 translate([-heatsink_l/2 + heatsink_hole_sep,
 149                                 -heatsink_w/2 + heatsink_hole_sep, -eps])
 150                         cube([heatsink_l-2*heatsink_hole_sep,
 151                                 heatsink_w-2*heatsink_hole_sep,
 152                                 heatsink_z+2*eps]);
 153         }
 154 }
 155
 156 translate([0, fraen_diam *1.5, 0])
 157         front_part($fn = 128);
 158
 159 rear_part($fn = 128);
 160