parts/rearlight.scad

   1 // Holder for Fraen FHS-HEB1-LB01-x lens for Luxeon LEDs.
   2 // I use it for my rear lights.
   3
   4 epsilon = 0.01;
   5 infty = 100;
   6 debug = 0;
   7
   8 wall_thickness = 1.5;
   9 fraen_diam = 30.90;
  10 fraen_h = 29.3;
  11 pin_diam = 4;
  12 pin_offset = 10.35*1.4142;
  13 pin_len = 9.2;
  14 front_add = 4;
  15
  16 rear_pin_dist = 9.1;
  17 rear_pin_diam = 3.25;
  18
  19 side_barrier_x_offset = 13;
  20 side_barrier_pin_z_offset = 4.2;
  21 side_barrier_thickness = 2;
  22
  23 heatsink_thickness = 2;
  24
  25 clip_h1 = 27; // front height (on the heatsink side)
  26 clip_h2 = 20; // rear height (on the lens side)
  27 clip_l  = 28;
  28 clip_wall = wall_thickness;
  29 clip_space = 3.5;
  30 clip_bolt1_z = 6;
  31 clip_bolt1_x = 19.5;
  32 clip_bolt2_z = 22;
  33 clip_bolt2_x = 21;
  34 clip_angle = 18;
  35 clip_top_xoff = clip_l*tan(clip_angle);
  36
  37 clip_y_off = 34;
  38 clip_x_off = 2;
  39 clip_x_rot = -3;
  40
  41 // z-axis is up
  42 module bolt_mount(d, h, w1, w2, fn) {
  43         difference() {
  44                 translate([0, 0, -epsilon])
  45                         cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
  46                 translate([0, 0, -2*epsilon])
  47                 cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
  48         };
  49 };
  50
  51 module seat_clip() {
  52         difference() {
  53                 union() {
  54                         // right part
  55                         hull() {
  56                                 translate([0, clip_space/2, 0])
  57                                         cube([clip_h1, clip_wall, epsilon]);
  58                                 translate([clip_top_xoff, clip_space/2, clip_l])
  59                                         cube([clip_h2, clip_wall, epsilon]);
  60                         };
  61
  62                         // left part
  63                         hull() {
  64                                 translate([0, -clip_space/2-clip_wall, 0])
  65                                         cube([clip_h1, clip_wall, epsilon]);
  66                                 translate([0+clip_top_xoff, -clip_space/2-clip_wall, clip_l])
  67                                         cube([clip_h2, clip_wall, epsilon]);
  68                         };
  69
  70                         // top part
  71                         hull() {
  72                                 translate([-2*clip_wall, -clip_space/2-clip_wall, 0])
  73                                         cube([2*clip_wall+epsilon, 2*clip_wall+clip_space, epsilon]);
  74                                 translate([-clip_wall+clip_top_xoff, -clip_space/2-clip_wall, clip_l])
  75                                         cube([clip_wall+epsilon, 2*clip_wall+clip_space, epsilon]);
  76                         };
  77
  78                         // bolt mounts
  79                         translate([clip_bolt1_x, clip_space/2 + clip_wall, clip_bolt1_z])
  80                         rotate([-90, 0, 0])
  81                         bolt_mount(6.5, 2, 7, 12, 6);
  82
  83                         translate([clip_bolt1_x, -clip_space/2 - clip_wall, clip_bolt1_z])
  84                         rotate([90, 0, 0])
  85                         bolt_mount(6.5, 2, 7, 12, 32);
  86
  87                         translate([clip_bolt2_x, clip_space/2 + clip_wall, clip_bolt2_z])
  88                         rotate([-90, 0, 0])
  89                         bolt_mount(6.5, 2, 7, 12, 6);
  90
  91                         translate([clip_bolt2_x, -clip_space/2 - clip_wall, clip_bolt2_z])
  92                         rotate([90, 0, 0])
  93                         bolt_mount(6.5, 2, 7, 12, 32);
  94                 };
  95                 // bolt holes
  96                 translate([clip_bolt1_x, infty/2, clip_bolt1_z])
  97                         rotate([90, 0, 0])
  98                         cylinder(r=2, h=infty, $fn = 6);
  99                 translate([clip_bolt2_x, infty/2, clip_bolt2_z])
 100                         rotate([90, 0, 0])
 101                         cylinder(r=2, h=infty, $fn = 6);
 102         }
 103
 104 }
 105
 106 // upper part of the lens holder
 107 module round_part() {
 108         difference() {
 109                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 110                         h = front_add + pin_len);
 111
 112                 hull() {
 113                         translate([0, 0, -epsilon])
 114                                 cylinder(r = fraen_diam/2,
 115                                         h = pin_len + front_add + 2*epsilon);
 116                         for (angle = [0, 90, 180, 270]) {
 117                                 rotate([0, 0, angle+45])
 118                                         translate([pin_offset, 0, -epsilon])
 119                                                 cylinder(r=pin_diam/2,
 120                                                         h=epsilon);
 121                         };
 122                 }
 123
 124                 // front cone
 125                 translate([0, 0, pin_len + 0.5*wall_thickness - epsilon])
 126                         cylinder(r1 = fraen_diam/2,
 127                                 r2 = (fraen_diam+pin_diam + wall_thickness)/2,
 128                                 h = front_add - 0.5*wall_thickness+ 2*epsilon);
 129                 // pin holes
 130                 for (angle = [0, 90, 180, 270]) {
 131                         rotate([0, 0, angle+45])
 132                                 translate([pin_offset, 0, epsilon])
 133                                         cylinder(r=pin_diam/2,
 134                                                 h=pin_len+epsilon);
 135                 };
 136         };
 137
 138         // side barriers
 139         for (angle = [0, 90, 180]) // omit the bottom one
 140                 rotate([0, 0, angle])
 141                         intersection() {
 142                                 cylinder(r=fraen_diam/2+epsilon, h=infty);
 143                                 translate([-infty/2, side_barrier_x_offset,
 144                                         pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
 145                                         cube([infty, infty, side_barrier_thickness]);
 146                 };
 147 };
 148
 149 module square_cone() {
 150         difference() {
 151                 hull() {
 152                         translate([0, 0, fraen_h - pin_len])
 153                                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 154                                         h = epsilon);
 155                         for (angle = [0, 90, 180, 270])
 156                                 rotate([0, 0, angle])
 157                                         translate([rear_pin_dist, rear_pin_dist, 0])
 158                                                 cylinder(r=wall_thickness+3.75/2, h = epsilon);
 159                 }
 160                 hull() {
 161                         translate([0, 0, fraen_h - pin_len + epsilon])
 162                                 cylinder(r = fraen_diam/2,
 163                                         h = epsilon);
 164                         for (angle = [0, 90, 180, 270]) {
 165                                 rotate([0, 0, angle])
 166                                         translate([rear_pin_dist, rear_pin_dist, -epsilon])
 167                                                 cylinder(r=3.75/2, h = epsilon);
 168                                 rotate([0, 0, angle+45])
 169                                         translate([pin_offset, 0, fraen_h - pin_len + epsilon])
 170                                                 cylinder(r=pin_diam/2,
 171                                                         h=epsilon);
 172                         }
 173                 }
 174         }
 175 }
 176
 177 rear_spring_w = 2*rear_pin_dist-rear_pin_diam-2;
 178 rear_spring_h = 1.5;
 179 rear_spring_center_w = 4;
 180 led_zoff = 6;
 181
 182 module rear_spring() {
 183         translate([0, 0, wall_thickness/2])
 184                 cube([rear_spring_center_w, rear_spring_w, wall_thickness],
 185                         center=true);
 186         translate([0, rear_spring_w/2-wall_thickness/2,
 187                 (led_zoff-heatsink_thickness)/2])
 188                 cube([rear_spring_center_w,
 189                         wall_thickness, led_zoff-heatsink_thickness],
 190                         center=true);
 191         translate([0, -rear_spring_w/2+wall_thickness/2,
 192                 (led_zoff-heatsink_thickness)/2])
 193                 cube([rear_spring_center_w,
 194                         wall_thickness, led_zoff-heatsink_thickness],
 195                         center=true);
 196
 197         for (angle=[0, 180]) {
 198                 rotate([0, 0, angle])
 199                 translate([5.5, 0, rear_spring_h/2])
 200                         rotate([0, 0, 45]) {
 201                                 cube([wall_thickness, 14, rear_spring_h],
 202                                         center=true);
 203                 }
 204         }
 205 }
 206
 207 module heatsink_holder() {
 208         for (angle = [0, 180]) {
 209                 rotate([0, 0, angle])
 210                         translate([rear_pin_dist+wall_thickness, 0, (led_zoff+wall_thickness)/2])
 211                         cube([rear_pin_diam/2+wall_thickness, 2*rear_pin_dist-rear_pin_diam-2, led_zoff+wall_thickness], center=true);
 212         }
 213 }
 214
 215 module lens_holder() {
 216         difference() {
 217                 union() {
 218                         translate([0, 0, fraen_h - pin_len])
 219                                 round_part();
 220                         square_cone();
 221                 };
 222
 223                 // 0.5mm hole in the bottom
 224                 // translate([side_barrier_x_offset-epsilon, -0.25, -epsilon])
 225                 translate([0, -0.25, (fraen_h - pin_len)/2])
 226                         cube([infty, 0.5, infty]);
 227
 228                 // cable hole, 2*3mm
 229                 translate([rear_pin_dist, 0, 6+3])
 230                         rotate([0, 0, 60])
 231                                 cube([infty, 2, 3]);
 232
 233                 // side LED hole, 3mm
 234                 translate([0, 0, fraen_h - pin_len])
 235                         rotate([90, 0, 0])
 236                                 cylinder(r=rear_pin_diam/2, h=infty, $fn=6);
 237         };
 238
 239         rear_spring();
 240         heatsink_holder();
 241 };
 242
 243 module full_joint() {
 244         difference() {
 245                 hull() {
 246                                 intersection() {
 247                                         rotate([-90, 0, 0])
 248                                         scale([0.25, 1, 1])
 249                                                 cylinder(r = fraen_h-pin_len, h = rear_pin_dist + wall_thickness+rear_pin_diam/2);
 250                                         translate([-infty/2, rear_pin_dist + wall_thickness + rear_pin_diam/2 - epsilon, 0])
 251                                                 cube(infty);
 252                                 };
 253                         translate([clip_x_off, clip_y_off, 0])
 254                                 intersection() {
 255                                         seat_clip_rotated();
 256                                         translate([(fraen_h-pin_len)*tan(clip_angle)-clip_wall, -clip_space/2-0.1*clip_wall+epsilon, 0])
 257                                                 rotate([90+clip_x_rot, 0, 0])
 258                                                 scale([0.45, 1, 1])
 259                                                         cylinder(r = fraen_h-pin_len, h = epsilon);
 260                                 };
 261                 };
 262                 hull() {
 263                         translate([0, 0, fraen_h - pin_len + epsilon])
 264                                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness/2,
 265                                         h = epsilon);
 266                         for (angle = [0, 90, 180, 270])
 267                                 rotate([0, 0, angle])
 268                                         translate([rear_pin_dist, rear_pin_dist, -epsilon])
 269                                                 cylinder(r=wall_thickness/2+3.75/2, h = epsilon);
 270                 };
 271         }
 272 };
 273
 274 module seat_clip_rotated() {
 275         difference() {
 276                 translate([clip_space/2+clip_wall, 0, 0])
 277                 rotate([clip_x_rot, 0, 0])
 278                 translate([-clip_space/2-clip_wall, 0, sin(clip_x_rot)*(clip_space/2+clip_wall+epsilon)])
 279                         seat_clip();
 280                 translate([-infty/2, -infty/2, -infty])
 281                         cube(infty);
 282         };
 283 };
 284
 285 module main() {
 286         lens_holder();
 287         translate([clip_x_off, clip_y_off, 0])
 288                 seat_clip_rotated();
 289         // xy_joint();
 290         // yz_joint();
 291         full_joint();
 292 };
 293
 294
 295 // scale([1, -1, 1]) main($fn=128);
 296 main($fn = 128);
 297         // vnitrni prumer kruhu by mel byt 30.75mm
 298         // vnejsi prumer aspon 35 mm
 299         // pin od stredu 10.35mm na x a y
 300         // prumer pinu 4 mm
 301         // pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm
 302
 303         // piny by mely pokracovat jeste tak 4mm pod nulu,
 304         // a pak uz muze jit konv.obal do ctverce
 305         // vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
 306         // vrch chladice (s LEDkou) -18.5
 307         // konec nozicek -24.5