// Holder for Fraen FHS-HEB1-LB01-x lens for Luxeon LEDs.
// I use it for my rear lights.

epsilon = 0.01;
infty = 100;
debug = 0;

heatsink_thickness = 2.5;
heatsink_width = 18-3.4;
heatsink_length = 58;

module fraen_lens_pin() {
	cylinder(r=4/2, h=23, $fn=32);
	translate([epsilon, 0, -5])
		cylinder(r=3.4/2, h=5+epsilon);
};

module fraen_lens() {
	cylinder(r1=6, r2=30.9/2, h=23);
	assign(off=10.35) {
	translate([off, off, 0])   fraen_lens_pin();
	translate([off, -off, 0])  fraen_lens_pin();
	translate([-off, off, 0])  fraen_lens_pin();
	translate([-off, -off, 0]) fraen_lens_pin();
	};
};

module heatsink() {
	translate([-heatsink_length+ 5 +heatsink_width/2, -heatsink_width/2, 0])
		cube([heatsink_length, heatsink_width, heatsink_thickness]);
}

module seat_holder() {
	translate([-41, 8, 29])
		cube([3, 30, 60], center=true);
};

module stem_ellipse(h, w, x, y) {
	translate([x, y, 0])
	difference() {
		translate([0, 0, 6])
			scale([1, w/2, h-6])
				rotate([0, 90, 0])
					cylinder(r=1, h=epsilon);
		translate([0, 0, -100]) cube([200, 200, 200], center=true);
	};
}

module main() {
	difference() {
		union() {
			hull() {
				cylinder(r=34/2, h=33);
				stem_ellipse(h = 15, w = 10, x = -21, y=-5);
			};
			hull() {
				stem_ellipse(h = 15, w = 10, x = -21-epsilon, y=-5);
				stem_ellipse(h = 15, w = 10, x = -33, y=-5);
			};
			hull() {
				stem_ellipse(h = 15, w = 10, x = -33-epsilon, y=-5);
				stem_ellipse(h = 25, w = 15, x = -40+epsilon, y=-2.5);
			};
			translate([-41, 5, 52/2])
				cube([7, 30, 52], center=true);
			// bolt hole ring
			translate([-44+epsilon, 10, 40]) rotate([0, -90, 0]) difference() {
				cylinder(r1=9, r2=6, h=3);
				translate([0, 0, -epsilon])
					cylinder(r=5, h=3+2*epsilon, $fn=6);
			}
			// screw hole ring
			translate([-38-epsilon, 10, 40]) rotate([0, 90, 0]) difference() {
				cylinder(r1=9, r2=6, h=3);
				translate([0, 0, -epsilon])
					cylinder(r=5, h=3+2*epsilon);
			}
		};
		translate([-47, 10, 40]) rotate([0, 90, 0])
			cylinder(r=2.5, h=12);
		translate([0, 0, 6-heatsink_thickness])
			cylinder(r=31/2, h=32);
		translate([0, 0, 6])
			fraen_lens();
		heatsink();
		seat_holder();
	}
	if (debug == 1) {
		translate([0, 0, 6]) color("gray") fraen_lens();
		color("lightblue") heatsink();
		color("lightgreen") seat_holder();
	}
}

module bolt_mount(d, h, w1, w2, fn) {
	difference() {
		translate([0, 0, -epsilon])
			cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
		translate([0, 0, -2*epsilon])
		cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
	};
};

clip_h1 = 25; // inner height
clip_h2 = 18; // inner height
clip_l  = 35;
clip_wall = 2;
clip_space = 4;
clip_bolt1_x = 10;
clip_bolt2_x = 25;

module clip_top_circle() {
	rotate([-90, 0, 0])
	difference() {
		translate([-clip_space/2, 0, 0])
			cylinder(r=clip_wall, h = epsilon, $fn=32);
		translate([-infty/2, clip_wall/2-epsilon, -epsilon])
			cube(infty);
		translate([clip_wall+epsilon, -infty/2, -epsilon])
			cube(infty);
	};
};

module clip_top() {
	hull() {
		translate([0, 0, clip_h1/2+clip_wall])
			clip_top_circle();
		translate([0, clip_l-epsilon, clip_h2/2+clip_wall])
			clip_top_circle();
	};
};

module seat_clip() {
	difference() {
		polyhedron(points = [
			[-clip_wall-clip_space/2, 0, clip_h1/2+clip_wall],
			[-clip_wall-clip_space/2, clip_l, clip_h2/2+clip_wall],
			[-clip_wall-clip_space/2, clip_l, -clip_h2/2],
			[-clip_wall-clip_space/2, 0, -clip_h1/2],
			[ clip_wall+clip_space/2,  0, clip_h1/2+clip_wall],
			[ clip_wall+clip_space/2, clip_l, clip_h2/2+clip_wall],
			[ clip_wall+clip_space/2, clip_l, -clip_h2/2],
			[ clip_wall+clip_space/2, 0, -clip_h1/2],
		], triangles = [
			[0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
			[0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
			[1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
		]);
		polyhedron(points = [
			[-clip_space/2, -epsilon, clip_h1/2],
			[-clip_space/2, clip_l+epsilon, clip_h2/2],
			[-clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
			[-clip_space/2, -epsilon, -clip_h1/2-epsilon],
			[ clip_space/2, -epsilon, clip_h1/2],
			[ clip_space/2, clip_l+epsilon, clip_h2/2],
			[ clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
			[ clip_space/2, -epsilon, -clip_h1/2-epsilon],
		], triangles = [
			[0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
			[0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
			[1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
		]);
		// bolt holes
		translate([0, clip_bolt1_x, 0])
			rotate([0, 90, 0])
			translate([0, 0, -clip_wall-clip_space/2-epsilon])
			cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
				$fn = 6);
		translate([0, clip_bolt2_x, 0])
			rotate([0, 90, 0])
			translate([0, 0, -clip_wall-clip_space/2-epsilon])
			cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
				$fn=6);
	};

	translate([-clip_space, clip_bolt1_x, 0])
	rotate([0, -90, 0])
	bolt_mount(6, 3, 7, 14, 6);

	translate([-clip_space, clip_bolt2_x, 0])
	rotate([0, -90, 0])
	bolt_mount(6, 3, 7, 14, 6);

	translate([clip_space, clip_bolt1_x, 0])
	rotate([0, 90, 0])
	bolt_mount(6, 3, 7, 14, 128);

	translate([clip_space, clip_bolt2_x, 0])
	rotate([0, 90, 0])
	bolt_mount(6, 3, 7, 14, 128);

	clip_top();
};

/*
seat_clip();

difference() {
	union() {
		hull() {
			translate([40, epsilon, 2])
				clip_top();
			clip_top();
		};

		translate([40, 0, 25])
			rotate([-90, 0, 0])
				cylinder(r=34/2, h=clip_l);

		hull() {
			translate([clip_space/2+epsilon, 0, 0])
				cube([clip_wall-epsilon, clip_wall, clip_h1/2+2*clip_wall-epsilon]);
			translate([40, 0, 14+epsilon])
				cube([clip_wall-epsilon, clip_wall, 34/2]);
		};
	};
	translate([40, 6, 25])
		rotate([-90, 0, 0]) {
			cylinder(r=31/2, h=clip_l);
			fraen_lens();
			heatsink();
		};
};
*/

wall_thickness = 1.5;
fraen_diam = 30.75;
fraen_h = 29.8;
pin_diam = 4;
pin_offset = 10.35*1.4142;
pin_len = 9.2;
front_add = 4;

side_barrier_x_offset = 13;
side_barrier_pin_z_offset = 4.2;
side_barrier_thickness = 2;

module round_part() {
	difference() {
		cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
			h = front_add + pin_len + wall_thickness);
		translate([0, 0, -epsilon])
			cylinder(r = fraen_diam/2,
			h = pin_len + wall_thickness + front_add + 2*epsilon);
		// front cone
		translate([0, 0, pin_len + 1.5*wall_thickness - epsilon])
			cylinder(r1 = fraen_diam/2,
				r2 = (fraen_diam+pin_diam + wall_thickness)/2,
				h = front_add + 2*epsilon);
		// pin holes
		for (angle = [0, 90, 180, 270]) {
			rotate([0, 0, angle+45])
				translate([pin_offset, 0, wall_thickness-epsilon])
					cylinder(r=pin_diam/2,
						h=pin_len+epsilon, $fn=32);
		};
	};

	// side barriers
	for (angle = [0, 90, 180]) // omit the bottom one
		rotate([0, 0, angle])
			intersection() {
				cylinder(r=fraen_diam/2+epsilon, h=infty);
				translate([-infty/2, side_barrier_x_offset,
					wall_thickness + pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
					cube([infty, infty, side_barrier_thickness]);
		};
};

module square_cone() {
	difference() {
		hull() {
			translate([0, 0, fraen_h - pin_len - wall_thickness])
				cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
					h = epsilon);
			for (angle = [0, 90, 180, 270])
				rotate([0, 0, angle])
					translate([9, 9, 0])
						cylinder(r=wall_thickness+3.5/2, h = epsilon);
		}
		hull() {
			translate([0, 0, fraen_h - pin_len - wall_thickness+epsilon])
				cylinder(r = fraen_diam/2,
					h = epsilon);
			for (angle = [0, 90, 180, 270])
				rotate([0, 0, angle])
					translate([9, 9, -epsilon])
						cylinder(r=3.5/2, h = epsilon);
		}
	}
}

rear_spring_w = 4;

module rear_spring() {
	translate([0, 0, wall_thickness/2])
		cube([18+2*wall_thickness+3.5, rear_spring_w, wall_thickness], center=true);
	difference() {
		rotate([90, 0, 0])
			translate([0, 0, -rear_spring_w/2])
			cylinder(r=6-heatsink_thickness, h = rear_spring_w);
		translate([0, 0, -infty/2+epsilon])
			cube(infty, center=true);
	};
};

module heatsink_holder() {
	for (angle = [0, 180]) {
		rotate([0, 0, angle])
			translate([9+wall_thickness, 0, 6/2])
			cube([3.5/2+wall_thickness, 2*9-3.5-0.5, 6], center=true);
	}
}

module lens_holder() {
	difference() {
		union() {
			translate([0, 0, fraen_h - pin_len - wall_thickness])
				round_part();
			square_cone();
		};
		
		// 0.5mm hole in the bottom
		// translate([side_barrier_x_offset-epsilon, -0.25, -epsilon])
		translate([0, -0.25, (fraen_h - pin_len - wall_thickness)/2])
			cube([infty, 0.5, infty]);

		// cable hole, 2*3mm
		translate([9, 0, 6+3])
			rotate([0, 0, 60])
				cube([infty, 2, 3]);
	};
		
	rear_spring();
	heatsink_holder();
};

lens_holder($fn = 128);

translate([20, 40, 0])
	rotate([90, 0, -90])
		seat_clip(, $fn=128);

hull() {
	translate([0, 9+3.5/2+epsilon, wall_thickness/2])
		cube([2*9+3.5, epsilon, wall_thickness], center=true);
	translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
		cube([clip_h1+clip_wall, epsilon/2, wall_thickness], center=true);
};

translate([7.5, 13.3, 0])
	cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);

	// vnitrni prumer kruhu by mel byt 30.75mm
	// vnejsi prumer aspon 35 mm
	// pin od stredu 10.35mm na x a y
	// prumer pinu 4 mm
	// pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm

	// piny by mely pokracovat jeste tak 4mm pod nulu,
	// a pak uz muze jit konv.obal do ctverce
	// vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
	// vrch chladice (s LEDkou) -18.5
	// konec nozicek -24.5