X-Git-Url: https://www.fi.muni.cz/~kas/git//home/kas/public_html/git/?p=bike-lights.git;a=blobdiff_plain;f=parts%2Frearlight.scad;h=05a79cb31cca19163c5507e42e9ebbcc8b97b229;hp=938c381e2b1620c99fd9676c0902fee1ea7851b3;hb=HEAD;hpb=74c8418108d14042c710aedcc0b9d0f0331c142f

diff --git a/parts/rearlight.scad b/parts/rearlight.scad
index 938c381..05a79cb 100644
--- a/parts/rearlight.scad
+++ b/parts/rearlight.scad
@@ -5,93 +5,40 @@ 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);
-};
+wall_thickness = 1.5;
+fraen_diam = 30.90;
+fraen_h = 29.3;
+pin_diam = 4;
+pin_offset = 10.35*1.4142;
+pin_len = 9.2;
+front_add = 4;
 
-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);
-	};
-}
+rear_pin_dist = 9.1;
+rear_pin_diam = 3.25;
 
-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();
-	}
-}
+side_barrier_x_offset = 13;
+side_barrier_pin_z_offset = 4.2;
+side_barrier_thickness = 2;
 
+heatsink_thickness = 2;
+
+clip_h1 = 27; // front height (on the heatsink side)
+clip_h2 = 20; // rear height (on the lens side)
+clip_l  = 28;
+clip_wall = wall_thickness;
+clip_space = 3.5;
+clip_bolt1_z = 6;
+clip_bolt1_x = 19.5;
+clip_bolt2_z = 22;
+clip_bolt2_x = 21;
+clip_angle = 18;
+clip_top_xoff = clip_l*tan(clip_angle);
+
+clip_y_off = 34;
+clip_x_off = 2;
+clip_x_rot = -3;
+
+// z-axis is up
 module bolt_mount(d, h, w1, w2, fn) {
 	difference() {
 		translate([0, 0, -epsilon])
@@ -101,158 +48,90 @@ module bolt_mount(d, h, w1, w2, 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);
+		union() {
+			// right part
+			hull() {
+				translate([0, clip_space/2, 0])
+					cube([clip_h1, clip_wall, epsilon]);
+				translate([clip_top_xoff, clip_space/2, clip_l])
+					cube([clip_h2, clip_wall, epsilon]);
+			};
 
-	translate([clip_space, clip_bolt2_x, 0])
-	rotate([0, 90, 0])
-	bolt_mount(6, 3, 7, 14, 128);
+			// left part
+			hull() {
+				translate([0, -clip_space/2-clip_wall, 0])
+					cube([clip_h1, clip_wall, epsilon]);
+				translate([0+clip_top_xoff, -clip_space/2-clip_wall, clip_l])
+					cube([clip_h2, clip_wall, epsilon]);
+			};
 
-	clip_top();
-};
+			// top part
+			hull() {
+				translate([-2*clip_wall, -clip_space/2-clip_wall, 0])
+					cube([2*clip_wall+epsilon, 2*clip_wall+clip_space, epsilon]);
+				translate([-clip_wall+clip_top_xoff, -clip_space/2-clip_wall, clip_l])
+					cube([clip_wall+epsilon, 2*clip_wall+clip_space, epsilon]);
+			};
 
-/*
-seat_clip();
+			// bolt mounts
+			translate([clip_bolt1_x, clip_space/2 + clip_wall, clip_bolt1_z])
+			rotate([-90, 0, 0])
+			bolt_mount(6.5, 2, 7, 12, 6);
 
-difference() {
-	union() {
-		hull() {
-			translate([40, epsilon, 2])
-				clip_top();
-			clip_top();
-		};
+			translate([clip_bolt1_x, -clip_space/2 - clip_wall, clip_bolt1_z])
+			rotate([90, 0, 0])
+			bolt_mount(6.5, 2, 7, 12, 32);
 
-		translate([40, 0, 25])
+			translate([clip_bolt2_x, clip_space/2 + clip_wall, clip_bolt2_z])
 			rotate([-90, 0, 0])
-				cylinder(r=34/2, h=clip_l);
+			bolt_mount(6.5, 2, 7, 12, 6);
 
-		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();
+			translate([clip_bolt2_x, -clip_space/2 - clip_wall, clip_bolt2_z])
+			rotate([90, 0, 0])
+			bolt_mount(6.5, 2, 7, 12, 32);
 		};
-};
-*/
-
-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;
+		// bolt holes
+		translate([clip_bolt1_x, infty/2, clip_bolt1_z])
+			rotate([90, 0, 0])
+			cylinder(r=2, h=infty, $fn = 6);
+		translate([clip_bolt2_x, infty/2, clip_bolt2_z])
+			rotate([90, 0, 0])
+			cylinder(r=2, h=infty, $fn = 6);
+	}
 
-side_barrier_x_offset = 13;
-side_barrier_pin_z_offset = 4.2;
-side_barrier_thickness = 2;
+}
 
+// upper part of the lens holder
 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);
+			h = front_add + pin_len);
+
+		hull() {
+			translate([0, 0, -epsilon])
+				cylinder(r = fraen_diam/2,
+					h = pin_len + front_add + 2*epsilon);
+			for (angle = [0, 90, 180, 270]) {
+				rotate([0, 0, angle+45])
+					translate([pin_offset, 0, -epsilon])
+						cylinder(r=pin_diam/2,
+							h=epsilon);
+			};
+		}
+
 		// front cone
-		translate([0, 0, pin_len + 1.5*wall_thickness - epsilon])
+		translate([0, 0, pin_len + 0.5*wall_thickness - epsilon])
 			cylinder(r1 = fraen_diam/2,
 				r2 = (fraen_diam+pin_diam + wall_thickness)/2,
-				h = front_add + 2*epsilon);
+				h = front_add - 0.5*wall_thickness+ 2*epsilon);
 		// pin holes
 		for (angle = [0, 90, 180, 270]) {
 			rotate([0, 0, angle+45])
-				translate([pin_offset, 0, wall_thickness-epsilon])
+				translate([pin_offset, 0, epsilon])
 					cylinder(r=pin_diam/2,
-						h=pin_len+epsilon, $fn=32);
+						h=pin_len+epsilon);
 		};
 	};
 
@@ -262,7 +141,7 @@ module round_part() {
 			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 ])
+					pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
 					cube([infty, infty, side_barrier_thickness]);
 		};
 };
@@ -270,87 +149,151 @@ module round_part() {
 module square_cone() {
 	difference() {
 		hull() {
-			translate([0, 0, fraen_h - pin_len - wall_thickness])
+			translate([0, 0, fraen_h - pin_len])
 				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);
+					translate([rear_pin_dist, rear_pin_dist, 0])
+						cylinder(r=wall_thickness+3.75/2, h = epsilon);
 		}
 		hull() {
-			translate([0, 0, fraen_h - pin_len - wall_thickness+epsilon])
+			translate([0, 0, fraen_h - pin_len + 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);
+			for (angle = [0, 90, 180, 270]) {
+				rotate([0, 0, angle]) 
+					translate([rear_pin_dist, rear_pin_dist, -epsilon])
+						cylinder(r=3.75/2, h = epsilon);
+				rotate([0, 0, angle+45])
+					translate([pin_offset, 0, fraen_h - pin_len + epsilon])
+						cylinder(r=pin_diam/2,
+							h=epsilon);
+			}
 		}
 	}
 }
 
-rear_spring_w = 4;
+rear_spring_w = 2*rear_pin_dist-rear_pin_diam-2;
+rear_spring_h = 1.5;
+rear_spring_center_w = 4;
+led_zoff = 6;
 
 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);
-	};
-};
+		cube([rear_spring_center_w, rear_spring_w, wall_thickness],
+			center=true);
+	translate([0, rear_spring_w/2-wall_thickness/2,
+		(led_zoff-heatsink_thickness)/2])
+		cube([rear_spring_center_w,
+			wall_thickness, led_zoff-heatsink_thickness],
+			center=true);
+	translate([0, -rear_spring_w/2+wall_thickness/2,
+		(led_zoff-heatsink_thickness)/2])
+		cube([rear_spring_center_w,
+			wall_thickness, led_zoff-heatsink_thickness],
+			center=true);
+
+	for (angle=[0, 180]) {
+		rotate([0, 0, angle])
+		translate([5.5, 0, rear_spring_h/2])
+			rotate([0, 0, 45]) {
+				cube([wall_thickness, 14, rear_spring_h],
+					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);
+			translate([rear_pin_dist+wall_thickness, 0, (led_zoff+wall_thickness)/2])
+			cube([rear_pin_diam/2+wall_thickness, 2*rear_pin_dist-rear_pin_diam-2, led_zoff+wall_thickness], center=true);
 	}
 }
 
 module lens_holder() {
 	difference() {
 		union() {
-			translate([0, 0, fraen_h - pin_len - wall_thickness])
+			translate([0, 0, fraen_h - pin_len])
 				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])
+		translate([0, -0.25, (fraen_h - pin_len)/2])
 			cube([infty, 0.5, infty]);
 
 		// cable hole, 2*3mm
-		translate([9, 0, 6+3])
+		translate([rear_pin_dist, 0, 6+3])
 			rotate([0, 0, 60])
 				cube([infty, 2, 3]);
+
+		// side LED hole, 3mm
+		translate([0, 0, fraen_h - pin_len])
+			rotate([90, 0, 0])
+				cylinder(r=rear_pin_diam/2, h=infty, $fn=6);
 	};
 		
 	rear_spring();
 	heatsink_holder();
 };
 
-lens_holder($fn = 128);
-
-translate([20, 40, 0])
-	rotate([90, 0, -90])
-		seat_clip(, $fn=128);
+module full_joint() {
+	difference() {
+		hull() {
+				intersection() {
+					rotate([-90, 0, 0])
+					scale([0.25, 1, 1])
+						cylinder(r = fraen_h-pin_len, h = rear_pin_dist + wall_thickness+rear_pin_diam/2);
+					translate([-infty/2, rear_pin_dist + wall_thickness + rear_pin_diam/2 - epsilon, 0])
+						cube(infty);
+				};
+			translate([clip_x_off, clip_y_off, 0])
+				intersection() {
+					seat_clip_rotated();
+					translate([(fraen_h-pin_len)*tan(clip_angle)-clip_wall, -clip_space/2-0.1*clip_wall+epsilon, 0])
+						rotate([90+clip_x_rot, 0, 0])
+						scale([0.45, 1, 1])
+							cylinder(r = fraen_h-pin_len, h = epsilon);
+				};
+		};
+		hull() {
+			translate([0, 0, fraen_h - pin_len + epsilon])
+				cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness/2,
+					h = epsilon);
+			for (angle = [0, 90, 180, 270])
+				rotate([0, 0, angle])
+					translate([rear_pin_dist, rear_pin_dist, -epsilon])
+						cylinder(r=wall_thickness/2+3.75/2, h = epsilon);
+		};
+	}
+};
 
-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);
+module seat_clip_rotated() {
+	difference() {
+		translate([clip_space/2+clip_wall, 0, 0])
+		rotate([clip_x_rot, 0, 0])
+		translate([-clip_space/2-clip_wall, 0, sin(clip_x_rot)*(clip_space/2+clip_wall+epsilon)])
+			seat_clip();
+		translate([-infty/2, -infty/2, -infty])
+			cube(infty);
+	};
+};
+			
+module main() {
+	lens_holder();
+	translate([clip_x_off, clip_y_off, 0])
+		seat_clip_rotated();
+	// xy_joint();
+	// yz_joint();
+	full_joint();
 };
 
-translate([7.5, 13.3, 0])
-	cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);
 
+// scale([1, -1, 1]) main($fn=128);
+main($fn = 128);
 	// vnitrni prumer kruhu by mel byt 30.75mm
 	// vnejsi prumer aspon 35 mm
 	// pin od stredu 10.35mm na x a y