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=2c8e7a97c7605ee51c1a64c2b1bd0bfd854b982a;hp=00a3cf625caeac0028454c830f0f29212b0dc6ca;hb=2767677de5d10d1aba770c8d051c431801360fcf;hpb=16918ca0a912dc0daf3a087ff25ea4ab8ffc30f0

diff --git a/parts/rearlight.scad b/parts/rearlight.scad
index 00a3cf6..2c8e7a9 100644
--- a/parts/rearlight.scad
+++ b/parts/rearlight.scad
@@ -5,226 +5,258 @@ epsilon = 0.01;
 infty = 100;
 debug = 0;
 
-heatsink_thickness = 2.5;
-heatsink_width = 18-3.4;
-heatsink_length = 58;
+wall_thickness = 2;
+fraen_diam = 30.75;
+fraen_h = 29.8;
+pin_diam = 4;
+pin_offset = 10.35*1.4142;
+pin_len = 9.2;
+front_add = 4;
 
-module fraen_lens_pin() {
-	cylinder(r1=2, r2=6.15/2, h=23);
-	translate([epsilon, 0, -5])
-		cylinder(r=3.4/2, h=5+epsilon);
-};
+side_barrier_x_offset = 13;
+side_barrier_pin_z_offset = 4.2;
+side_barrier_thickness = 2;
 
-module fraen_lens() {
-	cylinder(r1=6, r2=30.51/2, h=23);
-	translate([9, 9, 0])   fraen_lens_pin();
-	translate([9, -9, 0])  fraen_lens_pin();
-	translate([-9, 9, 0])  fraen_lens_pin();
-	translate([-9, -9, 0]) fraen_lens_pin();
-};
+heatsink_thickness = 2.5;
 
-module heatsink() {
-	translate([-heatsink_length+ 5 +heatsink_width/2, -heatsink_width/2, 0])
-		cube([heatsink_length, heatsink_width, heatsink_thickness]);
-}
+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 = 20;
+clip_bolt2_z = 22;
+clip_bolt2_x = 23;
+clip_angle = 24;
+clip_top_xoff = clip_l*tan(clip_angle);
 
-module seat_holder() {
-	translate([-41, 8, 29])
-		cube([3, 30, 60], center=true);
-};
+clip_y_off = 37;
+clip_x_off = 0;
 
-module stem_ellipse(h, w, x, y) {
-	translate([x, y, 0])
+// z-axis is up
+module bolt_mount(d, h, w1, w2, fn) {
 	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);
+		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);
 	};
-}
+};
 
-module main() {
+module seat_clip() {
 	difference() {
 		union() {
+			// right part
 			hull() {
-				cylinder(r=34/2, h=33);
-				stem_ellipse(h = 15, w = 10, x = -21, y=-5);
+				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]);
 			};
+
+			// left part
 			hull() {
-				stem_ellipse(h = 15, w = 10, x = -21-epsilon, y=-5);
-				stem_ellipse(h = 15, w = 10, x = -33, y=-5);
+				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]);
 			};
+
+			// top part
 			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([-clip_wall, -clip_space/2-clip_wall, 0])
+					cube([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]);
 			};
-			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);
-			}
+
+			// 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, 32);
+
+			translate([clip_bolt1_x, -clip_space/2 - clip_wall, clip_bolt1_z])
+			rotate([90, 0, 0])
+			bolt_mount(6.5, 2, 7, 12, 6);
+
+			translate([clip_bolt2_x, clip_space/2 + clip_wall, clip_bolt2_z])
+			rotate([-90, 0, 0])
+			bolt_mount(6.5, 2, 7, 12, 32);
+
+			translate([clip_bolt2_x, -clip_space/2 - clip_wall, clip_bolt2_z])
+			rotate([90, 0, 0])
+			bolt_mount(6.5, 2, 7, 12, 6);
 		};
-		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();
+		// 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);
 	}
+
 }
 
-module bolt_mount(d, h, w1, w2, fn) {
+// upper part of the lens holder
+module round_part() {
 	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);
-	};
-};
+		cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
+			h = front_add + pin_len);
 
-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;
+		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, $fn=32);
+			};
+		}
 
-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);
+		// front cone
+		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 - 0.5*wall_thickness+ 2*epsilon);
+		// pin holes
+		for (angle = [0, 90, 180, 270]) {
+			rotate([0, 0, angle+45])
+				translate([pin_offset, 0, epsilon])
+					cylinder(r=pin_diam/2,
+						h=pin_len+epsilon, $fn=32);
+		};
 	};
-};
 
-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();
-	};
+	// 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 seat_clip() {
+module square_cone() {
 	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=1.5, h=2*clip_wall+clip_space+2*epsilon);
-		translate([0, clip_bolt2_x, 0])
-			rotate([0, 90, 0])
-			translate([0, 0, -clip_wall-clip_space/2-epsilon])
-			cylinder(r=1.5, h=2*clip_wall+clip_space+2*epsilon);
-	};
-
-	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);
+		hull() {
+			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([9.1, 9.1, 0])
+						cylinder(r=wall_thickness+3.75/2, h = epsilon);
+		}
+		hull() {
+			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([9.1, 9.1, -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, $fn=32);
+			}
+		}
+	}
+}
 
-	translate([clip_space, clip_bolt2_x, 0])
-	rotate([0, 90, 0])
-	bolt_mount(6, 3, 7, 14, 128);
+rear_spring_w = 4;
 
-	clip_top();
+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);
+	};
 };
 
-seat_clip();
+module heatsink_holder() {
+	for (angle = [0, 180]) {
+		rotate([0, 0, angle])
+			translate([9.1+wall_thickness, 0, 6/2])
+			cube([3.5/2+wall_thickness, 2*9.1-3.5-0.5, 6], center=true);
+	}
+}
 
-difference() {
-	union() {
-		hull() {
-			translate([40, epsilon, 2])
-				clip_top();
-			clip_top();
+module lens_holder() {
+	difference() {
+		union() {
+			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)/2])
+			cube([infty, 0.5, infty]);
 
-		translate([40, 0, 25])
-			rotate([-90, 0, 0])
-				cylinder(r=34/2, h=clip_l);
+		// cable hole, 2*3mm
+		translate([9.1, 0, 6+3])
+			rotate([0, 0, 60])
+				cube([infty, 2, 3]);
 
-		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]);
-		};
+		// side LED hole, 3mm
+		translate([0, 0, fraen_h - pin_len])
+			rotate([90, 0, 0])
+				cylinder(r=3.5/2, h=infty, $fn=6);
 	};
-	translate([40, 6, 25])
-		rotate([-90, 0, 0]) {
-			cylinder(r=31/2, h=clip_l);
-			fraen_lens();
-			heatsink();
-		};
+		
+	rear_spring();
+	heatsink_holder();
 };
 
+union() {
+	lens_holder($fn = 128);
+	translate([clip_x_off, clip_y_off, 0])
+		seat_clip();
 /*
-if (debug == 1) {
-	difference() {
-		main($fn=64);
-		//translate([0, -100, 0]) cube([200, 200, 200], center=true);
-		rotate([0, 0, 40])translate([0, -100, 0]) cube([200, 200, 200], center=true);
-	};
-} else {
-	main($fn=128);
-}
+hull() {
+	translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
+		cube([9.1, epsilon, wall_thickness], center=true);
+	translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
+		cube([9.1, epsilon/2, wall_thickness], center=true);
+};
+
+hull() {
+	translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
+		cube([2*.259+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]);
+
+	}
+	//translate([-infty/2, -infty/2, 8])
+	//	cube(infty);
 */
+};
+
+
+	// 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