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 heatsink_thickness = 2.5;
   9 heatsink_width = 18-3.4;
  10 heatsink_length = 58;
  11
  12 module fraen_lens_pin() {
  13         cylinder(r1=2, r2=6.15/2, h=23);
  14         translate([epsilon, 0, -5])
  15                 cylinder(r=3.4/2, h=5+epsilon);
  16 };
  17
  18 module fraen_lens() {
  19         cylinder(r1=6, r2=30.51/2, h=23);
  20         translate([9, 9, 0])   fraen_lens_pin();
  21         translate([9, -9, 0])  fraen_lens_pin();
  22         translate([-9, 9, 0])  fraen_lens_pin();
  23         translate([-9, -9, 0]) fraen_lens_pin();
  24 };
  25
  26 module heatsink() {
  27         translate([-heatsink_length+ 5 +heatsink_width/2, -heatsink_width/2, 0])
  28                 cube([heatsink_length, heatsink_width, heatsink_thickness]);
  29 }
  30
  31 module seat_holder() {
  32         translate([-41, 8, 29])
  33                 cube([3, 30, 60], center=true);
  34 };
  35
  36 module stem_ellipse(h, w, x, y) {
  37         translate([x, y, 0])
  38         difference() {
  39                 translate([0, 0, 6])
  40                         scale([1, w/2, h-6])
  41                                 rotate([0, 90, 0])
  42                                         cylinder(r=1, h=epsilon);
  43                 translate([0, 0, -100]) cube([200, 200, 200], center=true);
  44         };
  45 }
  46
  47 module main() {
  48         difference() {
  49                 union() {
  50                         hull() {
  51                                 cylinder(r=34/2, h=33);
  52                                 stem_ellipse(h = 15, w = 10, x = -21, y=-5);
  53                         };
  54                         hull() {
  55                                 stem_ellipse(h = 15, w = 10, x = -21-epsilon, y=-5);
  56                                 stem_ellipse(h = 15, w = 10, x = -33, y=-5);
  57                         };
  58                         hull() {
  59                                 stem_ellipse(h = 15, w = 10, x = -33-epsilon, y=-5);
  60                                 stem_ellipse(h = 25, w = 15, x = -40+epsilon, y=-2.5);
  61                         };
  62                         translate([-41, 5, 52/2])
  63                                 cube([7, 30, 52], center=true);
  64                         // bolt hole ring
  65                         translate([-44+epsilon, 10, 40]) rotate([0, -90, 0]) difference() {
  66                                 cylinder(r1=9, r2=6, h=3);
  67                                 translate([0, 0, -epsilon])
  68                                         cylinder(r=5, h=3+2*epsilon, $fn=6);
  69                         }
  70                         // screw hole ring
  71                         translate([-38-epsilon, 10, 40]) rotate([0, 90, 0]) difference() {
  72                                 cylinder(r1=9, r2=6, h=3);
  73                                 translate([0, 0, -epsilon])
  74                                         cylinder(r=5, h=3+2*epsilon);
  75                         }
  76                 };
  77                 translate([-47, 10, 40]) rotate([0, 90, 0])
  78                         cylinder(r=2.5, h=12);
  79                 translate([0, 0, 6-heatsink_thickness])
  80                         cylinder(r=31/2, h=32);
  81                 translate([0, 0, 6])
  82                         fraen_lens();
  83                 heatsink();
  84                 seat_holder();
  85         }
  86         if (debug == 1) {
  87                 translate([0, 0, 6]) color("gray") fraen_lens();
  88                 color("lightblue") heatsink();
  89                 color("lightgreen") seat_holder();
  90         }
  91 }
  92
  93 module bolt_mount(d, h, w1, w2, fn) {
  94         difference() {
  95                 translate([0, 0, -epsilon])
  96                         cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
  97                 translate([0, 0, -2*epsilon])
  98                 cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
  99         };
 100 };
 101
 102 clip_h1 = 25; // inner height
 103 clip_h2 = 18; // inner height
 104 clip_l  = 35;
 105 clip_wall = 2;
 106 clip_space = 4;
 107 clip_bolt1_x = 10;
 108 clip_bolt2_x = 25;
 109
 110 module clip_top_circle() {
 111         rotate([-90, 0, 0])
 112         difference() {
 113                 translate([-clip_space/2, 0, 0])
 114                         cylinder(r=clip_wall, h = epsilon, $fn=32);
 115                 translate([-infty/2, clip_wall/2-epsilon, -epsilon])
 116                         cube(infty);
 117                 translate([clip_wall+epsilon, -infty/2, -epsilon])
 118                         cube(infty);
 119         };
 120 };
 121
 122 module clip_top() {
 123         hull() {
 124                 translate([0, 0, clip_h1/2+clip_wall])
 125                         clip_top_circle();
 126                 translate([0, clip_l-epsilon, clip_h2/2+clip_wall])
 127                         clip_top_circle();
 128         };
 129 };
 130
 131 module seat_clip() {
 132         difference() {
 133                 polyhedron(points = [
 134                         [-clip_wall-clip_space/2, 0, clip_h1/2+clip_wall],
 135                         [-clip_wall-clip_space/2, clip_l, clip_h2/2+clip_wall],
 136                         [-clip_wall-clip_space/2, clip_l, -clip_h2/2],
 137                         [-clip_wall-clip_space/2, 0, -clip_h1/2],
 138                         [ clip_wall+clip_space/2,  0, clip_h1/2+clip_wall],
 139                         [ clip_wall+clip_space/2, clip_l, clip_h2/2+clip_wall],
 140                         [ clip_wall+clip_space/2, clip_l, -clip_h2/2],
 141                         [ clip_wall+clip_space/2, 0, -clip_h1/2],
 142                 ], triangles = [
 143                         [0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
 144                         [0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
 145                         [1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
 146                 ]);
 147                 polyhedron(points = [
 148                         [-clip_space/2, -epsilon, clip_h1/2],
 149                         [-clip_space/2, clip_l+epsilon, clip_h2/2],
 150                         [-clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
 151                         [-clip_space/2, -epsilon, -clip_h1/2-epsilon],
 152                         [ clip_space/2, -epsilon, clip_h1/2],
 153                         [ clip_space/2, clip_l+epsilon, clip_h2/2],
 154                         [ clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
 155                         [ clip_space/2, -epsilon, -clip_h1/2-epsilon],
 156                 ], triangles = [
 157                         [0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
 158                         [0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
 159                         [1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
 160                 ]);
 161                 // bolt holes
 162                 translate([0, clip_bolt1_x, 0])
 163                         rotate([0, 90, 0])
 164                         translate([0, 0, -clip_wall-clip_space/2-epsilon])
 165                         cylinder(r=1.5, h=2*clip_wall+clip_space+2*epsilon);
 166                 translate([0, clip_bolt2_x, 0])
 167                         rotate([0, 90, 0])
 168                         translate([0, 0, -clip_wall-clip_space/2-epsilon])
 169                         cylinder(r=1.5, h=2*clip_wall+clip_space+2*epsilon);
 170         };
 171
 172         translate([-clip_space, clip_bolt1_x, 0])
 173         rotate([0, -90, 0])
 174         bolt_mount(6, 3, 7, 14, 6);
 175
 176         translate([-clip_space, clip_bolt2_x, 0])
 177         rotate([0, -90, 0])
 178         bolt_mount(6, 3, 7, 14, 6);
 179
 180         translate([clip_space, clip_bolt1_x, 0])
 181         rotate([0, 90, 0])
 182         bolt_mount(6, 3, 7, 14, 128);
 183
 184         translate([clip_space, clip_bolt2_x, 0])
 185         rotate([0, 90, 0])
 186         bolt_mount(6, 3, 7, 14, 128);
 187
 188         clip_top();
 189 };
 190
 191 seat_clip();
 192
 193 difference() {
 194         union() {
 195                 hull() {
 196                         translate([40, epsilon, 2])
 197                                 clip_top();
 198                         clip_top();
 199                 };
 200
 201                 translate([40, 0, 25])
 202                         rotate([-90, 0, 0])
 203                                 cylinder(r=34/2, h=clip_l);
 204
 205                 hull() {
 206                         translate([clip_space/2+epsilon, 0, 0])
 207                                 cube([clip_wall-epsilon, clip_wall, clip_h1/2+2*clip_wall-epsilon]);
 208                         translate([40, 0, 14+epsilon])
 209                                 cube([clip_wall-epsilon, clip_wall, 34/2]);
 210                 };
 211         };
 212         translate([40, 6, 25])
 213                 rotate([-90, 0, 0]) {
 214                         cylinder(r=31/2, h=clip_l);
 215                         fraen_lens();
 216                         heatsink();
 217                 };
 218 };
 219
 220 /*
 221 if (debug == 1) {
 222         difference() {
 223                 main($fn=64);
 224                 //translate([0, -100, 0]) cube([200, 200, 200], center=true);
 225                 rotate([0, 0, 40])translate([0, -100, 0]) cube([200, 200, 200], center=true);
 226         };
 227 } else {
 228         main($fn=128);
 229 }
 230 */