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 = 2;
   9 fraen_diam = 30.75;
  10 fraen_h = 29.8;
  11 pin_diam = 4;
  12 pin_offset = 10.35*1.4142;
  13 pin_len = 9.2;
  14 front_add = 4;
  15
  16 side_barrier_x_offset = 13;
  17 side_barrier_pin_z_offset = 4.2;
  18 side_barrier_thickness = 2;
  19
  20 heatsink_thickness = 2.5;
  21
  22 clip_h1 = 27; // front height (on the heatsink side)
  23 clip_h2 = 20; // rear height (on the lens side)
  24 clip_l  = 28;
  25 clip_wall = wall_thickness;
  26 clip_space = 3.5;
  27 clip_bolt1_z = 6;
  28 clip_bolt1_x = 20;
  29 clip_bolt2_z = 22;
  30 clip_bolt2_x = 23;
  31 clip_angle = 24;
  32 clip_top_xoff = clip_l*tan(clip_angle);
  33
  34 clip_y_off = 37;
  35 clip_x_off = 0;
  36
  37 // z-axis is up
  38 module bolt_mount(d, h, w1, w2, fn) {
  39         difference() {
  40                 translate([0, 0, -epsilon])
  41                         cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
  42                 translate([0, 0, -2*epsilon])
  43                 cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
  44         };
  45 };
  46
  47 module seat_clip() {
  48         difference() {
  49                 union() {
  50                         // right part
  51                         hull() {
  52                                 translate([0, clip_space/2, 0])
  53                                         cube([clip_h1, clip_wall, epsilon]);
  54                                 translate([clip_top_xoff, clip_space/2, clip_l])
  55                                         cube([clip_h2, clip_wall, epsilon]);
  56                         };
  57
  58                         // left part
  59                         hull() {
  60                                 translate([0, -clip_space/2-clip_wall, 0])
  61                                         cube([clip_h1, clip_wall, epsilon]);
  62                                 translate([0+clip_top_xoff, -clip_space/2-clip_wall, clip_l])
  63                                         cube([clip_h2, clip_wall, epsilon]);
  64                         };
  65
  66                         // top part
  67                         hull() {
  68                                 translate([-clip_wall, -clip_space/2-clip_wall, 0])
  69                                         cube([clip_wall+epsilon, 2*clip_wall+clip_space, epsilon]);
  70                                 translate([-clip_wall+clip_top_xoff, -clip_space/2-clip_wall, clip_l])
  71                                         cube([clip_wall+epsilon, 2*clip_wall+clip_space, epsilon]);
  72                         };
  73
  74                         // bolt mounts
  75                         translate([clip_bolt1_x, clip_space/2 + clip_wall, clip_bolt1_z])
  76                         rotate([-90, 0, 0])
  77                         bolt_mount(6.5, 2, 7, 12, 32);
  78
  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_bolt2_x, clip_space/2 + clip_wall, clip_bolt2_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                 // bolt holes
  92                 translate([clip_bolt1_x, infty/2, clip_bolt1_z])
  93                         rotate([90, 0, 0])
  94                         cylinder(r=2, h=infty, $fn = 6);
  95                 translate([clip_bolt2_x, infty/2, clip_bolt2_z])
  96                         rotate([90, 0, 0])
  97                         cylinder(r=2, h=infty, $fn = 6);
  98         }
  99
 100 }
 101
 102 // upper part of the lens holder
 103 module round_part() {
 104         difference() {
 105                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 106                         h = front_add + pin_len);
 107
 108                 hull() {
 109                         translate([0, 0, -epsilon])
 110                                 cylinder(r = fraen_diam/2,
 111                                         h = pin_len + front_add + 2*epsilon);
 112                         for (angle = [0, 90, 180, 270]) {
 113                                 rotate([0, 0, angle+45])
 114                                         translate([pin_offset, 0, -epsilon])
 115                                                 cylinder(r=pin_diam/2,
 116                                                         h=epsilon, $fn=32);
 117                         };
 118                 }
 119
 120                 // front cone
 121                 translate([0, 0, pin_len + 0.5*wall_thickness - epsilon])
 122                         cylinder(r1 = fraen_diam/2,
 123                                 r2 = (fraen_diam+pin_diam + wall_thickness)/2,
 124                                 h = front_add - 0.5*wall_thickness+ 2*epsilon);
 125                 // pin holes
 126                 for (angle = [0, 90, 180, 270]) {
 127                         rotate([0, 0, angle+45])
 128                                 translate([pin_offset, 0, epsilon])
 129                                         cylinder(r=pin_diam/2,
 130                                                 h=pin_len+epsilon, $fn=32);
 131                 };
 132         };
 133
 134         // side barriers
 135         for (angle = [0, 90, 180]) // omit the bottom one
 136                 rotate([0, 0, angle])
 137                         intersection() {
 138                                 cylinder(r=fraen_diam/2+epsilon, h=infty);
 139                                 translate([-infty/2, side_barrier_x_offset,
 140                                         wall_thickness + pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
 141                                         cube([infty, infty, side_barrier_thickness]);
 142                 };
 143 };
 144
 145 module square_cone() {
 146         difference() {
 147                 hull() {
 148                         translate([0, 0, fraen_h - pin_len])
 149                                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 150                                         h = epsilon);
 151                         for (angle = [0, 90, 180, 270])
 152                                 rotate([0, 0, angle])
 153                                         translate([9.1, 9.1, 0])
 154                                                 cylinder(r=wall_thickness+3.75/2, h = epsilon);
 155                 }
 156                 hull() {
 157                         translate([0, 0, fraen_h - pin_len + epsilon])
 158                                 cylinder(r = fraen_diam/2,
 159                                         h = epsilon);
 160                         for (angle = [0, 90, 180, 270]) {
 161                                 rotate([0, 0, angle])
 162                                         translate([9.1, 9.1, -epsilon])
 163                                                 cylinder(r=3.75/2, h = epsilon);
 164                                 rotate([0, 0, angle+45])
 165                                         translate([pin_offset, 0, fraen_h - pin_len + epsilon])
 166                                                 cylinder(r=pin_diam/2,
 167                                                         h=epsilon, $fn=32);
 168                         }
 169                 }
 170         }
 171 }
 172
 173 rear_spring_w = 4;
 174
 175 module rear_spring() {
 176         translate([0, 0, wall_thickness/2])
 177                 cube([18+2*wall_thickness+3.5, rear_spring_w, wall_thickness], center=true);
 178         difference() {
 179                 rotate([90, 0, 0])
 180                         translate([0, 0, -rear_spring_w/2])
 181                         cylinder(r=6-heatsink_thickness, h = rear_spring_w);
 182                 translate([0, 0, -infty/2+epsilon])
 183                         cube(infty, center=true);
 184         };
 185 };
 186
 187 module heatsink_holder() {
 188         for (angle = [0, 180]) {
 189                 rotate([0, 0, angle])
 190                         translate([9.1+wall_thickness, 0, 6/2])
 191                         cube([3.5/2+wall_thickness, 2*9.1-3.5-0.5, 6], center=true);
 192         }
 193 }
 194
 195 module lens_holder() {
 196         difference() {
 197                 union() {
 198                         translate([0, 0, fraen_h - pin_len])
 199                                 round_part();
 200                         square_cone();
 201                 };
 202
 203                 // 0.5mm hole in the bottom
 204                 // translate([side_barrier_x_offset-epsilon, -0.25, -epsilon])
 205                 translate([0, -0.25, (fraen_h - pin_len)/2])
 206                         cube([infty, 0.5, infty]);
 207
 208                 // cable hole, 2*3mm
 209                 translate([9.1, 0, 6+3])
 210                         rotate([0, 0, 60])
 211                                 cube([infty, 2, 3]);
 212
 213                 // side LED hole, 3mm
 214                 translate([0, 0, fraen_h - pin_len])
 215                         rotate([90, 0, 0])
 216                                 cylinder(r=3.5/2, h=infty, $fn=6);
 217         };
 218
 219         rear_spring();
 220         heatsink_holder();
 221 };
 222
 223 union() {
 224         lens_holder($fn = 128);
 225         translate([clip_x_off, clip_y_off, 0])
 226                 seat_clip();
 227 /*
 228 hull() {
 229         translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
 230                 cube([9.1, epsilon, wall_thickness], center=true);
 231         translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
 232                 cube([9.1, epsilon/2, wall_thickness], center=true);
 233 };
 234
 235 hull() {
 236         translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
 237                 cube([2*.259+3.5, epsilon, wall_thickness], center=true);
 238         translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
 239                 cube([clip_h1+clip_wall, epsilon/2, wall_thickness], center=true);
 240 };
 241
 242 translate([7.5, 13.3, 0])
 243         cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);
 244
 245         }
 246         //translate([-infty/2, -infty/2, 8])
 247         //      cube(infty);
 248 */
 249 };
 250
 251
 252         // vnitrni prumer kruhu by mel byt 30.75mm
 253         // vnejsi prumer aspon 35 mm
 254         // pin od stredu 10.35mm na x a y
 255         // prumer pinu 4 mm
 256         // pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm
 257
 258         // piny by mely pokracovat jeste tak 4mm pod nulu,
 259         // a pak uz muze jit konv.obal do ctverce
 260         // vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
 261         // vrch chladice (s LEDkou) -18.5
 262         // konec nozicek -24.5