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 bolt_mount(d, h, w1, w2, fn) {
  13         difference() {
  14                 translate([0, 0, -epsilon])
  15                         cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
  16                 translate([0, 0, -2*epsilon])
  17                 cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
  18         };
  19 };
  20
  21 clip_h1 = 25; // inner height
  22 clip_h2 = 18; // inner height
  23 clip_l  = 35;
  24 clip_wall = 2;
  25 clip_space = 4;
  26 clip_bolt1_x = 10;
  27 clip_bolt2_x = 25;
  28
  29 module clip_top_circle() {
  30         rotate([-90, 0, 0])
  31         difference() {
  32                 translate([-clip_space/2, 0, 0])
  33                         cylinder(r=clip_wall, h = epsilon, $fn=32);
  34                 translate([-infty/2, clip_wall/2-epsilon, -epsilon])
  35                         cube(infty);
  36                 translate([clip_wall+epsilon, -infty/2, -epsilon])
  37                         cube(infty);
  38         };
  39 };
  40
  41 module seat_clip() {
  42         difference() {
  43                 polyhedron(points = [
  44                         [-clip_wall-clip_space/2, 0, clip_h1/2+clip_wall],
  45                         [-clip_wall-clip_space/2, clip_l, clip_h2/2+clip_wall],
  46                         [-clip_wall-clip_space/2, clip_l, -clip_h2/2],
  47                         [-clip_wall-clip_space/2, 0, -clip_h1/2],
  48                         [ clip_wall+clip_space/2,  0, clip_h1/2+clip_wall],
  49                         [ clip_wall+clip_space/2, clip_l, clip_h2/2+clip_wall],
  50                         [ clip_wall+clip_space/2, clip_l, -clip_h2/2],
  51                         [ clip_wall+clip_space/2, 0, -clip_h1/2],
  52                 ], triangles = [
  53                         [0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
  54                         [0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
  55                         [1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
  56                 ]);
  57                 polyhedron(points = [
  58                         [-clip_space/2, -epsilon, clip_h1/2],
  59                         [-clip_space/2, clip_l+epsilon, clip_h2/2],
  60                         [-clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
  61                         [-clip_space/2, -epsilon, -clip_h1/2-epsilon],
  62                         [ clip_space/2, -epsilon, clip_h1/2],
  63                         [ clip_space/2, clip_l+epsilon, clip_h2/2],
  64                         [ clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
  65                         [ clip_space/2, -epsilon, -clip_h1/2-epsilon],
  66                 ], triangles = [
  67                         [0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
  68                         [0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
  69                         [1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
  70                 ]);
  71                 // bolt holes
  72                 translate([0, clip_bolt1_x, 0])
  73                         rotate([0, 90, 0])
  74                         translate([0, 0, -clip_wall-clip_space/2-epsilon])
  75                         cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
  76                                 $fn = 6);
  77                 translate([0, clip_bolt2_x, 0])
  78                         rotate([0, 90, 0])
  79                         translate([0, 0, -clip_wall-clip_space/2-epsilon])
  80                         cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
  81                                 $fn=6);
  82         };
  83
  84         translate([-clip_space, clip_bolt1_x, 0])
  85         rotate([0, -90, 0])
  86         bolt_mount(6, 3, 7, 14, 6);
  87
  88         translate([-clip_space, clip_bolt2_x, 0])
  89         rotate([0, -90, 0])
  90         bolt_mount(6, 3, 7, 14, 6);
  91
  92         translate([clip_space, clip_bolt1_x, 0])
  93         rotate([0, 90, 0])
  94         bolt_mount(6, 3, 7, 14, 128);
  95
  96         translate([clip_space, clip_bolt2_x, 0])
  97         rotate([0, 90, 0])
  98         bolt_mount(6, 3, 7, 14, 128);
  99 };
 100
 101 /*
 102 seat_clip();
 103
 104 difference() {
 105         union() {
 106                 hull() {
 107                         translate([40, epsilon, 2])
 108                                 clip_top();
 109                         clip_top();
 110                 };
 111
 112                 translate([40, 0, 25])
 113                         rotate([-90, 0, 0])
 114                                 cylinder(r=34/2, h=clip_l);
 115
 116                 hull() {
 117                         translate([clip_space/2+epsilon, 0, 0])
 118                                 cube([clip_wall-epsilon, clip_wall, clip_h1/2+2*clip_wall-epsilon]);
 119                         translate([40, 0, 14+epsilon])
 120                                 cube([clip_wall-epsilon, clip_wall, 34/2]);
 121                 };
 122         };
 123         translate([40, 6, 25])
 124                 rotate([-90, 0, 0]) {
 125                         cylinder(r=31/2, h=clip_l);
 126                         fraen_lens();
 127                         heatsink();
 128                 };
 129 };
 130 */
 131
 132 wall_thickness = 1.5;
 133 fraen_diam = 30.75;
 134 fraen_h = 29.8;
 135 pin_diam = 4;
 136 pin_offset = 10.35*1.4142;
 137 pin_len = 9.2;
 138 front_add = 4;
 139
 140 side_barrier_x_offset = 13;
 141 side_barrier_pin_z_offset = 4.2;
 142 side_barrier_thickness = 2;
 143
 144 module round_part() {
 145         difference() {
 146                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 147                         h = front_add + pin_len);
 148
 149                 hull() {
 150                         translate([0, 0, -epsilon])
 151                                 cylinder(r = fraen_diam/2,
 152                                         h = pin_len + front_add + 2*epsilon);
 153                         for (angle = [0, 90, 180, 270]) {
 154                                 rotate([0, 0, angle+45])
 155                                         translate([pin_offset, 0, -epsilon])
 156                                                 cylinder(r=pin_diam/2,
 157                                                         h=epsilon, $fn=32);
 158                         };
 159                 }
 160
 161                 // front cone
 162                 translate([0, 0, pin_len + 0.5*wall_thickness - epsilon])
 163                         cylinder(r1 = fraen_diam/2,
 164                                 r2 = (fraen_diam+pin_diam + wall_thickness)/2,
 165                                 h = front_add + 2*epsilon);
 166                 // pin holes
 167                 for (angle = [0, 90, 180, 270]) {
 168                         rotate([0, 0, angle+45])
 169                                 translate([pin_offset, 0, epsilon])
 170                                         cylinder(r=pin_diam/2,
 171                                                 h=pin_len+epsilon, $fn=32);
 172                 };
 173         };
 174
 175         // side barriers
 176         for (angle = [0, 90, 180]) // omit the bottom one
 177                 rotate([0, 0, angle])
 178                         intersection() {
 179                                 cylinder(r=fraen_diam/2+epsilon, h=infty);
 180                                 translate([-infty/2, side_barrier_x_offset,
 181                                         wall_thickness + pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
 182                                         cube([infty, infty, side_barrier_thickness]);
 183                 };
 184 };
 185
 186 module square_cone() {
 187         difference() {
 188                 hull() {
 189                         translate([0, 0, fraen_h - pin_len])
 190                                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 191                                         h = epsilon);
 192                         for (angle = [0, 90, 180, 270])
 193                                 rotate([0, 0, angle])
 194                                         translate([9.1, 9.1, 0])
 195                                                 cylinder(r=wall_thickness+3.75/2, h = epsilon);
 196                 }
 197                 hull() {
 198                         translate([0, 0, fraen_h - pin_len + epsilon])
 199                                 cylinder(r = fraen_diam/2,
 200                                         h = epsilon);
 201                         for (angle = [0, 90, 180, 270]) {
 202                                 rotate([0, 0, angle])
 203                                         translate([9.1, 9.1, -epsilon])
 204                                                 cylinder(r=3.75/2, h = epsilon);
 205                                 rotate([0, 0, angle+45])
 206                                         translate([pin_offset, 0, fraen_h - pin_len + epsilon])
 207                                                 cylinder(r=pin_diam/2,
 208                                                         h=epsilon, $fn=32);
 209                         }
 210                 }
 211         }
 212 }
 213
 214 rear_spring_w = 4;
 215
 216 module rear_spring() {
 217         translate([0, 0, wall_thickness/2])
 218                 cube([18+2*wall_thickness+3.5, rear_spring_w, wall_thickness], center=true);
 219         difference() {
 220                 rotate([90, 0, 0])
 221                         translate([0, 0, -rear_spring_w/2])
 222                         cylinder(r=6-heatsink_thickness, h = rear_spring_w);
 223                 translate([0, 0, -infty/2+epsilon])
 224                         cube(infty, center=true);
 225         };
 226 };
 227
 228 module heatsink_holder() {
 229         for (angle = [0, 180]) {
 230                 rotate([0, 0, angle])
 231                         translate([9.1+wall_thickness, 0, 6/2])
 232                         cube([3.5/2+wall_thickness, 2*9.1-3.5-0.5, 6], center=true);
 233         }
 234 }
 235
 236 module lens_holder() {
 237         difference() {
 238                 union() {
 239                         translate([0, 0, fraen_h - pin_len])
 240                                 round_part();
 241                         square_cone();
 242                 };
 243
 244                 // 0.5mm hole in the bottom
 245                 // translate([side_barrier_x_offset-epsilon, -0.25, -epsilon])
 246                 translate([0, -0.25, (fraen_h - pin_len)/2])
 247                         cube([infty, 0.5, infty]);
 248
 249                 // cable hole, 2*3mm
 250                 translate([9.1, 0, 6+3])
 251                         rotate([0, 0, 60])
 252                                 cube([infty, 2, 3]);
 253
 254                 // side LED hole, 3mm
 255                 translate([0, 0, fraen_h - pin_len])
 256                         rotate([90, 0, 0])
 257                                 cylinder(r=3.5/2, h=infty, $fn=6);
 258         };
 259
 260         rear_spring();
 261         heatsink_holder();
 262 };
 263
 264 difference() {
 265         union() {
 266         lens_holder($fn = 128);
 267
 268 translate([20, 40, 0])
 269         rotate([90, 0, -90])
 270                 seat_clip(, $fn=128);
 271
 272 hull() {
 273         translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
 274                 cube([9.1, epsilon, wall_thickness], center=true);
 275         translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
 276                 cube([9.1, epsilon/2, wall_thickness], center=true);
 277 };
 278
 279 hull() {
 280         translate([0, 9.1+3.5/2+epsilon, wall_thickness/2])
 281                 cube([2*.259+3.5, epsilon, wall_thickness], center=true);
 282         translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
 283                 cube([clip_h1+clip_wall, epsilon/2, wall_thickness], center=true);
 284 };
 285
 286 translate([7.5, 13.3, 0])
 287         cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);
 288
 289         }
 290 /*
 291         translate([-infty/2, -infty/2, 8])
 292                 cube(infty);
 293 */
 294 };
 295
 296
 297         // vnitrni prumer kruhu by mel byt 30.75mm
 298         // vnejsi prumer aspon 35 mm
 299         // pin od stredu 10.35mm na x a y
 300         // prumer pinu 4 mm
 301         // pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm
 302
 303         // piny by mely pokracovat jeste tak 4mm pod nulu,
 304         // a pak uz muze jit konv.obal do ctverce
 305         // vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
 306         // vrch chladice (s LEDkou) -18.5
 307         // konec nozicek -24.5