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(r=4/2, h=23, $fn=32);
  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=30.9/2, h=23);
  20         assign(off=10.35) {
  21         translate([off, off, 0])   fraen_lens_pin();
  22         translate([off, -off, 0])  fraen_lens_pin();
  23         translate([-off, off, 0])  fraen_lens_pin();
  24         translate([-off, -off, 0]) fraen_lens_pin();
  25         };
  26 };
  27
  28 module heatsink() {
  29         translate([-heatsink_length+ 5 +heatsink_width/2, -heatsink_width/2, 0])
  30                 cube([heatsink_length, heatsink_width, heatsink_thickness]);
  31 }
  32
  33 module seat_holder() {
  34         translate([-41, 8, 29])
  35                 cube([3, 30, 60], center=true);
  36 };
  37
  38 module stem_ellipse(h, w, x, y) {
  39         translate([x, y, 0])
  40         difference() {
  41                 translate([0, 0, 6])
  42                         scale([1, w/2, h-6])
  43                                 rotate([0, 90, 0])
  44                                         cylinder(r=1, h=epsilon);
  45                 translate([0, 0, -100]) cube([200, 200, 200], center=true);
  46         };
  47 }
  48
  49 module main() {
  50         difference() {
  51                 union() {
  52                         hull() {
  53                                 cylinder(r=34/2, h=33);
  54                                 stem_ellipse(h = 15, w = 10, x = -21, y=-5);
  55                         };
  56                         hull() {
  57                                 stem_ellipse(h = 15, w = 10, x = -21-epsilon, y=-5);
  58                                 stem_ellipse(h = 15, w = 10, x = -33, y=-5);
  59                         };
  60                         hull() {
  61                                 stem_ellipse(h = 15, w = 10, x = -33-epsilon, y=-5);
  62                                 stem_ellipse(h = 25, w = 15, x = -40+epsilon, y=-2.5);
  63                         };
  64                         translate([-41, 5, 52/2])
  65                                 cube([7, 30, 52], center=true);
  66                         // bolt hole ring
  67                         translate([-44+epsilon, 10, 40]) rotate([0, -90, 0]) difference() {
  68                                 cylinder(r1=9, r2=6, h=3);
  69                                 translate([0, 0, -epsilon])
  70                                         cylinder(r=5, h=3+2*epsilon, $fn=6);
  71                         }
  72                         // screw hole ring
  73                         translate([-38-epsilon, 10, 40]) rotate([0, 90, 0]) difference() {
  74                                 cylinder(r1=9, r2=6, h=3);
  75                                 translate([0, 0, -epsilon])
  76                                         cylinder(r=5, h=3+2*epsilon);
  77                         }
  78                 };
  79                 translate([-47, 10, 40]) rotate([0, 90, 0])
  80                         cylinder(r=2.5, h=12);
  81                 translate([0, 0, 6-heatsink_thickness])
  82                         cylinder(r=31/2, h=32);
  83                 translate([0, 0, 6])
  84                         fraen_lens();
  85                 heatsink();
  86                 seat_holder();
  87         }
  88         if (debug == 1) {
  89                 translate([0, 0, 6]) color("gray") fraen_lens();
  90                 color("lightblue") heatsink();
  91                 color("lightgreen") seat_holder();
  92         }
  93 }
  94
  95 module bolt_mount(d, h, w1, w2, fn) {
  96         difference() {
  97                 translate([0, 0, -epsilon])
  98                         cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
  99                 translate([0, 0, -2*epsilon])
 100                 cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
 101         };
 102 };
 103
 104 clip_h1 = 25; // inner height
 105 clip_h2 = 18; // inner height
 106 clip_l  = 35;
 107 clip_wall = 2;
 108 clip_space = 4;
 109 clip_bolt1_x = 10;
 110 clip_bolt2_x = 25;
 111
 112 module clip_top_circle() {
 113         rotate([-90, 0, 0])
 114         difference() {
 115                 translate([-clip_space/2, 0, 0])
 116                         cylinder(r=clip_wall, h = epsilon, $fn=32);
 117                 translate([-infty/2, clip_wall/2-epsilon, -epsilon])
 118                         cube(infty);
 119                 translate([clip_wall+epsilon, -infty/2, -epsilon])
 120                         cube(infty);
 121         };
 122 };
 123
 124 module clip_top() {
 125         hull() {
 126                 translate([0, 0, clip_h1/2+clip_wall])
 127                         clip_top_circle();
 128                 translate([0, clip_l-epsilon, clip_h2/2+clip_wall])
 129                         clip_top_circle();
 130         };
 131 };
 132
 133 module seat_clip() {
 134         difference() {
 135                 polyhedron(points = [
 136                         [-clip_wall-clip_space/2, 0, clip_h1/2+clip_wall],
 137                         [-clip_wall-clip_space/2, clip_l, clip_h2/2+clip_wall],
 138                         [-clip_wall-clip_space/2, clip_l, -clip_h2/2],
 139                         [-clip_wall-clip_space/2, 0, -clip_h1/2],
 140                         [ clip_wall+clip_space/2,  0, clip_h1/2+clip_wall],
 141                         [ clip_wall+clip_space/2, clip_l, clip_h2/2+clip_wall],
 142                         [ clip_wall+clip_space/2, clip_l, -clip_h2/2],
 143                         [ clip_wall+clip_space/2, 0, -clip_h1/2],
 144                 ], triangles = [
 145                         [0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
 146                         [0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
 147                         [1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
 148                 ]);
 149                 polyhedron(points = [
 150                         [-clip_space/2, -epsilon, clip_h1/2],
 151                         [-clip_space/2, clip_l+epsilon, clip_h2/2],
 152                         [-clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
 153                         [-clip_space/2, -epsilon, -clip_h1/2-epsilon],
 154                         [ clip_space/2, -epsilon, clip_h1/2],
 155                         [ clip_space/2, clip_l+epsilon, clip_h2/2],
 156                         [ clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
 157                         [ clip_space/2, -epsilon, -clip_h1/2-epsilon],
 158                 ], triangles = [
 159                         [0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
 160                         [0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
 161                         [1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
 162                 ]);
 163                 // bolt holes
 164                 translate([0, clip_bolt1_x, 0])
 165                         rotate([0, 90, 0])
 166                         translate([0, 0, -clip_wall-clip_space/2-epsilon])
 167                         cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
 168                                 $fn = 6);
 169                 translate([0, clip_bolt2_x, 0])
 170                         rotate([0, 90, 0])
 171                         translate([0, 0, -clip_wall-clip_space/2-epsilon])
 172                         cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
 173                                 $fn=6);
 174         };
 175
 176         translate([-clip_space, clip_bolt1_x, 0])
 177         rotate([0, -90, 0])
 178         bolt_mount(6, 3, 7, 14, 6);
 179
 180         translate([-clip_space, clip_bolt2_x, 0])
 181         rotate([0, -90, 0])
 182         bolt_mount(6, 3, 7, 14, 6);
 183
 184         translate([clip_space, clip_bolt1_x, 0])
 185         rotate([0, 90, 0])
 186         bolt_mount(6, 3, 7, 14, 128);
 187
 188         translate([clip_space, clip_bolt2_x, 0])
 189         rotate([0, 90, 0])
 190         bolt_mount(6, 3, 7, 14, 128);
 191
 192         clip_top();
 193 };
 194
 195 /*
 196 seat_clip();
 197
 198 difference() {
 199         union() {
 200                 hull() {
 201                         translate([40, epsilon, 2])
 202                                 clip_top();
 203                         clip_top();
 204                 };
 205
 206                 translate([40, 0, 25])
 207                         rotate([-90, 0, 0])
 208                                 cylinder(r=34/2, h=clip_l);
 209
 210                 hull() {
 211                         translate([clip_space/2+epsilon, 0, 0])
 212                                 cube([clip_wall-epsilon, clip_wall, clip_h1/2+2*clip_wall-epsilon]);
 213                         translate([40, 0, 14+epsilon])
 214                                 cube([clip_wall-epsilon, clip_wall, 34/2]);
 215                 };
 216         };
 217         translate([40, 6, 25])
 218                 rotate([-90, 0, 0]) {
 219                         cylinder(r=31/2, h=clip_l);
 220                         fraen_lens();
 221                         heatsink();
 222                 };
 223 };
 224 */
 225
 226 wall_thickness = 1.5;
 227 fraen_diam = 30.75;
 228 fraen_h = 29.8;
 229 pin_diam = 4;
 230 pin_offset = 10.35*1.4142;
 231 pin_len = 9.2;
 232 front_add = 4;
 233
 234 side_barrier_x_offset = 13;
 235 side_barrier_pin_z_offset = 4.2;
 236 side_barrier_thickness = 2;
 237
 238 module round_part() {
 239         difference() {
 240                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 241                         h = front_add + pin_len + wall_thickness);
 242                 translate([0, 0, -epsilon])
 243                         cylinder(r = fraen_diam/2,
 244                         h = pin_len + wall_thickness + front_add + 2*epsilon);
 245                 // front cone
 246                 translate([0, 0, pin_len + 1.5*wall_thickness - epsilon])
 247                         cylinder(r1 = fraen_diam/2,
 248                                 r2 = (fraen_diam+pin_diam + wall_thickness)/2,
 249                                 h = front_add + 2*epsilon);
 250                 // pin holes
 251                 for (angle = [0, 90, 180, 270]) {
 252                         rotate([0, 0, angle+45])
 253                                 translate([pin_offset, 0, wall_thickness-epsilon])
 254                                         cylinder(r=pin_diam/2,
 255                                                 h=pin_len+epsilon, $fn=32);
 256                 };
 257         };
 258
 259         // side barriers
 260         for (angle = [0, 90, 180]) // omit the bottom one
 261                 rotate([0, 0, angle])
 262                         intersection() {
 263                                 cylinder(r=fraen_diam/2+epsilon, h=infty);
 264                                 translate([-infty/2, side_barrier_x_offset,
 265                                         wall_thickness + pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
 266                                         cube([infty, infty, side_barrier_thickness]);
 267                 };
 268 };
 269
 270 module square_cone() {
 271         difference() {
 272                 hull() {
 273                         translate([0, 0, fraen_h - pin_len - wall_thickness])
 274                                 cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
 275                                         h = epsilon);
 276                         for (angle = [0, 90, 180, 270])
 277                                 rotate([0, 0, angle])
 278                                         translate([9, 9, 0])
 279                                                 cylinder(r=wall_thickness+3.5/2, h = epsilon);
 280                 }
 281                 hull() {
 282                         translate([0, 0, fraen_h - pin_len - wall_thickness+epsilon])
 283                                 cylinder(r = fraen_diam/2,
 284                                         h = epsilon);
 285                         for (angle = [0, 90, 180, 270])
 286                                 rotate([0, 0, angle])
 287                                         translate([9, 9, -epsilon])
 288                                                 cylinder(r=3.5/2, h = epsilon);
 289                 }
 290         }
 291 }
 292
 293 rear_spring_w = 4;
 294
 295 module rear_spring() {
 296         translate([0, 0, wall_thickness/2])
 297                 cube([18+2*wall_thickness+3.5, rear_spring_w, wall_thickness], center=true);
 298         difference() {
 299                 rotate([90, 0, 0])
 300                         translate([0, 0, -rear_spring_w/2])
 301                         cylinder(r=6-heatsink_thickness, h = rear_spring_w);
 302                 translate([0, 0, -infty/2+epsilon])
 303                         cube(infty, center=true);
 304         };
 305 };
 306
 307 module heatsink_holder() {
 308         for (angle = [0, 180]) {
 309                 rotate([0, 0, angle])
 310                         translate([9+wall_thickness, 0, 6/2])
 311                         cube([3.5/2+wall_thickness, 2*9-3.5-0.5, 6], center=true);
 312         }
 313 }
 314
 315 module lens_holder() {
 316         difference() {
 317                 union() {
 318                         translate([0, 0, fraen_h - pin_len - wall_thickness])
 319                                 round_part();
 320                         square_cone();
 321                 };
 322
 323                 // 0.5mm hole in the bottom
 324                 // translate([side_barrier_x_offset-epsilon, -0.25, -epsilon])
 325                 translate([0, -0.25, (fraen_h - pin_len - wall_thickness)/2])
 326                         cube([infty, 0.5, infty]);
 327
 328                 // cable hole, 2*3mm
 329                 translate([9, 0, 6+3])
 330                         rotate([0, 0, 60])
 331                                 cube([infty, 2, 3]);
 332         };
 333
 334         rear_spring();
 335         heatsink_holder();
 336 };
 337
 338 lens_holder($fn = 128);
 339
 340 translate([20, 40, 0])
 341         rotate([90, 0, -90])
 342                 seat_clip(, $fn=128);
 343
 344 hull() {
 345         translate([0, 9+3.5/2+epsilon, wall_thickness/2])
 346                 cube([2*9+3.5, epsilon, wall_thickness], center=true);
 347         translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
 348                 cube([clip_h1+clip_wall, epsilon/2, wall_thickness], center=true);
 349 };
 350
 351 translate([7.5, 13.3, 0])
 352         cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);
 353
 354         // vnitrni prumer kruhu by mel byt 30.75mm
 355         // vnejsi prumer aspon 35 mm
 356         // pin od stredu 10.35mm na x a y
 357         // prumer pinu 4 mm
 358         // pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm
 359
 360         // piny by mely pokracovat jeste tak 4mm pod nulu,
 361         // a pak uz muze jit konv.obal do ctverce
 362         // vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
 363         // vrch chladice (s LEDkou) -18.5
 364         // konec nozicek -24.5