// Holder for Fraen FHS-HEB1-LB01-x lens for Luxeon LEDs.
// I use it for my rear lights.

epsilon = 0.01;
infty = 100;
debug = 0;

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;

side_barrier_x_offset = 13;
side_barrier_pin_z_offset = 4.2;
side_barrier_thickness = 2;

heatsink_thickness = 2.5;

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);

clip_y_off = 37;
clip_x_off = 0;

// z-axis is up
module bolt_mount(d, h, w1, w2, fn) {
	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);
	};
};

module seat_clip() {
	difference() {
		union() {
			// right part
			hull() {
				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() {
				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() {
				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]);
			};

			// 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);
		};
		// 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);
	}

}

// upper part of the lens holder
module round_part() {
	difference() {
		cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
			h = front_add + pin_len);

		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);
			};
		}

		// 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);
		};
	};

	// 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 square_cone() {
	difference() {
		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);
			}
		}
	}
}

rear_spring_w = 4;

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);
	};
};

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);
	}
}

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]);

		// cable hole, 2*3mm
		translate([9.1, 0, 6+3])
			rotate([0, 0, 60])
				cube([infty, 2, 3]);

		// side LED hole, 3mm
		translate([0, 0, fraen_h - pin_len])
			rotate([90, 0, 0])
				cylinder(r=3.5/2, h=infty, $fn=6);
	};
		
	rear_spring();
	heatsink_holder();
};

union() {
	lens_holder($fn = 128);
	translate([clip_x_off, clip_y_off, 0])
		seat_clip();
/*
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