From 818fee1bacf0da1a03d6ffec9b164d8136e009c8 Mon Sep 17 00:00:00 2001
From: "Jan \"Yenya\" Kasprzak" <kas@fi.muni.cz>
Date: Tue, 18 Aug 2020 17:00:57 +0200
Subject: [PATCH] rearlight-dual holder

---
 parts/rearlight-dual.scad | 160 ++++++++++++++++++++++++++++++++++++++
 1 file changed, 160 insertions(+)
 create mode 100644 parts/rearlight-dual.scad

diff --git a/parts/rearlight-dual.scad b/parts/rearlight-dual.scad
new file mode 100644
index 0000000..9746f27
--- /dev/null
+++ b/parts/rearlight-dual.scad
@@ -0,0 +1,160 @@
+// Holder for two Fraen FHS-HEB1-LB01-x lenses for Luxeon LEDs.
+
+eps = 0.01;
+infty = 100;
+
+wall = 1.5;
+lens_dist = 48;
+fraen_diam = 30.90;
+fraen_h = 29.3;
+pin_diam = 4;
+pin_offset = 10.35*1.4142;
+pin_len = 9.2;
+front_add = 4;
+
+rear_pin_dist = 9.1;
+rear_pin_diam = 3.25;
+
+side_barrier_x_offset = 13;
+side_barrier_pin_z_offset = 4.2;
+side_barrier_thickness = 2;
+
+heatsink_thickness = 2;
+heatsink_w = 15 + 0.5;
+heatsink_l = lens_dist + 1.5*heatsink_w;
+heatsink_z = 1 + wall;
+heatsink_hole_sep = 2*wall;
+
+clip_h1 = 27; // front height (on the heatsink side)
+clip_h2 = 20; // rear height (on the lens side)
+clip_l  = 28;
+clip_wall = wall;
+clip_space = 3.5;
+clip_bolt1_z = 6;
+clip_bolt1_x = 19.5;
+clip_bolt2_z = 22;
+clip_bolt2_x = 21;
+clip_angle = 18;
+clip_top_xoff = clip_l*tan(clip_angle);
+
+clip_y_off = 34;
+clip_x_off = 2;
+clip_x_rot = -3;
+
+screw_yoff = 13;
+screw_d = 4;
+screw_d2 = 12;
+screw_h = 8;
+screw_wall = 3*wall;
+
+	// 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
+
+front_len = fraen_h + wall;
+rear_mount_depth = 10;
+rear_sep = 0.3;
+
+module front_body() {
+	hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 0]) {
+		cylinder(r = fraen_diam/2 + pin_diam/2 + wall,
+			h = front_len + wall);
+	}
+}
+
+module front_part() {
+	difference() {
+		front_body();
+		for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 0]) {
+			// front narower ring
+			translate([0, 0, -eps])
+				cylinder(r = fraen_diam/2 - wall, h = wall+2*eps);
+			// main holes
+			translate([0, 0, wall])
+				cylinder(r = fraen_diam/2 , h = front_len + eps);
+			// pin holes
+			for (angle = [0, 90, 180, 270]) {
+				rotate([0, 0, angle+45])
+					translate([pin_offset, 0, wall])
+						cylinder(r=pin_diam/2,
+							h=front_len + eps);
+			};
+		}
+		// rear mount
+		difference() {
+		hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, front_len - rear_mount_depth] ) {
+			cylinder(r = fraen_diam/2 + pin_diam/2,
+				h = wall + rear_mount_depth + eps);
+		}
+		for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, front_len])
+		for (angle = [0, 90, 180, 270]) rotate([0, 0, angle])
+			translate([rear_pin_dist, rear_pin_dist, 0])
+				cylinder(r=rear_pin_diam/2, h = wall);
+		}
+		// screw holes
+		for (y = [-1, 1]) translate([0, y*screw_yoff, -eps])
+			cylinder(r = screw_d/2,
+				h = front_len + wall + 2*eps);
+	}
+}
+
+module rear_body() {
+	hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 0] ) {
+		cylinder(r = fraen_diam/2 + pin_diam/2 - rear_sep,
+			h = wall + rear_mount_depth);
+	}
+}
+
+module rear_part() {
+	difference() {
+		rear_body();
+		// pins
+		for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, wall])
+		for (angle = [0, 90, 180, 270]) rotate([0, 0, angle])
+			translate([rear_pin_dist, rear_pin_dist, 0])
+				cylinder(r=rear_pin_diam/2, h = rear_mount_depth+wall+eps);
+		// pins hull
+		// for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, 2*wall]) hull()
+		// for (angle = [0, 90, 180, 270]) rotate([0, 0, angle])
+		// 	translate([rear_pin_dist, rear_pin_dist, 0])
+		// 		cylinder(r=rear_pin_diam/2, h = rear_mount_depth);
+		difference() {
+			// outer wall
+			hull() for (x = [-1, 1]) scale([x, 1, 1]) translate([lens_dist/2, 0, heatsink_z + heatsink_thickness] ) {
+				cylinder(r = fraen_diam/2 + pin_diam/2 - rear_sep - wall,
+					h = rear_mount_depth + wall + eps);
+			}
+			// minus screw mounts
+			for (y = [-1, 1]) translate([0, y*screw_yoff, 0])
+				cylinder(r = screw_d/2 + screw_wall,
+					h = rear_mount_depth + wall + eps);
+		}
+		// screw holes
+		for (y = [-1, 1]) translate([0, y*screw_yoff, -eps])
+			cylinder(r = screw_d/2,
+				h = rear_mount_depth + wall + 2*eps);
+		// heatsink
+		translate([-heatsink_l/2, -heatsink_w/2, heatsink_z])
+			cube([heatsink_l, heatsink_w, rear_mount_depth]);
+		// heatsink back hole
+		translate([-heatsink_l/2 + heatsink_hole_sep,
+				-heatsink_w/2 + heatsink_hole_sep, -eps])
+			cube([heatsink_l-2*heatsink_hole_sep,
+				heatsink_w-2*heatsink_hole_sep,
+				heatsink_z+2*eps]);
+	}
+}
+
+translate([0, fraen_diam *1.5, 0])
+	front_part($fn = 128);
+
+rear_part($fn = 128);
+
-- 
2.39.3