Created
December 18, 2011 09:04
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lasercut enclosure design, triggers a bug in openscad 2011.12.13
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/** | |
* Rough box measurements (based on the electronics board size) | |
* | |
* Height 15cm -> 10cm should be enough | |
* Width 30cm | |
* Depth 20cm | |
* | |
* Coilforms: | |
* 4.0” DIA | |
* 3.22” DIA | |
* Torus thickness 72mm | |
* | |
* Fans: | |
* 60mm*60mm (4mm mounting holes) | |
* | |
* Holes for the power and interrupter signal wires will be drilled/milled afterwards | |
*/ | |
/************************** | |
* Basic units. | |
* | |
* Originally by Hans Häggström, 2010. | |
* Dual licenced under Creative Commons Attribution-Share Alike 3.0 and LGPL2 or later | |
*/ | |
mm = 1; | |
cm = 10 * mm; | |
dm = 100 * mm; | |
m = 1000 * mm; | |
inch = 25.4 * mm; | |
M3 = 3*mm; | |
M4 = 4*mm; | |
M5 = 5*mm; | |
M6 = 6*mm; | |
M8 = 8*mm; | |
// When a small distance is needed to overlap shapes for boolean cutting, etc. | |
epsilon = 0.01*mm; | |
TAU = 6.2831853071; //2*PI, see http://tauday.com/ | |
PI = TAU/2; | |
/************************/ | |
/*********************** | |
* Some globally needed variables | |
*/ | |
material_z = 8*mm; | |
box_z = 10*cm + 2*material_z; // We need the 10cm on the *inside* | |
box_x = 30*cm; | |
box_y = 20*cm; | |
secondary_coil_r = (3.22*inch)/2; | |
primary_coil_r = (4.0*inch)/2; | |
front_top_slot_offset = 20; | |
front_left_slot_offset = 20; | |
front_leg_z=13; | |
/************************/ | |
/*********************** | |
* Coilforms for visually checking the design | |
*/ | |
module coilform_3d(cr,ch) | |
{ | |
$fa=0.5; | |
$fs=0.1; | |
difference() | |
{ | |
cylinder(r=cr, h=ch); | |
translate([0,0,-1]) | |
{ | |
cylinder(r=cr-2, h=ch+2); | |
} | |
} | |
} | |
module secondary_coilform_3d() | |
{ | |
cr=secondary_coil_r; | |
ch=11*inch; | |
coilform_3d(cr, ch); | |
translate([0,0,11*inch]) | |
{ | |
coilform_torus_3d(cr); | |
} | |
} | |
module coilform_torus_3d(cr) | |
{ | |
th=72/2; | |
ri=cr; | |
$fn=50; | |
translate([0,0,th]) | |
{ | |
rotate_extrude(convexity = 10) | |
{ | |
translate([ri, 0, 0]) | |
{ | |
circle(r = th); | |
} | |
} | |
} | |
} | |
module primary_coilform_3d() | |
{ | |
cr=primary_coil_r; | |
ch=62; | |
coilform_3d(cr, ch); | |
} | |
module coilforms_3d() | |
{ | |
primary_coilform_3d(); | |
secondary_coilform_3d(); | |
} | |
//coilforms_3d(); | |
/************************/ | |
module slot_2d(w,d=material_z*1.1) | |
{ | |
$fa=0.5; | |
$fs=0.1; | |
slot_corner_r=0.25; | |
union() | |
{ | |
// These cylinders are to avoid weak points in the acrylic, see http://blog.ponoko.com/2010/06/17/how-to-make-snug-joints-in-acrylic/ | |
square([w,d]); | |
circle(r=slot_corner_r); | |
translate([0,d,0]) | |
{ | |
circle(r=slot_corner_r); | |
} | |
translate([w,0,0]) | |
{ | |
circle(r=slot_corner_r); | |
translate([0,d,0]) | |
{ | |
circle(r=slot_corner_r); | |
} | |
} | |
} | |
} | |
//slot_2d(30); | |
module span(r_inner, width, tan_angle) | |
{ | |
$fa=0.5; | |
$fs=0.1; | |
cr = width/2; | |
a_len = r_inner+width; | |
mirror([1,0,0]) | |
{ | |
union() | |
{ | |
intersection() | |
{ | |
// Full circle | |
difference() | |
{ | |
circle(r=r_inner+width); | |
circle(r=r_inner); | |
} | |
// right-angled triagle | |
translate([0,a_len,0]) | |
{ | |
mirror([1,1,0]) | |
{ | |
polygon(points=[[0,0],[a_len,0],[0,tan(tan_angle) * a_len]], paths=[[0,1,2]]); | |
} | |
} | |
} | |
translate([0,r_inner+cr,0]) | |
{ | |
circle(r=cr, center=false); | |
} | |
rotate([0,0,tan_angle]) | |
{ | |
translate([0,r_inner+cr,0]) | |
{ | |
circle(r=cr, center=false); | |
} | |
} | |
} | |
} | |
} | |
//span(primary_coil_r*2+2, 5, 30); | |
module multi_span_test(tan_angle) | |
{ | |
for(i=[0:(360/tan_angle)-1]) | |
{ | |
rotate([0,0,i*tan_angle]) | |
{ | |
span(primary_coil_r*2+2, 5, tan_angle); | |
} | |
} | |
} | |
//multi_span_test(30); | |
module slot_tight_2d(w,d=material_z*1.1) | |
{ | |
$fa=0.5; | |
$fs=0.1; | |
tf=d/20; | |
difference() | |
{ | |
slot_2d(w,d); | |
translate([-d+tf,d/2,0]) | |
{ | |
circle(r=d); | |
} | |
translate([w+d-tf,d/2,0]) | |
{ | |
circle(r=d); | |
} | |
} | |
} | |
//slot_tight_2d(30); | |
module front_back_top_bottom_slots() | |
{ | |
translate([front_top_slot_offset,0]) | |
{ | |
slot_tight_2d(box_x-front_top_slot_offset*2); | |
} | |
} | |
module front_back_left_right_slots() | |
{ | |
translate([0,front_left_slot_offset]) | |
{ | |
rotate([0,0,90]) | |
{ | |
slot_tight_2d(box_z-front_top_slot_offset*2); | |
} | |
} | |
} | |
module back_et_front_2d() | |
{ | |
leg_w=25; | |
difference() | |
{ | |
translate([0,-front_leg_z]) | |
{ | |
// Main face with "legs" | |
difference() | |
{ | |
square([box_x, box_z+front_leg_z]); | |
translate([leg_w,-epsilon]) | |
{ | |
square([box_x-2*leg_w, front_leg_z-material_z/2]); | |
} | |
} | |
} | |
// Slot for top plate | |
translate([0,box_z-material_z+epsilon]) | |
{ | |
front_back_top_bottom_slots(); | |
} | |
// Slot for bottom plate | |
translate([0,0]) | |
{ | |
front_back_top_bottom_slots(); | |
} | |
// Slot for left plate | |
translate([material_z-epsilon,0]) | |
{ | |
front_back_left_right_slots(); | |
} | |
// Slot for right plate | |
translate([box_x+epsilon,0]) | |
{ | |
front_back_left_right_slots(); | |
} | |
} | |
} | |
//back_et_front_2d(); | |
module back_2d() | |
{ | |
lightning_holes = 5; | |
difference() | |
{ | |
back_et_front_2d(); | |
// 5 HV lightning shaped ventilation holes | |
for(i=[0:lightning_holes-1]) | |
{ | |
translate([((box_x-2*material_z)/lightning_holes)*i+6*material_z,20,0]) | |
{ | |
mirror([1,0,0]) | |
{ | |
scale([2,2,2]) | |
{ | |
hv_lightning(); | |
} | |
} | |
} | |
} | |
} | |
// ventilation holes ? | |
} | |
module back_3d() | |
{ | |
color([(34/255), (232/255), (234/255), 0.75]) | |
{ | |
translate([0,box_y,0]) | |
{ | |
rotate([90,0,0]) | |
{ | |
linear_extrude(height=material_z) | |
{ | |
back_2d(); | |
} | |
} | |
} | |
} | |
} | |
//back_3d(); | |
module front_2d() | |
{ | |
back_et_front_2d(); | |
// ventilation holes ? | |
} | |
module front_3d() | |
{ | |
color([(34/255), (232/255), (234/255), 0.75]) | |
{ | |
translate([0,material_z,0]) | |
{ | |
rotate([90,0,0]) | |
{ | |
linear_extrude(height=material_z) | |
{ | |
front_2d(); | |
} | |
} | |
} | |
} | |
} | |
//front_3d(); | |
module top_bottom_front_back_slots() | |
{ | |
translate([-epsilon,0]) | |
{ | |
slot_2d(front_top_slot_offset+2*epsilon); | |
} | |
translate([box_x-front_top_slot_offset,0]) | |
{ | |
slot_2d(front_top_slot_offset+epsilon); | |
} | |
} | |
module top_bottom_plate_2d() | |
{ | |
difference() | |
{ | |
square([box_x, box_y]); | |
translate([-epsilon,-epsilon]) | |
{ | |
top_bottom_front_back_slots(); | |
} | |
translate([-epsilon, box_y-material_z+epsilon]) | |
{ | |
top_bottom_front_back_slots(); | |
} | |
} | |
} | |
module top_2d() | |
{ | |
$fa=0.5; | |
$fs=0.1; | |
primary_hole_width = 5; // mm | |
primary_hole_size = 10; // degrees | |
primary_hole_count = 8; | |
difference() | |
{ | |
top_bottom_plate_2d(); | |
translate([box_x/2, box_y/2]) // center | |
{ | |
// Hole for securing the coilforms | |
circle(r=M5); | |
// Holes for passing through the primary coil wires (for various tunings) | |
for(i=[0:primary_hole_count-1]) | |
{ | |
rotate([0,0,i*(360/primary_hole_count)]) | |
{ | |
span(primary_coil_r+3, primary_hole_width, primary_hole_size); | |
} | |
} | |
} | |
} | |
} | |
//top_2d(); | |
module top_3d() | |
{ | |
color([(71/255), (48/255), (212/255), 0.75]) | |
{ | |
translate([0,0,box_z-material_z]) | |
{ | |
linear_extrude(height=material_z) | |
{ | |
top_2d(); | |
} | |
} | |
} | |
} | |
//top_3d(); | |
module bottom_2d() | |
{ | |
top_bottom_plate_2d(); | |
// TODO: Add ventilation holes/slots ? | |
} | |
//bottom_2d(); | |
module bottom_3d() | |
{ | |
color([(71/255), (48/255), (212/255), 0.75]) | |
{ | |
linear_extrude(height=material_z) | |
{ | |
bottom_2d(); | |
} | |
} | |
} | |
//bottom_3d(); | |
module left_right_front_back_slots() | |
{ | |
//front_left_slot_offset | |
translate([-epsilon,0]) | |
{ | |
slot_2d(front_left_slot_offset-material_z); | |
} | |
translate([box_z-material_z-front_left_slot_offset+epsilon,0]) | |
{ | |
slot_2d(front_left_slot_offset-material_z); | |
} | |
} | |
module left_right_plate() | |
{ | |
difference() | |
{ | |
square([box_z-(2*material_z),box_y]); | |
translate([0,0]) | |
{ | |
left_right_front_back_slots(); | |
} | |
translate([0,box_y-material_z+epsilon]) | |
{ | |
left_right_front_back_slots(); | |
} | |
} | |
} | |
module left_2d() | |
{ | |
lightning_holes = 3; | |
difference() | |
{ | |
left_right_plate(); | |
// 3 HV lightning shaped ventilation holes | |
for(i=[0:lightning_holes-1]) | |
{ | |
translate([40,((box_y-2*material_z)/lightning_holes)*i+5.5*material_z,0]) | |
{ | |
mirror([0,0,0]) | |
{ | |
rotate([0,0,-90]) | |
{ | |
hv_lightning(); | |
} | |
} | |
} | |
} | |
// Ventilation hole, the leftover doubles as stiffener bottom plate | |
translate([material_z, 3*material_z,0]) | |
{ | |
square([front_leg_z, box_y-6*material_z]); | |
} | |
} | |
} | |
//left_2d(); | |
module left_3d() | |
{ | |
color([(34/255), (222/255), (52/255), 0.75]) | |
{ | |
translate([material_z,0,material_z]) | |
{ | |
rotate([0,-90,0]) | |
{ | |
linear_extrude(height=material_z) | |
{ | |
left_2d(); | |
} | |
} | |
} | |
} | |
} | |
//left_3d(); | |
module right_2d() | |
{ | |
lightning_holes = 3; | |
difference() | |
{ | |
left_right_plate(); | |
// 3 HV lightning shaped ventilation holes | |
for(i=[0:lightning_holes-1]) | |
{ | |
translate([40,((box_y-2*material_z)/lightning_holes)*i+4*material_z,0]) | |
{ | |
mirror([0,1,0]) | |
{ | |
rotate([0,0,-90]) | |
{ | |
hv_lightning(); | |
} | |
} | |
} | |
} | |
// Ventilation hole, the leftover doubles as stiffener bottom plate | |
translate([material_z, 3*material_z,0]) | |
{ | |
square([front_leg_z, box_y-6*material_z]); | |
} | |
} | |
} | |
//right_2d(); | |
module right_3d() | |
{ | |
color([(34/255), (222/255), (52/255), 0.75]) | |
{ | |
translate([box_x,0,material_z]) | |
{ | |
rotate([0,-90,0]) | |
{ | |
linear_extrude(height=material_z) | |
{ | |
right_2d(); | |
} | |
} | |
} | |
} | |
} | |
//right_3d(); | |
module box_3d() | |
{ | |
bottom_3d(); | |
top_3d(); | |
back_3d(); | |
front_3d(); | |
left_3d(); | |
right_3d(); | |
} | |
//box_3d(); | |
module rendering() | |
{ | |
box_3d(); | |
translate([box_x/2,box_y/2,box_z]) | |
{ | |
coilforms_3d(); | |
} | |
} | |
//rendering(); | |
module hv_lightning() | |
{ | |
translate([-15,-148,0]) | |
{ | |
import(file="high_voltage_lightningonly.dxf"); | |
} | |
} | |
//hv_lightning(); | |
/** | |
* Seems front_2d module triggers some sort of infinite-loop (ran out of swapspace once because of that...) | |
* but only when used alone (the 3D extrusion [and cutting a projection from that] works fine...) | |
*/ | |
module front_2d_fromprojection() | |
{ | |
projection(cut=false) | |
{ | |
rotate([90,0,0]) | |
{ | |
front_3d(); | |
} | |
} | |
} | |
//front_2d_fromprojection(); | |
/** | |
* Ditto for back_2d | |
*/ | |
module back_2d_fromprojection() | |
{ | |
projection(cut=false) | |
{ | |
rotate([90,0,0]) | |
{ | |
back_3d(); | |
} | |
} | |
} | |
//back_2d_fromprojection(); | |
// Trigger bug | |
front_2d(); | |
/** | |
* Calls to the 2D modules in single place for easier exporting | |
* | |
bottom_2d(); | |
top_2d(); | |
front_2d(); | |
back_2d(); | |
left_2d(); | |
right_2d(); | |
*/ |
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AcDbEntity | |
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AcDbDictionary | |
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AcDbDictionary | |
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AcDbDictionary | |
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AcDbDictionary | |
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EOF |
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