feat(rackmount_ears): asymetry slider

models/flexmount/flexmount.scad

@@ -0,0 +1,199 @@
+// import BOSL2
+include <BOSL2/std.scad>
+
+
+
+/* [Hidden] */
+// constants which shouldn't be changed
+$fn=100;
+
+// This is the HomeRacker base unit. don't change this!
+BASE_UNIT=15; // mm
+// Standard tolerance for the mount. This is a sane default.
+TOLERANCE=0.2; // mm
+// Base strength. This is a sane default.
+BASE_STRENGTH=2; // mm
+// Chamfer size. This is a sane default.
+CHAMFER=1; // mm
+// Lock Pin side length
+LOCK_PIN_SIDE=4; // mm
+// lock pin edge distance
+LOCK_PIN_EDGE_DISTANCE=5.5; // mm
+
+/* [Device Measurements] */
+// Width of the device in mm. Will determine how far apart the actual mounts are in width.
+device_width=100 // [20:0.1:500]
+; // TODO test for zero cube
+// Depth of the device in mm. Will determine how far apart the actual mounts are in depth.
+device_depth=99; // [54:0.1:400]
+// Height of the device in mm. Will determine how far apart the actual mounts are in height.
+device_height=25.5; // [10:0.1:400]
+
+/* [Bracket] */
+// Defines the bracket thickness on top of the device.
+bracket_strength_top=7.5; // [1:0.1:50]
+// Defines how much the bracket will overlap to the sides of the device.
+bracket_strength_sides=7.5; // [2:0.1:50]
+
+// diff_width resembles the gap between the device and the mount. This gap will be filled with a cuboid
+modulo_width=(BASE_UNIT - ( device_width + TOLERANCE ) % BASE_UNIT);
+WIDTH_DIFF = modulo_width==15 ? 0 : modulo_width;
+echo("Diff Width: ", WIDTH_DIFF);
+mount_gap_filler_start=(device_width+TOLERANCE)/2;
+// echo("mount_gap_filler_start: ", mount_gap_filler_start);
+// echo("effective mount distance: ", device_width+WIDTH_DIFF+TOLERANCE);
+
+
+DEPTH_DIFF=device_depth % BASE_UNIT;
+echo("Diff Depth: ", DEPTH_DIFF);
+mount_offset_depth=(device_depth-DEPTH_DIFF-BASE_UNIT)/2;
+echo("mount_offset_depth*2: ", mount_offset_depth*2);
+
+/* Code */
+// creates a bracket around the device with TOLERANCE as additional space and BASE_STRENGTH as the strength of the bracket
+module bracket(width,depth,height) {
+    // Bracket
+    outer_width=width+BASE_STRENGTH*2+TOLERANCE;
+    outer_depth=depth+BASE_STRENGTH*2+TOLERANCE;
+    outer_height=height+BASE_STRENGTH;
+    inner_width=width-bracket_strength_top*2+TOLERANCE;
+    inner_depth=depth-bracket_strength_top*2+TOLERANCE;
+    bottom_recess_height=height-bracket_strength_sides;
+    
+    intersection(){
+      difference() {
+        // Outer
+        cuboid(
+            size=[outer_width,outer_depth,outer_height],
+            anchor=BOTTOM,
+            chamfer=CHAMFER, edges=[TOP,FRONT,BACK,LEFT,RIGHT], except=[BOTTOM]
+        );
+        // Top Skeleton (cut the middle to leave only a bracket to the sides)
+        cuboid(
+            size=[inner_width,inner_depth,outer_height],
+            anchor=BOTTOM,
+            chamfer=-CHAMFER, edges=[TOP]
+        );
+        // Bottom Recess (cut the cube to leave only a top bracket)
+        cuboid(
+          size=[outer_width,outer_depth,bottom_recess_height],
+          anchor=BOTTOM
+        );
+        // Subtract Device to from bracket (cut the device into the bracket)
+        cuboid(
+        size=[width+TOLERANCE,depth+TOLERANCE,height+TOLERANCE/2],
+        anchor=BOTTOM
+    );
+      }
+      // chamfer intersection for the outer bottom chamfer of the bracket
+      translate([0,0,outer_height])
+      cuboid(
+        size=[outer_width,outer_depth,bracket_strength_sides+BASE_STRENGTH-TOLERANCE/2],
+        anchor=TOP,
+        chamfer=CHAMFER, edges=[BOTTOM]
+      );  
+    }
+}
+
+
+// Mount
+module mount(){
+  depth=BASE_UNIT+BASE_STRENGTH*2+TOLERANCE;
+  gap_filler_width=(WIDTH_DIFF)/2;
+
+  // depth translation
+  translate([0,mount_offset_depth,0])
+
+  union(){
+   
+    translate([mount_gap_filler_start,0,0])
+    // Mount
+    union(){      
+      top_width=BASE_STRENGTH;
+      bottom_width=BASE_UNIT+gap_filler_width;
+      // Bridge
+      difference(){
+        cuboid_width = bottom_width;
+        cuboid_chamfer = bottom_width;
+        prismoid(
+          size1 = [bottom_width, depth],  // Bottom face: width 30, depth 60
+          size2 = [top_width, depth],   // Top face: becomes a line segment (width 0)
+          shift = [(-bottom_width+top_width)/2, 0],   // Shift top edge center to X=+15 (aligns with right edge of base)
+          chamfer=CHAMFER,
+          h = device_height,             // Height
+          //chamfer=CHAMFER/2,
+          anchor = BOTTOM+LEFT // Anchor bottom left
+        );
+        translate([0,0,BASE_STRENGTH])
+        cuboid(
+          size=[cuboid_width,BASE_UNIT,device_height],
+          anchor=BOTTOM+LEFT,
+          chamfer=BASE_UNIT/2, edges=[BOTTOM], except=[RIGHT]
+        );
+      }
+
+      // Depth enforcement
+      depth_enforcement_x = BASE_STRENGTH;
+      depth_enforcemnt_y2 = BASE_UNIT*2;
+      prismoid(
+        size1 = [depth_enforcement_x, depth],  
+        size2 = [depth_enforcement_x, depth_enforcemnt_y2],
+        shift = [0, (depth-depth_enforcemnt_y2)/2], 
+        h = device_height,             
+        chamfer=[CHAMFER,0,0,CHAMFER],
+        anchor = BOTTOM+LEFT 
+      );
+      
+      // Mount Rail with holes
+      difference(){
+        // Mount Rail
+        difference(){
+          height=BASE_UNIT+TOLERANCE/2;
+          // outer
+          cuboid(
+            size=[bottom_width,depth,height],
+            anchor=TOP+LEFT,
+            chamfer=CHAMFER, edges=[BOTTOM,RIGHT], except=[TOP]
+          );
+          // support recess
+          cuboid(
+            size=[bottom_width,BASE_UNIT+TOLERANCE,height],
+            anchor=TOP+LEFT
+          );
+        }
+        // holes
+        translate([bottom_width-LOCK_PIN_EDGE_DISTANCE,0,-LOCK_PIN_EDGE_DISTANCE-TOLERANCE/2])
+        cuboid(
+          size=[LOCK_PIN_SIDE,depth,LOCK_PIN_SIDE],
+          anchor=TOP+RIGHT
+        );
+      }
+    }
+  }
+}
+
+
+module mirror_mount_x_plane(){
+  mount();
+  x_mirror_plane = [1,0,0];
+  mirror(x_mirror_plane) {
+    mount();
+  }
+}
+
+// Assembly
+rotate([180,0,0])
+union() {
+  bracket(device_width,device_depth,device_height);
+
+  // Mount Right
+  mirror_mount_x_plane();
+
+  y_mirror_plane = [0,1,0];
+  mirror(y_mirror_plane) {
+    mirror_mount_x_plane();
+  }
+  
+}
+
+

models/rackmount_ears/rackmount_ears.scad

@@ -1,13 +1,26 @@
 // import BOSL2
 include <BOSL2/std.scad>
 
+/* [Hidden] */
 $fn=100;
+CAGE_BOLT_DIAMETER=6.5;
+RACK_BORE_DISTANCE_VERTICAL=15.875;
+RACK_BORE_DISTANCE_TOP_BOTTOM=6.35;
+RACK_MOUNT_SURFACE_WIDTH=15.875;
+RACK_BORE_DISTANCE_HORIZONTAL=RACK_MOUNT_SURFACE_WIDTH/2;
+RACK_HEIGHT_UNIT=44.5; // mm
+
+RACK_WIDTH_10_INCH_INNER=222.25; // mm
+RACK_WIDTH_10_INCH_OUTER=254; // mm
+RACK_WIDTH_19_INCH=482.6; // mm
 
 /* [Base] */
 // automatically chooses the tightest fit for the rackmount ears based on the device width. If true, rack_size will be ignored.
 autosize=true;
 // rack size in inches. If autosize is true, this value will be ignored. Only 10 and 19 inch racks are supported.
 rack_size=10; // [10:10 inch,19:19 inch]
+// Asymetry Slider. If autosize is true, this value will be ignored. CAUTION: there's no sanity check for this slider!
+asymetry=100; // [-150:0.1:150]
 
 // Width of the device in mm. Will determine the width of the rackmount ears depending on rack_size.
 device_width=201;
@@ -38,44 +51,18 @@ device_bore_rows=2;
 // If true, the device will be aligned to the center of the rackmount ear. Otherwise it will be aligned to the bottom of the rackmount ear.
 center_device_bore_alignment=false;
 
-
+/* [Derived] */
-/* [CONSTANTS (shouldn't need to be changed)] */
-CAGE_BOLT_DIAMETER=6.5;
 CHAMFER=min(strength/3,0.5);
-RACK_BORE_DISTANCE_VERTICAL=15.875;
-RACK_BORE_DISTANCE_TOP_BOTTOM=6.35;
-RACK_MOUNT_SURFACE_WIDTH=15.875;
-RACK_BORE_DISTANCE_HORIZONTAL=RACK_MOUNT_SURFACE_WIDTH/2;
 RACK_BORE_WIDTH=RACK_MOUNT_SURFACE_WIDTH-2*max(strength,2);
-RACK_HEIGHT_UNIT=44.5; // mm
 RACK_HEIGHT_UNIT_COUNT=max(1,ceil(device_height/RACK_HEIGHT_UNIT));
 RACK_HEIGHT=RACK_HEIGHT_UNIT_COUNT*RACK_HEIGHT_UNIT; // actual height calculated by height unit size x number of units
 RACK_BORE_COUNT=RACK_HEIGHT_UNIT_COUNT*3; // 3 holes for each units
-RACK_WIDTH_10_INCH_INNER=222.25; // mm
-RACK_WIDTH_10_INCH_OUTER=254; // mm
-RACK_WIDTH_19_INCH=482.6; // mm
-
-// Base assertions
-module validate_params() {
-    valid_rack_sizes=[10,19];
-    if(autosize == false){
-        assert(rack_size == 10 || rack_size == 19, "Invalid rack_size. Only 10 and 19 inch racks are supported. Choose a valid one or set autosize to true.");
-    }
-}
-
-validate_params();
 
 // Debug
 echo("Height: ", RACK_HEIGHT);
 echo("Rack Bore Count: ", RACK_BORE_COUNT);
 
-// Calculate the width of the ear
+
-function get_ear_width(device_width) =
-    device_width > RACK_WIDTH_10_INCH_INNER || autosize == false && rack_size == 19 ?
-        (RACK_WIDTH_19_INCH - device_width) / 2 :
-        (RACK_WIDTH_10_INCH_OUTER - device_width) / 2
-;
-rack_ear_width = get_ear_width(device_width);
 
 function get_bore_depth(device_bore_margin_horizontal,device_bore_columns) =
     (device_bore_columns - 1) * device_bore_margin_horizontal
@@ -92,7 +79,7 @@ device_screw_alignment = [strength,depth/2,device_screw_alignment_vertical];
 module base_ear(width,strength,height) {
     union() {
         // Front face
-        cuboid([rack_ear_width,strength,height],anchor=LEFT+BOTTOM+FRONT,chamfer=CHAMFER);
+        cuboid([width,strength,height],anchor=LEFT+BOTTOM+FRONT,chamfer=CHAMFER);
         // Side face
         cuboid([strength,depth,height],anchor=LEFT+BOTTOM+FRONT,chamfer=CHAMFER);
     }
@@ -110,15 +97,33 @@ module screws_countersunk(length, diameter_head, length_head, diameter_shaft) {
 
 
 // Assemble the rackmount ear
-difference() {
+module rackmount_ear(asym=0){
+    ear_width_19_inch=(RACK_WIDTH_19_INCH - device_width) / 2 + asym;
+    ear_width_10_inch=(RACK_WIDTH_10_INCH_OUTER - device_width) / 2 + asym;
+    // Calculate the width of the ear
+    rack_ear_width = device_width > RACK_WIDTH_10_INCH_INNER || autosize == false && rack_size == 19 ?
+            ear_width_19_inch:
+            ear_width_10_inch
+    ;
     difference() {
-        // Create the base of the ear
+        difference() {
-        base_ear(device_width,strength,RACK_HEIGHT);
+            // Create the base of the ear
-        // Create the holes for the device screws
+            base_ear(rack_ear_width,strength,RACK_HEIGHT);
-        screws_countersunk(length=strength,diameter_head=device_bore_hole_head_diameter,length_head=device_bore_hole_head_length,diameter_shaft=device_bore_hole_diameter);
+            // Create the holes for the device screws
+            screws_countersunk(length=strength,diameter_head=device_bore_hole_head_diameter,length_head=device_bore_hole_head_length,diameter_shaft=device_bore_hole_diameter);
+        }
+        // Create the holes for the rackmount screws
+        zcopies(spacing=RACK_HEIGHT_UNIT,n=RACK_HEIGHT_UNIT_COUNT,sp=[0,0,0])
+        zcopies(spacing=RACK_BORE_DISTANCE_VERTICAL,n=3,sp=[rack_ear_width-RACK_BORE_DISTANCE_HORIZONTAL,0,RACK_BORE_DISTANCE_TOP_BOTTOM])
+        cuboid([RACK_BORE_WIDTH,strength+1,CAGE_BOLT_DIAMETER], rounding=CAGE_BOLT_DIAMETER/2, edges=[TOP+LEFT,TOP+RIGHT,BOTTOM+LEFT,BOTTOM+RIGHT], anchor=FRONT);
     }
-    // Create the holes for the rackmount screws
+}
-    zcopies(spacing=RACK_HEIGHT_UNIT,n=RACK_HEIGHT_UNIT_COUNT,sp=[0,0,0])
+
-    zcopies(spacing=RACK_BORE_DISTANCE_VERTICAL,n=3,sp=[rack_ear_width-RACK_BORE_DISTANCE_HORIZONTAL,0,RACK_BORE_DISTANCE_TOP_BOTTOM])
+// Place the ears
-    cuboid([RACK_BORE_WIDTH,strength+1,CAGE_BOLT_DIAMETER], rounding=CAGE_BOLT_DIAMETER/2, edges=[TOP+LEFT,TOP+RIGHT,BOTTOM+LEFT,BOTTOM+RIGHT], anchor=FRONT);
+rackmount_ear(asymetry);
+
+x_mirror_plane = [1,0,0];
+translate([-device_width,0,0])
+mirror(x_mirror_plane){
+    rackmount_ear(-asymetry);
 }