fix(wallmount): orientation

Added "insane" asymetry slider to create differently sized rackmount
ears.

models/flexmount/README.md

@@ -1,5 +0,0 @@
-Fully customizable mount to be used with HomeRacker.
-It's intended for non-standard devices you want to mount on HomeRacker.
-Non-standard being devices which aren't originally meant to be mounted in 10 or 19" racks.
-Devices might be PSU's for Raspberry Pis or small smart switches like on these pictures:
-<TODO: insert pics here>

models/flexmount/flexmount.scad

@@ -1,10 +1,11 @@
 // import BOSL2
 include <BOSL2/std.scad>
 
-$fn=100;
+
 
 /* [Hidden] */
 // constants which shouldn't be changed
+$fn=100;
 
 // This is the HomeRacker base unit. don't change this!
 BASE_UNIT=15; // mm
@@ -19,23 +20,20 @@ LOCK_PIN_SIDE=4; // mm
 // lock pin edge distance
 LOCK_PIN_EDGE_DISTANCE=5.5; // mm
 
-/* [Base] */
-// If set to true, the mount will be fitted to align with the 10/19 inch HomRacker rackmount kit.
-//fit_to_rack=true;
-
 /* [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]
+device_width=100; // [20:0.1:500]
-; // TODO test for zero cube
+ // 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; // [54:0.1:500]
+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; // [15:0.1:500]
+device_height=25.5; // [10:0.1:400]
 
 /* [Bracket] */
 // Defines the bracket thickness on top of the device.
-bracket_strength_top=7.5; // [4:0.1:20]
+bracket_strength_top=7.5; // [1:0.1:50]
-bracket_strength_sides=7.5; // [4:0.1:20]
+// 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);
@@ -58,6 +56,10 @@ module bracket(width,depth,height) {
     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
@@ -66,36 +68,33 @@ module bracket(width,depth,height) {
             anchor=BOTTOM,
             chamfer=CHAMFER, edges=[TOP,FRONT,BACK,LEFT,RIGHT], except=[BOTTOM]
         );
-        // Top Skeleton
+        // Top Skeleton (cut the middle to leave only a bracket to the sides)
         cuboid(
-            size=[width-bracket_strength_top,depth-bracket_strength_top,outer_height],
+            size=[inner_width,inner_depth,outer_height],
             anchor=BOTTOM,
             chamfer=-CHAMFER, edges=[TOP]
         );
-        // Bottom Recess
+        // Bottom Recess (cut the cube to leave only a top bracket)
         cuboid(
-          size=[outer_width,outer_depth,height-bracket_strength_sides],
+          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],
+        size=[outer_width,outer_depth,bracket_strength_sides+BASE_STRENGTH-TOLERANCE/2],
         anchor=TOP,
         chamfer=CHAMFER, edges=[BOTTOM]
       );  
     }
 }
 
-// device module adds TOLERANCE to the device size and creates a cuboid with the device size
-// this is used to create the device in the mount and add TOLERANCE to the device size for spacing
-module device(width,depth,height) {
-    // Device
-    cuboid(
-        size=[width+TOLERANCE,depth+TOLERANCE,height+TOLERANCE],
-        anchor=BOTTOM
-    );
-}
 
 // Mount
 module mount(){
@@ -185,12 +184,8 @@ module mirror_mount_x_plane(){
 // Assembly
 rotate([180,0,0])
 union() {
+  bracket(device_width,device_depth,device_height);
 
-  
-  difference() {
-    bracket(device_width,device_depth,device_height);
-    device(device_width,device_depth,device_height);
-  }
   // Mount Right
   mirror_mount_x_plane();
 

models/rackmount_ears/rackmount_ears.scad

@@ -1,13 +1,28 @@
 // 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. CAUTION: there's no sanity check for this slider!
+asymetry=0; // [-150:0.1:150]
+// shows the distance between the rackmount ears considering the device width.
+show_distance=false;
 
 // Width of the device in mm. Will determine the width of the rackmount ears depending on rack_size.
 device_width=201;
@@ -38,44 +53,18 @@ 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 +81,7 @@ 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 +99,36 @@ 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])
+// Ear distance
-    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);
+ear_distance = show_distance ? -device_width : -CAGE_BOLT_DIAMETER;
+
+// Place the ears
+rackmount_ear(asymetry);
+
+x_mirror_plane = [1,0,0];
+translate([ear_distance,0,0])
+mirror(x_mirror_plane){
+    rackmount_ear(-asymetry);
 }

models/wallmount/wallmount.scad

@@ -0,0 +1,130 @@
+// 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
+// lock pin chamfer
+LOCK_PIN_CHAMFER=0.8; // mm
+// Negative chamfer fix: 
+NEGATIVE_CHAMFER_TRANSLATE=0.01;
+
+mount_units=2;
+
+/* [Base] */
+// TODO: enable mount units
+// How many units shall the mount span across the support
+//mount_units=2; //[2:1:10]
+// Shall bores be countersunk or flathead
+bore_type="flathead"; //[flathead,countersunk]
+// Bore Shaft Diameter in mm 
+bore_shaft_diameter=4;
+// Bore Head Diameter in mm (only relevant if bore_type=countersunk)
+bore_head_diameter=8.5;
+
+
+/* [Finetuning] */
+// Defines the angle of the head rejuvenation. 90° is ISO standard. (only relevant if bore_type=countersunk)
+countersunk_angle=90;
+// Tolerance (in mm) for the bore holes. This is a sane default.
+bore_tolerance=0.2;
+
+// Calculate the head depth based on the countersunk angle.
+head_depth = bore_head_diameter/2 - bore_shaft_diameter/2 * tan( countersunk_angle/2 );
+
+
+echo("head_depth: ", head_depth);
+
+
+connector_width_net=BASE_UNIT+TOLERANCE;
+connector_width_gross=connector_width_net+BASE_STRENGTH*2;
+//Wall Mount
+mount_thickness=head_depth+BASE_STRENGTH;
+mount_height=mount_units*BASE_UNIT;
+mount_width=mount_units*2*BASE_UNIT+connector_width_gross;
+
+
+// Support Interface
+module mount(){
+  difference() {
+    union(){
+      cuboid([mount_width,mount_height,mount_thickness],anchor=CENTER+BOTTOM,chamfer=CHAMFER);
+      cuboid([connector_width_gross,mount_height,connector_width_gross],anchor=CENTER+BOTTOM,chamfer=CHAMFER);
+    }
+    translate([0,0,BASE_STRENGTH])
+    cuboid([connector_width_net,mount_height,connector_width_net],anchor=CENTER+BOTTOM);
+  }
+}
+
+// Lock pin Holes
+module lock_pin_hole(){
+  // fix for negative chamfer. Otherwise the holes would not reach the surface
+  translate([0,0,-NEGATIVE_CHAMFER_TRANSLATE/2])
+  cuboid(
+    size=[LOCK_PIN_SIDE,LOCK_PIN_SIDE,connector_width_gross+0.01],
+    anchor=CENTER+BOTTOM,
+    chamfer=-LOCK_PIN_CHAMFER,edges=[TOP,BOTTOM]
+    );
+}
+
+module lock_pin_holes(){
+  // ycopies
+  ycopies(BASE_UNIT,mount_units)
+  // Create cross
+  union(){
+    lock_pin_hole();
+    yrot(90,cp=[0,0,connector_width_gross/2])
+    lock_pin_hole();
+  }
+}
+
+//// Bores
+// Shafts
+module bore(){
+  bore_shaft_radius=(bore_shaft_diameter+bore_tolerance)/2;
+  bore_head_radius=(bore_head_diameter+bore_tolerance)/2;
+  if (bore_type=="flathead") {
+    cylinder(r=bore_shaft_radius,h=mount_thickness,anchor=CENTER+BOTTOM);
+  } else if (bore_type=="countersunk") {
+    // Countersunk
+    union() {
+      // Head
+      translate([0,0,mount_thickness])
+      cylinder(r1=bore_shaft_radius,r2=bore_head_radius,h=head_depth,anchor=CENTER+TOP);
+      // Shaft
+      cylinder(r=bore_shaft_radius,h=mount_thickness,anchor=CENTER+BOTTOM);
+    }
+    
+  }
+}
+
+bore_position_x=BASE_STRENGTH+BASE_UNIT/2+TOLERANCE/2+BASE_UNIT;
+echo("bore_position_x: ", bore_position_x);
+// Assembly
+ translate([0,0,BASE_UNIT]) rotate([90,0,0])
+union(){
+  difference() {
+    mount();
+    translate([-bore_position_x,0,0])
+    bore();
+    translate([bore_position_x,0,0])
+    bore();
+
+    // Lock Pin Holes
+    lock_pin_holes();
+  }
+  
+}