chore: defaults

models/flexmount/README.md

@@ -0,0 +1,5 @@
+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

@@ -1,11 +1,10 @@
 // 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
@@ -20,20 +19,23 @@ 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]
 ; // 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]
+device_depth=99; // [54:0.1:500]
 // 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]
+device_height=25.5; // [15:0.1:500]
 
 /* [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]
+bracket_strength_top=7.5; // [4:0.1:20]
+bracket_strength_sides=7.5; // [4:0.1:20]
 
 // 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);
@@ -56,10 +58,6 @@ 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
@@ -68,33 +66,36 @@ module bracket(width,depth,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)
+        // Top Skeleton
         cuboid(
-            size=[inner_width,inner_depth,outer_height],
+            size=[width-bracket_strength_top,depth-bracket_strength_top,outer_height],
             anchor=BOTTOM,
             chamfer=-CHAMFER, edges=[TOP]
         );
-        // Bottom Recess (cut the cube to leave only a top bracket)
+        // Bottom Recess
         cuboid(
-          size=[outer_width,outer_depth,bottom_recess_height],
+          size=[outer_width,outer_depth,height-bracket_strength_sides],
           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],
+        size=[outer_width,outer_depth,bracket_strength_sides],
         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(){
@@ -184,8 +185,12 @@ 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

@@ -1,26 +1,13 @@
 // 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;
@@ -51,18 +38,44 @@ 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
@@ -79,7 +92,7 @@ device_screw_alignment = [strength,depth/2,device_screw_alignment_vertical];
 module base_ear(width,strength,height) {
     union() {
         // Front face
-        cuboid([width,strength,height],anchor=LEFT+BOTTOM+FRONT,chamfer=CHAMFER);
+        cuboid([rack_ear_width,strength,height],anchor=LEFT+BOTTOM+FRONT,chamfer=CHAMFER);
         // Side face
         cuboid([strength,depth,height],anchor=LEFT+BOTTOM+FRONT,chamfer=CHAMFER);
     }
@@ -97,33 +110,15 @@ module screws_countersunk(length, diameter_head, length_head, diameter_shaft) {
 
 
 // Assemble the rackmount ear
-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() {
     difference() {
-        difference() {
-            // Create the base of the ear
-            base_ear(rack_ear_width,strength,RACK_HEIGHT);
-            // 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 base of the ear
+        base_ear(device_width,strength,RACK_HEIGHT);
+        // 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);
     }
-}
-
-// Place the ears
-rackmount_ear(asymetry);
-
-x_mirror_plane = [1,0,0];
-translate([-device_width,0,0])
-mirror(x_mirror_plane){
-    rackmount_ear(-asymetry);
+    // 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);
 }