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
+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

@@ -1,28 +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. 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;
@@ -53,18 +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
@@ -81,7 +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);
     }
@@ -99,36 +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);
     }
-}
-
-// Ear distance
-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);
+    // 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);
 }

models/wallmount/wallmount.scad

@@ -1,130 +0,0 @@
-// 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();
-  }
-  
-}