NopSCADlib/printed/psu_shroud.scad

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//
// NopSCADlib Copyright Chris Palmer 2018
// nop.head@gmail.com
// hydraraptor.blogspot.com
//
// This file is part of NopSCADlib.
//
// NopSCADlib is free software: you can redistribute it and/or modify it under the terms of the
// GNU General Public License as published by the Free Software Foundation, either version 3 of
// the License, or (at your option) any later version.
//
// NopSCADlib is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY;
// without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
// See the GNU General Public License for more details.
//
// You should have received a copy of the GNU General Public License along with NopSCADlib.
// If not, see <https://www.gnu.org/licenses/>.
//
//
//! A cover to go over the mains end of a PSU terminal strip to make it safe.
//! The stl and assembly must be given a name and parameterless wrappers for the stl and assembly added to the project.
//
include <../core.scad>
include <../vitamins/screws.scad>
include <../vitamins/inserts.scad>
use <../vitamins/wire.scad>
use <../vitamins/psu.scad>
use <../utils/round.scad>
wall = 1.8;
top = 1.5;
screw = M3_cap_screw;
insert = screw_insert(screw);
boss_r = insert_boss_radius(insert, wall);
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counter_bore = 2;
rad = 2;
clearance = layer_height;
overlap = 6;
cable_tie_inset = wall + 4;
function psu_shroud_extent(type) = 15 + wall; //! How far it extends beyond the PSU to clear the connections
function psu_shroud_depth(type) = //! Outside depth of the shroud
psu_left_bay(type) + overlap + psu_shroud_extent(type);
function psu_shroud_width(type) = //! Outside width of the shroud
let(terminals = psu_terminals(type))
terminals ?
let(y = terminals.y, tb = terminals.z)
wall + clearance / 2 + y + 3 * terminal_block_pitch(tb) + terminal_block_divider(tb) / 2 + wall / 2
: psu_width(type) + 2 * wall + clearance;
function psu_shroud_height(type) = psu_height(type) + top + clearance; //! Outside height
function psu_shroud_centre_y(type) = //! Shroud centre relative to PSU centre
psu_width(type) / 2 + clearance / 2 + wall - psu_shroud_width(type) / 2;
function psu_shroud_pitch(type) = psu_shroud_width(type) - 2 * boss_r - eps;
function psu_shroud_screw(type) = screw; //! Screw used to fasten
function psu_shroud_cable_pitch(cable_d) = cable_d + 5; //! Pitch between cable entries
module psu_shroud_hole_positions(type) //! Place children at the screw hole positions
for($side = [-1, 1])
translate([-psu_length(type) / 2 - boss_r - 1, psu_shroud_centre_y(type) + $side * psu_shroud_pitch(type) / 2])
children();
module psu_shroud_cable_positions(type, cable_d, cables = 1) //! Place children at the cable tie positions
for(i = [0 : 1 : cables - 1])
translate([-psu_length(type) / 2 - psu_shroud_extent(type) + cable_tie_inset,
psu_shroud_centre_y(type) + (i - cables / 2 + 0.5) * psu_shroud_cable_pitch(cable_d)])
children();
module psu_shroud_holes(type, cable_d, cables = 1) { //! Drill the screw and ziptie holes
psu_shroud_hole_positions(type)
drill(screw_clearance_radius(screw), 0);
psu_shroud_cable_positions(type, cable_d, cables)
cable_tie_holes(cable_d / 2, h = 0);
}
module psu_shroud(type, cable_d, name, cables = 1) { //! Generate the STL file for a specified ssr and cable
stl(str("psu_shroud_", name));
extent = psu_shroud_extent(type);
depth = psu_shroud_depth(type);
width = psu_shroud_width(type);
height = psu_shroud_height(type);
centre_x = -psu_length(type) / 2 - psu_shroud_extent(type) + psu_shroud_depth(type) / 2;
centre_y = psu_shroud_centre_y(type);
terminal_clearance = 0.5;
tb = psu_terminals(type).z;
module shape() {
difference() {
round(or = wall / 2 - eps, ir = 0) difference() {
rounded_square([depth, width], rad);
rounded_square([depth - 2 * wall, width - 2 * wall], rad - wall);
translate([depth / 2, 0])
square([2 * rad, width], center = true);
translate([depth / 2, width / 2 - 5])
square([2 * (overlap + terminal_clearance), 10], center = true);
}
for(i = [0 : 1 : cables - 1])
translate([0, (i - cables / 2 + 0.5) * psu_shroud_cable_pitch(cable_d)])
square([depth + 1, cable_d], center = true);
}
}
// base and sides
translate([centre_x, -centre_y]) {
rounded_rectangle([depth - eps, width - eps, top], rad, center = false);
linear_extrude(height = height)
difference() {
shape();
translate([depth / 2, width / 2 - 5])
square([2 * (depth - extent + terminal_clearance), 10], center = true);
}
linear_extrude(height = height - terminal_block_height(tb) - psu_terminal_block_z(type) - terminal_clearance)
shape();
}
// cable slots
for(i = [0 : 1 : cables - 1])
translate([centre_x - depth / 2 + wall / 2, -centre_y + (i - cables / 2 + 0.5) * psu_shroud_cable_pitch(cable_d), height / 2])
rotate([90, 0, 90])
linear_extrude(height = wall, center = true)
difference() {
square([cable_d + eps, height], center = true);
translate([0, height / 2])
vertical_tearslot(h = 0, r = cable_d / 2, l = cable_d);
}
// insert lugs
mirror([0, 1, 0])
psu_shroud_hole_positions(type)
translate_z(height)
rotate($side * 90)
insert_lug(insert, wall, counter_bore);
}
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module psu_shroud_assembly(type, cable_d, name, cables = 1) //! The printed parts with inserts fitted
assembly(str("psu_shroud_", name)) {
translate_z(psu_shroud_height(type))
vflip()
color(pp1_colour) psu_shroud(type, cable_d, name, cables);
psu_shroud_hole_positions(type)
vflip()
insert(insert);
}
module psu_shroud_fastened_assembly(type, cable_d, thickness, name, cables = 1) //! Assembly with screws in place
{
washer = screw_washer(screw);
screw_length = screw_shorter_than(2 * washer_thickness(washer) + thickness + insert_length(insert) + counter_bore);
psu_shroud_assembly(type, cable_d, name, cables);
translate_z(-thickness)
psu_shroud_hole_positions(type)
vflip()
screw_and_washer(screw, screw_length, true);
psu_shroud_cable_positions(type, cable_d, cables)
cable_tie(cable_d / 2, thickness);
}