Better ziptie model.

Better cable_tie using zipties.
Added cable ties to ssr_shroud_fastened_assembly().
Added test and documentation for wire.scad.

printed/ssr_shroud.scad

@@ -24,13 +24,14 @@
 include <../core.scad>
 include <../vitamins/screws.scad>
 include <../vitamins/inserts.scad>
+
+use <../vitamins/wire.scad>
 use <../vitamins/ssr.scad>
 use <../utils/round.scad>
 
 wall = 1.8;
 top = 1.5;
 screw = M3_cap_screw;
-screw_length = 10;
 insert = screw_insert(screw);
 boss_r = wall + corrected_radius(insert_hole_radius(insert));
 boss_h = insert_hole_length(insert);
@@ -44,6 +45,7 @@ function ssr_shroud_screw(type) = screw;                                    //!
 function ssr_shroud_extent(type, cable_d) = 2 * boss_r + 1 + cable_d + rad; //! How far it extends beyond the SSR
 function ssr_shroud_width(type) = ssr_width(type) + 2 * wall + clearance;   //! Outside width of shroud
 function ssr_shroud_height(type) = ssr_height(type) + top + clearance;      //! Outside height
+function ssr_shroud_cable_x(type, cable_d) =  -ssr_length(type) / 2 - 2 * boss_r - 1 - cable_d / 2; //! Position of cable entry holes
 
 module ssr_shroud_hole_positions(type)                                      //! Place children at the screw hole positions
     for($side = [-1, 1])
@@ -51,19 +53,27 @@ module ssr_shroud_hole_positions(type)                                      //!
             vflip()
                 children();
 
-module ssr_shroud_holes(type) //: Drill the screw holes
+module ssr_shroud_holes(type, cable_d) { //! Drill the screw and ziptie holes
     ssr_shroud_hole_positions(type)
         drill(screw_clearance_radius(screw), 0);
 
+    for(side = [-1, 1])
+        translate([ssr_shroud_cable_x(type, cable_d), side * (ssr_width(type) / 2 - 2 * boss_r)])
+            rotate(-90)
+                cable_tie_holes(cable_d / 2, h = 0);
+
+}
+
 module ssr_shroud(type, cable_d, name) {    //! Generate the STL file for a specified ssr and cable
     stl(str("ssr_shroud_", name));
 
     width = ssr_shroud_width(type);
     depth = ssr_length(type) / 3 + ssr_shroud_extent(type, cable_d);
     height = ssr_shroud_height(type);
-    cable_x = -ssr_length(type) / 2 - 2 * boss_r - 1 - cable_d / 2;
+    cable_x = ssr_shroud_cable_x(type, cable_d);
     center_x = -ssr_length(type) / 6 - depth / 2;
 
+    // base and sides
     translate([center_x, 0]) {
         rounded_rectangle([depth - eps, width - eps, top], rad, center = false);
 
@@ -81,6 +91,7 @@ module ssr_shroud(type, cable_d, name) {    //! Generate the STL file for a spec
                 square([cable_d, width + 1], center = true);
         }
     }
+    // cable slots
     for(side = [-1, 1])
         translate([cable_x, side * (width / 2 - wall / 2), height / 2])
             rotate([90, 0, 0])
@@ -91,7 +102,7 @@ module ssr_shroud(type, cable_d, name) {    //! Generate the STL file for a spec
                         translate([0, height / 2])
                             vertical_tearslot(h = 0, r = cable_d / 2, l = cable_d);
                     }
-
+    // insert boss
     translate_z(height - boss_h)
         linear_extrude(height = boss_h)
             ssr_shroud_hole_positions(type)
@@ -105,6 +116,7 @@ module ssr_shroud(type, cable_d, name) {    //! Generate the STL file for a spec
                     poly_circle(insert_hole_radius(insert));
                 }
 
+    // insert boss counter_bore
     translate_z(height - boss_h2)
         linear_extrude(height = counter_bore + eps)
             ssr_shroud_hole_positions(type)
@@ -117,7 +129,7 @@ module ssr_shroud(type, cable_d, name) {    //! Generate the STL file for a spec
                     }
                     poly_circle(insert_screw_diameter(insert) / 2 + 0.1);
                 }
-
+    // support cones
     ssr_shroud_hole_positions(type)
         hull() {
             translate_z(-height + boss_h2) {
@@ -146,9 +158,25 @@ assembly(str("ssr_shroud_", name)) {
 
 module ssr_shroud_fastened_assembly(type, cable_d, thickness, name) //! Assembly with screws in place
 {
+    washer = screw_washer(screw);
+    screw_length = screw_shorter_than(2 * washer_thickness(washer) + thickness + insert_length(insert) + counter_bore);
+
     ssr_shroud_assembly(type, cable_d, name);
 
     translate_z(-thickness)
         ssr_shroud_hole_positions(type)
             screw_and_washer(screw, screw_length, true);
+
+    for(side = [-1, 1])
+        translate([ssr_shroud_cable_x(type, cable_d), side * (ssr_width(type) / 2 - 2 * boss_r)]) {
+            rotate(-90)
+                cable_tie(cable_d / 2, thickness);
+
+            *translate_z(cable_d / 2)
+                rotate([90, 0, 0])
+                    color(grey20)
+                        cylinder(d = cable_d, h = 20, center = true);
+        }
+
+
 }

readme.md

@@ -42,8 +42,8 @@ See [usage](docs/usage.md) for requirements, installation instructions and a usa
 <tr><td> <a href = "#Meter">Meter</a> </td><td> <a href = "#Variacs">Variacs</a> </td><td></td><td></td><td></td></tr>
 <tr><td> <a href = "#Microswitches">Microswitches</a> </td><td> <a href = "#Veroboard">Veroboard</a> </td><td></td><td></td><td></td></tr>
 <tr><td> <a href = "#Microview">Microview</a> </td><td> <a href = "#Washers">Washers</a> </td><td></td><td></td><td></td></tr>
-<tr><td> <a href = "#Modules">Modules</a> </td><td> <a href = "#Zipties">Zipties</a> </td><td></td><td></td><td></td></tr>
-<tr><td> <a href = "#Nuts">Nuts</a> </td><td></td><td></td><td></td><td></td></tr>
+<tr><td> <a href = "#Modules">Modules</a> </td><td> <a href = "#Wire">Wire</a> </td><td></td><td></td><td></td></tr>
+<tr><td> <a href = "#Nuts">Nuts</a> </td><td> <a href = "#Zipties">Zipties</a> </td><td></td><td></td><td></td></tr>
 </table>
 
 ---
@@ -2750,6 +2750,53 @@ If a washer is given a child, usually a screw or a nut, then it is placed on its
 |   1 | M80_washer.stl |
 
 
+<a href="#top">Top</a>
+
+---
+<a name="Wire"></a>
+## Wire
+Just a BOM entry at the moment and cable bundle size functions for holes, plus cable ties.
+
+
+[vitamins/wire.scad](vitamins/wire.scad) Implementation.
+
+[tests/wire.scad](tests/wire.scad) Code for this example.
+
+### Functions
+| Function | Description |
+|:--- |:--- |
+| ```cable_bundle(cable)``` | Arrangement of a bundle in a flat cable clip |
+| ```cable_height(cable)``` | Height in flat clip |
+| ```cable_radius(cable)``` | Radius of a bundle of wires, see <http://mathworld.wolfram.com/CirclePacking.html>. |
+| ```cable_width(cable)``` | Width in flat clip |
+| ```cable_wire_size(cable)``` | Size of each wire in a bundle |
+| ```cable_wires(cable)``` | Number of wires in a bindle |
+| ```wire_hole_radius(cable)``` | Radius of a hole to accept a bundle of wires |
+
+### Modules
+| Module | Description |
+|:--- |:--- |
+| ```cable_tie(cable_r, thickness)``` | A ziptie threaded around cable radius ```cable_r``` and through a panel with specified ```thickness```. |
+| ```cable_tie_holes(cable_r, h = 100)``` | Holes to thread a ziptie through a panel to make a cable tie. |
+| ```mouse_hole(cable, h = 100)``` | A mouse hole to allow a panel to go over a wire bundle. |
+| ```ribbon_cable(ways, length)``` | Add ribbon cable to the BOM |
+| ```wire(color, strands, length, strand = 0.2)``` | Add stranded wire to the BOM |
+
+![wire](tests/png/wire.png)
+
+### Vitamins
+| Qty | Module call | BOM entry |
+| ---:|:--- |:---|
+|   1 |  |  Wire black 7/0.2mm strands, length 90mm |
+|   1 |  |  Wire blue 7/0.2mm strands, length 90mm |
+|   1 |  |  Wire brown 7/0.2mm strands, length 90mm |
+|   1 |  |  Wire green 7/0.2mm strands, length 90mm |
+|   1 |  |  Wire orange 7/0.2mm strands, length 90mm |
+|   1 |  |  Wire red 7/0.2mm strands, length 90mm |
+|   1 |  |  Wire yellow 7/0.2mm strands, length 90mm |
+|   1 | ```ziptie(small_ziptie, 2.1)``` |  Ziptie 100mm min length |
+
+
 <a href="#top">Top</a>
 
 ---
@@ -2773,6 +2820,11 @@ Cable zipties.
 | ```ziptie_thickness(type)``` | Thickness |
 | ```ziptie_width(type)``` | Width |
 
+### Modules
+| Module | Description |
+|:--- |:--- |
+| ```ziptie(type, r, t = 0)``` | Draw specified ziptie wrapped around radius ```r``` and optionally through panel thickness ```t``` |
+
 ![zipties](tests/png/zipties.png)
 
 ### Vitamins
@@ -3603,6 +3655,7 @@ The stl and assembly must be given a name and parameterless wrappers for the stl
 ### Functions
 | Function | Description |
 |:--- |:--- |
+| ```ssr_shroud_cable_x(type, cable_d)``` | Position of cable entry holes |
 | ```ssr_shroud_extent(type, cable_d)``` | How far it extends beyond the SSR |
 | ```ssr_shroud_height(type)``` | Outside height |
 | ```ssr_shroud_screw(type)``` | Screw used to fasten |
@@ -3615,6 +3668,7 @@ The stl and assembly must be given a name and parameterless wrappers for the stl
 | ```ssr_shroud_assembly(type, cable_d, name)``` | The printed parts with inserts fitted |
 | ```ssr_shroud_fastened_assembly(type, cable_d, thickness, name)``` | Assembly with screws in place |
 | ```ssr_shroud_hole_positions(type)``` | Place children at the screw hole positions |
+| ```ssr_shroud_holes(type, cable_d)``` | Drill the screw and ziptie holes |
 
 ![ssr_shroud](tests/png/ssr_shroud.png)
 
@@ -3625,6 +3679,7 @@ The stl and assembly must be given a name and parameterless wrappers for the stl
 |   4 | ```screw(M3_cap_screw, 10)``` |  Screw M3 cap x 10mm |
 |   4 | ```washer(M3_washer)``` |  Washer  M3 x 7mm x 0.5mm |
 |   4 | ```star_washer(M3_washer)``` |  Washer star M3 x 0.5mm |
+|   4 | ```ziptie(small_ziptie, 3)``` |  Ziptie 100mm min length |
 
 ### Printed
 | Qty | Filename |

tests/wire.scad

@@ -0,0 +1,82 @@
+//
+// 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/>.
+//
+include <../core.scad>
+
+include <../vitamins/wire.scad>
+
+bundle = [7, 1.4];
+
+bundle_r = cable_radius(bundle);
+
+thickness = 2;
+w = 50;
+d = 20;
+h = 40;
+wire_l = 90;
+
+module wires() {
+    translate_z(bundle_r)
+        rotate([0, 90, 0]) {
+            n = cable_wires(bundle);
+            d = cable_wire_size(bundle);
+            if(n > 6)
+                color("green") {
+                    cylinder(d = d, h = wire_l, center = true);
+                    wire("green", 7, wire_l);
+                }
+
+            m = n > 6 ? n - 1 : n;
+            for(i = [0 : m - 1])
+                rotate(i * 360 / m)
+                    translate([bundle_r - d / 2, 0]) {
+                        colour = ["black", "brown", "red", "orange", "yellow", "blue", "purple"][i];
+                        wire(colour, 7, wire_l);
+                        color(colour)
+                            cylinder(d = d, h = wire_l, center = true);
+                   }
+
+            %cylinder(r = bundle_r, h = wire_l - 10, center = true);
+        }
+
+    color(pp1_colour) {
+        rotate([90, 0, 90])
+            linear_extrude(height = thickness)
+                difference() {
+                    translate([-w / 2, 0])
+                        square([w, h]);
+
+                    mouse_hole(bundle, 0);
+                }
+
+        translate_z(-thickness)
+            linear_extrude(height = thickness)
+                difference() {
+                    translate([thickness -d, -w / 2])
+                        square([d, w]);
+
+                    translate([-15, 0])
+                        cable_tie_holes(bundle_r, 0);
+                }
+    }
+    translate([-15, 0])
+        cable_tie(bundle_r, thickness);
+}
+
+if($preview)
+    wires();

vitamins/wire.scad

@@ -18,59 +18,55 @@
 //
 
 //
-//! Wires. Just a BOM entry at the moment and cable bundle size fuctions for holes. See
-//! <http://mathworld.wolfram.com/CirclePacking.html>.
+//! Just a BOM entry at the moment and cable bundle size functions for holes, plus cable ties.
 //
 include <../core.scad>
 include <zipties.scad>
 
-module wire(color, strands, length, strand = 0.2)
+module wire(color, strands, length, strand = 0.2)   //! Add stranded wire to the BOM
     vitamin(str(": Wire ", color, " ", strands, "/", strand, "mm strands, length ",length, "mm"));
 
-module ribbon_cable(ways, length)
+module ribbon_cable(ways, length)                   //! Add ribbon cable to the BOM
     vitamin(str(": Ribbon cable ", ways, " way ", length, "mm"));
 
 //
 // Cable sizes
 //
-function cable_wires(cable)     = cable[0];
-function cable_wire_size(cable) = cable[1];
+function cable_wires(cable)     = cable[0]; //! Number of wires in a bindle
+function cable_wire_size(cable) = cable[1]; //! Size of each wire in a bundle
 
 // numbers from http://mathworld.wolfram.com/CirclePacking.html
-function cable_radius(cable) = ceil([0, 1, 2, 2.15, 2.41, 2.7, 3, 3, 3.3][cable_wires(cable)] * cable_wire_size(cable)) / 2; // radius of a bundle
+function cable_radius(cable) = [0, 1, 2, 2.15, 2.41, 2.7, 3, 3, 3.3][cable_wires(cable)] * cable_wire_size(cable) / 2; //! Radius of a bundle of wires, see <http://mathworld.wolfram.com/CirclePacking.html>.
 
-function wire_hole_radius(cable) = cable_radius(cable) + 0.5;
+function wire_hole_radius(cable) = cable_radius(cable) + 0.5; //! Radius of a hole to accept a bundle of wires
 
-// arrangement of bundle in flat cable clip
-function cable_bundle(cable) = [[0,0], [1,1], [2,1], [2, 0.5 + sin(60)], [2,2], [3, 0.5 + sin(60)], [3,2]][cable_wires(cable)];
 
-function cable_width(cable)  = cable_bundle(cable)[0] * cable_wire_size(cable); // width in flat clip
-function cable_height(cable) = cable_bundle(cable)[1] * cable_wire_size(cable); // height in flat clip
+function cable_bundle(cable) = //! Arrangement of a bundle in a flat cable clip
+    [[0,0], [1,1], [2,1], [2, 0.5 + sin(60)], [2,2], [3, 0.5 + sin(60)], [3,2]][cable_wires(cable)];
 
-module mouse_hole(cable, h = 100) {
+function cable_width(cable)  = cable_bundle(cable)[0] * cable_wire_size(cable); //! Width in flat clip
+function cable_height(cable) = cable_bundle(cable)[1] * cable_wire_size(cable); //! Height in flat clip
+
+module mouse_hole(cable, h = 100) { //! A mouse hole to allow a panel to go over a wire bundle.
     r = wire_hole_radius(cable);
 
     rotate(90) slot(r, 2 * r, h = h);
 }
 
-module cable_tie_holes(cable_r, h = 100) {
+module cable_tie_holes(cable_r, h = 100) { //! Holes to thread a ziptie through a panel to make a cable tie.
     r = cnc_bit_r;
     l = 3;
     extrude_if(h)
         for(side = [-1, 1])
-            translate([0, side * (cable_r + r)])
+            translate([0, side * (cable_r + ziptie_thickness(small_ziptie) / 2)])
                 hull()
                     for(end = [-1, 1])
                         translate([end * (l / 2 - r), 0])
                             drill(r, 0);
 }
 
-module cable_tie(cable_r, thickness) {
-    w =  2 * (cable_r + cnc_bit_r);
-    translate_z(thickness / 2)
+module cable_tie(cable_r, thickness) { //! A ziptie threaded around cable radius ```cable_r``` and through a panel with specified ```thickness```.
+    translate_z(cable_r)
         rotate([-90, 0, 90])
-            ziptie(small_ziptie, w / 2);
+            ziptie(small_ziptie, cable_r, thickness);
 }
-
-//cable_tie_holes(6 / 2);
-//cable_tie(6 / 2, 3);

vitamins/ziptie.scad

@@ -22,7 +22,7 @@
 //
 
 include <../core.scad>
-use <../utils/tube.scad>
+use <../utils/rounded_polygon.scad>
 
 function ziptie_width(type)     = type[1]; //! Width
 function ziptie_thickness(type) = type[2]; //! Thickness
@@ -30,24 +30,41 @@ function ziptie_latch(type)     = type[3]; //! Latch dimensions
 function ziptie_colour(type)    = type[4]; //! Colour
 function ziptie_tail(type)      = type[5]; //! The length without teeth
 
-module ziptie(type, r)
+module ziptie(type, r, t = 0) //! Draw specified ziptie wrapped around radius ```r``` and optionally through panel thickness ```t```
 {
     latch = ziptie_latch(type);
-    length = ceil(2 * PI * r + ziptie_tail(type) + latch.z + 1);
+    lx = latch.x / 2;
+    zt = ziptie_thickness(type);
+    cr = zt;                        // sharp corner raduus
+    z = r + t - cr;
+    x = r - cr;
+    inside_corners  = t ? [ [0, 0, r],      [-x, z, cr],      [x, z, cr]      ] : [];
+    outside_corners = t ? [ [0, 0, r + zt], [-x, z, cr + zt], [x, z, cr + zt] ] : [];
+    x1 = lx - zt / 2;
+    x2 = x1 + x1 * zt / r;
+    inside_path  = concat([ [0, 0, r],      [x1, -r,      eps] ], inside_corners);
+    outside_path = concat([ [0, 0, r + zt], [x2, -r - zt, eps] ], outside_corners);
+
+    tangents = rounded_polygon_tangents(outside_path);
+    length = ceil(rounded_polygon_length(outside_path, tangents) + ziptie_tail(type) + latch.z + 1);
     len = length <= 100 ? 100 : length;
+
     vitamin(str("ziptie(", type[0], ", ", r, "): Ziptie ", len, "mm min length"));
 
-    angle = (r > latch.x / 2) ? asin((latch.x / 2) / r) - asin(ziptie_thickness(type) / latch.x) : 0;
-    color(ziptie_colour(type)) union() {
-        tube(ir = r, or = r + ziptie_thickness(type), h = ziptie_width(type));
-        translate([0, -r, - latch.y / 2])
-            rotate([90, 0, angle]) {
-                union() {
-                    cube(latch);
+    color(ziptie_colour(type)){
+        linear_extrude(height = ziptie_width(type), center = true)
+            difference() {
+                rounded_polygon(outside_path, tangents);
+                rounded_polygon(inside_path);
+             }
 
-                    translate([latch.x / 2, latch.y / 2, (latch.z + 1) / 2])
+        translate([lx, -r])
+             rotate([90, 0, 0])
+                union() {
+                    rounded_rectangle(latch, 0.5, center = false);
+
+                    translate_z((latch.z + 1) / 2)
                         cube([ziptie_thickness(type), ziptie_width(type), latch.z + 1], center = true);
                 }
      }
-    }
 }