Fixed bugs in poly_ring() and insert_boss().

IEC screw length fixed at 10 if inserts used.

examples/MainsBreakOutBox/bom/bom.json

@@ -26,7 +26,7 @@
                     "vitamins": {
                         "washer(M3_washer): Washer  M3 x 7mm x 0.5mm": 8,
                         "screw(M3_dome_screw, 10): Screw M3 dome x 10mm": 4,
-                        "nut(M3_nut, nyloc = true): Nut M3 nyloc": 4
+                        "nut(M3_nut, nyloc = true): Nut M3 x 2.4mm nyloc": 4
                     },
                     "printed": {
                         "foot.stl": 4
@@ -42,7 +42,7 @@
                 "iec(IEC_inlet_atx): IEC inlet for ATX": 1,
                 "screw(M3_cs_cap_screw, 12): Screw M3 cs cap x 12mm": 2,
                 "washer(M3_washer): Washer  M3 x 7mm x 0.5mm": 2,
-                "nut(M3_nut, nyloc = true): Nut M3 nyloc": 2
+                "nut(M3_nut, nyloc = true): Nut M3 x 2.4mm nyloc": 2
             },
             "printed": {},
             "routed": {}

examples/MainsBreakOutBox/bom/bom.txt

@@ -17,7 +17,7 @@ Vitamins:
   |  | 1|  |  1 4mm shielded jack socket brown
   |  | 2|  |  2 4mm shielded jack socket green
   |  | 1|  |  1 Mains socket 13A
-  | 4|  | 2|  6 Nut M3 nyloc
+  | 4|  | 2|  6 Nut M3 x 2.4mm nyloc
   |  |  | 2|  2 Screw M3 cs cap x 12mm
   |  | 2|  |  2 Screw M3 cs cap x 20mm
   | 4|  |  |  4 Screw M3 dome x 10mm

examples/MainsBreakOutBox/bom/feet_assembly.txt

@@ -1,6 +1,6 @@
 feet_assembly:
 Vitamins:
-  4 Nut M3 nyloc
+  4 Nut M3 x 2.4mm nyloc
   4 Screw M3 dome x 10mm
   8 Washer  M3 x 7mm x 0.5mm
 

examples/MainsBreakOutBox/bom/mains_in_assembly.txt

@@ -4,7 +4,7 @@ Vitamins:
   2 Wire brown 30/0.25mm strands, length 150mm - not shown
   1 Wire green & yellow 30/0.25mm strands, length 150mm - not shown
   1 IEC inlet for ATX
-  2 Nut M3 nyloc
+  2 Nut M3 x 2.4mm nyloc
   2 Screw M3 cs cap x 12mm
   3 Heatshrink sleeving ID 3.2mm x 15mm - not shown
   2 Washer  M3 x 7mm x 0.5mm

examples/MainsBreakOutBox/readme.md

@@ -39,7 +39,7 @@ Earth leakage can be measured Canadian CSA style by disconnected the neutral lin
 |   .  |   .  |   3  |   5  |    8  |    Heatshrink sleeving ID 3.2mm x 15mm - not shown |
 |   .  |   .  |   1  |   .  |    1  |    IEC inlet for ATX |
 |   .  |   .  |   .  |   1  |    1  |    Mains socket 13A |
-|   .  |   4  |   2  |   .  |    6  |    Nut M3 nyloc |
+|   .  |   4  |   2  |   .  |    6  |    Nut M3 x 2.4mm nyloc |
 |   .  |   .  |   2  |   .  |    2  |    Screw M3 cs cap x 12mm |
 |   .  |   .  |   .  |   2  |    2  |    Screw M3 cs cap x 20mm |
 |   .  |   4  |   .  |   .  |    4  |    Screw M3 dome x 10mm |
@@ -88,7 +88,7 @@ Earth leakage can be measured Canadian CSA style by disconnected the neutral lin
 |--:|:----------|
 |8| Washer  M3 x 7mm x 0.5mm|
 |4| Screw M3 dome x 10mm|
-|4| Nut M3 nyloc|
+|4| Nut M3 x 2.4mm nyloc|
 
 
 ### 3D Printed parts
@@ -129,7 +129,7 @@ Earth leakage can be measured Canadian CSA style by disconnected the neutral lin
 |1| IEC inlet for ATX|
 |2| Screw M3 cs cap x 12mm|
 |2| Washer  M3 x 7mm x 0.5mm|
-|2| Nut M3 nyloc|
+|2| Nut M3 x 2.4mm nyloc|
 
 
 ### Sub-assemblies

readme.md

@@ -781,12 +781,18 @@ IEC mains inlets and outlet.
 | ```iec_spades(type)``` | Spade type |
 | ```iec_width(type)``` | Widest part including the lugs |
 
+### Functions
+| Function | Description |
+|:--- |:--- |
+| ```iec_insert_screw_length()``` | Screw length used for inserts |
+
 ### Modules
 | Module | Description |
 |:--- |:--- |
 | ```iec(type)``` | Draw specified IEC connector |
 | ```iec_assembly(type, thickness)``` | Assembly with fasteners given panel thickness |
 | ```iec_holes(type, h = 100, poly = false, horizontal = false, insert = false)``` | Drill the required panel holes |
+| ```iec_inserts(type)``` | Place the inserts |
 | ```iec_screw_positions(type)``` | Position children at the screw holes |
 
 ![iecs](tests/png/iecs.png)

utils/core/polyholes.scad

@@ -23,9 +23,9 @@
 //!
 //! The module provides `poly_circle()`, `poly_cylinder()` and `poly_ring()` that is useful for making printed washers and pillars.
 //
-function sides(r) = max(round(4 * r), 3); //! Optimium number of sides for specified radius
+function sides(r) = max(round(4 * r), 3);                                       //! Optimium number of sides for specified radius
-function corrected_radius(r, n = 0)   = r / cos(180 / (n ? n : sides(r))); //! Adjusted radius to make flats lie on the circle
+function corrected_radius(r, n = 0)   = r / cos(180 / (n ? n : sides(r)));      //! Adjusted radius to make flats lie on the circle
-function corrected_diameter(d, n = 0) = d / cos(180 / (n ? n : sides(d / 2))); //! Adjusted diameter to make flats lie on the circle
+function corrected_diameter(d, n = 0) = d / cos(180 / (n ? n : sides(d / 2)));  //! Adjusted diameter to make flats lie on the circle
 
 module poly_circle(r, sides = 0) { //! Make a circle adjusted to print the correct size
     n = sides ? sides : sides(r);
@@ -38,8 +38,8 @@ module poly_cylinder(r, h, center = false, sides = 0) //! Make a cylinder adjust
 
 module poly_ring(or, ir) { //! Make a 2D ring adjusted to have the correct internal radius
     cir = corrected_radius(ir);
-    filaments = floor((or - cir) / extrusion_width);
+    filaments = (or - cir) / extrusion_width;
-    if(filaments > 3)
+    if(filaments > 3 + eps)
         difference() {
             circle(or);
 

vitamins/iec.scad

@@ -46,7 +46,8 @@ function iec_depth(type)    = type[16]; //! Depth of the body below the flange
 function iec_spades(type)   = type[17]; //! Spade type
 function iec_male(type)     = type[18]; //! True for an outlet
 
-insert_overlap = 1.1; // chosen to make cap screws 10mm long.
+insert_screw_length = 10;
+function iec_insert_screw_length() = insert_screw_length; //! Screw length used for inserts
 
 module iec(type) { //! Draw specified IEC connector
     vitamin(str("iec(", type[0], "): ", iec_part(type)));
@@ -181,18 +182,24 @@ module iec_screw_positions(type) //! Position children at the screw holes
 
 module iec_holes(type, h = 100, poly = false, horizontal = false, insert = false) { //! Drill the required panel holes
     clearance = 0.2;
+    screw = iec_screw(type);
+    insert_type = screw_insert(screw);
+    insert_overlap = max(0, insert_screw_length + clearance - iec_flange_t(type) - insert_hole_length(insert_type));
 
     iec_screw_positions(type)
         if(insert)
-            insert_hole(screw_insert(iec_screw(type)), insert_overlap, horizontal = horizontal);
+            if(h)
+                insert_hole(insert_type, insert_overlap, horizontal = horizontal);
+            else
+                poly_circle(insert_hole_radius(insert_type));
         else
             if(horizontal)
-                teardrop_plus(r = screw_clearance_radius(iec_screw(type)), h = h);
+                teardrop_plus(r = screw_clearance_radius(screw), h = h);
             else
                 if(poly)
-                    poly_cylinder(r = screw_clearance_radius(iec_screw(type)), h = h, center = true);
+                    poly_cylinder(r = screw_clearance_radius(screw), h = h, center = true);
                 else
-                    drill(screw_clearance_radius(iec_screw(type)), h);
+                    drill(screw_clearance_radius(screw), h);
 
     extrude_if(h)
         hull()
@@ -204,13 +211,20 @@ module iec_holes(type, h = 100, poly = false, horizontal = false, insert = false
                         drill(iec_slot_r(type) + clearance / 2, 0);
 }
 
-module iec_assembly(type, thickness) { //! Assembly with fasteners given panel thickness
+module iec_inserts(type) {              //! Place the inserts
+    insert = screw_insert(iec_screw(type));
+
+    iec_screw_positions(type)
+        insert(insert);
+}
+
+module iec_assembly(type, thickness) {  //! Assembly with fasteners given panel thickness
     screw = iec_screw(type);
     washer = screw_washer(screw);
     nut = screw_nut(screw);
     insert = screw_insert(screw);
     screw_length = thickness ? screw_longer_than(iec_flange_t(type) + thickness + washer_thickness(washer) + nut_thickness(nut, true))
-                             : screw_shorter_than(iec_flange_t(type) + insert_hole_length(insert) + insert_overlap);
+                             : insert_screw_length;
 
     iec(type);
 
@@ -222,7 +236,5 @@ module iec_assembly(type, thickness) { //! Assembly with fasteners given panel t
             translate_z(-thickness)
                 vflip()
                     nut_and_washer(nut, true);
-        else
-            insert(insert);
     }
 }

vitamins/insert.scad

@@ -94,12 +94,14 @@ module insert_hole(type, counterbore = 0, horizontal = false) { //! Make a hole
 }
 
 module insert_boss(type, z, wall = 2 * extrusion_width) { //! Make a boss to take an insert
-    difference() {
+    render(convexity = 3)
-        ir = insert_hole_radius(type);
+        difference() {
-        linear_extrude(height = z)
+            ir = insert_hole_radius(type);
-            poly_ring(corrected_radius(ir) + wall, insert_screw_diameter(type) / 2 + 0.1);
+            linear_extrude(height = z)
+                hull()
+                    poly_ring(corrected_radius(ir) + wall, ir);
 
-        translate_z(z)
+            translate_z(z)
-            insert_hole(type, max(0, z - insert_hole_length(type) - 2 * layer_height));
+                insert_hole(type, max(0, z - insert_hole_length(type) - 2 * layer_height));
-    }
+        }
 }