IEC mains connector models more accurate.

examples/MainsBreakOutBox/scad/bob_main.scad

@@ -60,7 +60,7 @@ insert_length = insert_length(insert);
 insert_boss = mains_socket_insert_boss(socket);
 screw_length = screw_longer_than(mains_socket_height(socket) + insert_length(insert));
 
-iec_h = iec_slot_h(iec) + 1;
+iec_h = iec_body_h(iec) + 1;
 
 box_height = socket_depth + iec_h;
 base_thickness = wall;

readme.md

@@ -766,6 +766,10 @@ IEC mains inlets and outlet.
 | ```iec_bezel_r(type)``` | Bezel corner radius |
 | ```iec_bezel_t(type)``` | Bezel thickness |
 | ```iec_bezel_w(type)``` | Bezel width |
+| ```iec_body_h(type)``` | Body height |
+| ```iec_body_r(type)``` | Body corner radius |
+| ```iec_body_w(type)``` | Body width |
+| ```iec_body_w2(type)``` | Body width at the narrow part |
 | ```iec_depth(type)``` | Depth of the body below the flange |
 | ```iec_flange_h(type)``` | Flange height |
 | ```iec_flange_r(type)``` | Flange corner radius |
@@ -775,9 +779,6 @@ IEC mains inlets and outlet.
 | ```iec_part(type)``` | Description |
 | ```iec_pitch(type)``` | Screw hole pitch |
 | ```iec_screw(type)``` | Screw type |
-| ```iec_slot_h(type)``` | Body height |
-| ```iec_slot_r(type)``` | Body corner radius |
-| ```iec_slot_w(type)``` | Body width |
 | ```iec_spades(type)``` | Spade type |
 | ```iec_width(type)``` | Widest part including the lugs |
 
@@ -800,14 +801,15 @@ IEC mains inlets and outlet.
 ### Vitamins
 | Qty | Module call | BOM entry |
 | ---:|:--- |:---|
-|   1 | ```iec(IEC_fused_inlet)``` |  IEC fused inlet |
+|   1 | ```iec(IEC_fused_inlet)``` |  IEC fused inlet JR-101-1F |
+|   1 | ```iec(IEC_fused_inlet2)``` |  IEC fused inlet old |
 |   1 | ```iec(IEC_inlet)``` |  IEC inlet |
 |   1 | ```iec(IEC_inlet_atx)``` |  IEC inlet for ATX |
-|   1 | ```iec(IEC_outlet)``` |  IEC outlet |
+|   1 | ```iec(IEC_outlet)``` |  IEC outlet RS 811-7193 |
-|   8 | ```nut(M3_nut, nyloc = true)``` |  Nut M3 x 2.4mm nyloc |
+|  10 | ```nut(M3_nut, nyloc = true)``` |  Nut M3 x 2.4mm nyloc |
 |   4 | ```screw(M3_cs_cap_screw, 10)``` |  Screw M3 cs cap x 10mm |
-|   4 | ```screw(M3_cs_cap_screw, 12)``` |  Screw M3 cs cap x 12mm |
+|   6 | ```screw(M3_cs_cap_screw, 12)``` |  Screw M3 cs cap x 12mm |
-|   8 | ```washer(M3_washer)``` |  Washer  M3 x 7mm x 0.5mm |
+|  10 | ```washer(M3_washer)``` |  Washer  M3 x 7mm x 0.5mm |
 
 
 <a href="#top">Top</a>

vitamins/iec.scad

@@ -30,21 +30,22 @@ include <inserts.scad>
 function iec_part(type)     = type[1];  //! Description
 function iec_screw(type)    = type[2];  //! Screw type
 function iec_pitch(type)    = type[3];  //! Screw hole pitch
-function iec_slot_w(type)   = type[4];  //! Body width
+function iec_body_w(type)   = type[4];  //! Body width
-function iec_slot_h(type)   = type[5];  //! Body height
+function iec_body_w2(type)  = type[5];  //! Body width at the narrow part
-function iec_slot_r(type)   = type[6];  //! Body corner radius
+function iec_body_h(type)   = type[6];  //! Body height
-function iec_bezel_w(type)  = type[7];  //! Bezel width
+function iec_body_r(type)   = type[7];  //! Body corner radius
-function iec_bezel_h(type)  = type[8];  //! Bezel height
+function iec_bezel_w(type)  = type[8];  //! Bezel width
-function iec_bezel_r(type)  = type[9];  //! Bezel corner radius
+function iec_bezel_h(type)  = type[9];  //! Bezel height
-function iec_bezel_t(type)  = type[10]; //! Bezel thickness
+function iec_bezel_r(type)  = type[10];  //! Bezel corner radius
-function iec_flange_w(type) = type[11]; //! Flange width not including the lugs
+function iec_bezel_t(type)  = type[11]; //! Bezel thickness
-function iec_flange_h(type) = type[12]; //! Flange height
+function iec_flange_w(type) = type[12]; //! Flange width not including the lugs
-function iec_flange_r(type) = type[13]; //! Flange corner radius
+function iec_flange_h(type) = type[13]; //! Flange height
-function iec_flange_t(type) = type[14]; //! Flange thickness
+function iec_flange_r(type) = type[14]; //! Flange corner radius
-function iec_width(type)    = type[15]; //! Widest part including the lugs
+function iec_flange_t(type) = type[15]; //! Flange thickness
-function iec_depth(type)    = type[16]; //! Depth of the body below the flange
+function iec_width(type)    = type[16]; //! Widest part including the lugs
-function iec_spades(type)   = type[17]; //! Spade type
+function iec_depth(type)    = type[17]; //! Depth of the body below the flange
-function iec_male(type)     = type[18]; //! True for an outlet
+function iec_spades(type)   = type[18]; //! Spade type
+function iec_male(type)     = type[19]; //! True for an outlet
 
 insert_screw_length = 10;
 function iec_insert_screw_length() = insert_screw_length; //! Screw length used for inserts
@@ -68,10 +69,10 @@ module iec(type) { //! Draw specified IEC connector
                     cube([pin_w, pin_d, h - pin_chamfer], center = true);
             }
 
-    socket_w  = 24;
+    socket_w  = 24.5;
     socket_w2 = 14;
-    socket_h  = 16.5;
+    socket_h  = 16.34;
-    socket_h2 = 12;
+    socket_h2 = socket_h - (socket_w - socket_w2);
     socket_d  = 17;
     socket_r = 3;
     socket_r2 = 0.5;
@@ -83,7 +84,7 @@ module iec(type) { //! Draw specified IEC connector
                 translate([side * (socket_w / 2 - socket_r), -socket_h / 2 + socket_r])
                     circle(socket_r);
 
-                translate([side * (socket_w / 2 - socket_r2), -socket_h / 2 + socket_h2 + socket_r2])
+                translate([side * (socket_w / 2 - socket_r2), socket_h2 / 2 - socket_r2])
                     circle(socket_r2);
 
                 translate([side * (socket_w2 / 2 - socket_r2), socket_h / 2 - socket_r2])
@@ -94,7 +95,7 @@ module iec(type) { //! Draw specified IEC connector
         translate([0, socket_offset])
             if(iec_male(type))
                 difference() {
-                    offset(3)
+                    offset(2)
                         socket_shape();
 
                     difference() {
@@ -111,6 +112,28 @@ module iec(type) { //! Draw specified IEC connector
             else
                 socket_shape();
 
+    module body_shape() {
+        hull() {
+            bw = iec_body_w(type);
+            bh = iec_body_h(type);
+            br = iec_body_r(type);
+            bw2 = iec_body_w2(type);
+            bh2 = bh - (bw - bw2);
+            br2 = 1;
+
+            for(side = [-1, 1]) {
+                translate([side * (bw / 2 - br), -bh / 2 + br])
+                    circle4n(br);
+
+                translate([side * (bw / 2 - br2), bh2 / 2 - br2])
+                    circle4n(br2);
+
+                translate([side * (bw2 / 2 - br2), bh / 2 - br2])
+                    circle4n(br2);
+            }
+        }
+    }
+
     color(grey20) {
         // Flange
         flange_t = iec_flange_t(type);
@@ -153,12 +176,14 @@ module iec(type) { //! Draw specified IEC connector
         translate_z(-h)
             linear_extrude(height = h)
                 difference() {
-                    rounded_square([iec_slot_w(type), iec_slot_h(type)], iec_slot_r(type));
+                    body_shape();
+
                     oriffice_shape();
                 }
         // Back
         translate_z(-iec_depth(type))
-            rounded_rectangle([iec_slot_w(type), iec_slot_h(type), iec_depth(type) - h], iec_slot_r(type), center = false);
+            linear_extrude(height = iec_depth(type) - h)
+                body_shape();
     }
     if(!iec_male(type))
         translate([0, socket_offset, iec_flange_t(type) + iec_bezel_t(type) - socket_d]) {
@@ -175,6 +200,8 @@ module iec(type) { //! Draw specified IEC connector
                 spade(spade[0], spade[1]);
 }
 
+function iec_spade_depth(type) = iec_depth(type) + max([for(spade = iec_spades(type)) spade[1]]);
+
 module iec_screw_positions(type) //! Position children at the screw holes
     for(side = [-1, 1])
         translate([side * iec_pitch(type) / 2, 0])
@@ -204,11 +231,11 @@ module iec_holes(type, h = 100, poly = false, horizontal = false, insert = false
     extrude_if(h)
         hull()
             for(x = [-1, 1], y = [-1, 1], sag = horizontal && y > 1 ? layer_height : 0)
-                translate([x * (iec_slot_w(type) / 2 - iec_slot_r(type)), y * (iec_slot_h(type) / 2  - iec_slot_r(type) + sag )])
+                translate([x * (iec_body_w(type) / 2 - iec_body_r(type)), y * (iec_body_h(type) / 2  - iec_body_r(type) + sag )])
                     if(horizontal)
-                        teardrop(0, iec_slot_r(type) + clearance / 2 + layer_height / 4);
+                        teardrop(0, iec_body_r(type) + clearance / 2 + layer_height / 4);
                     else
-                        drill(iec_slot_r(type) + clearance / 2, 0);
+                        drill(iec_body_r(type) + clearance / 2, 0);
 }
 
 module iec_inserts(type) {              //! Place the inserts

vitamins/iecs.scad

@@ -19,29 +19,43 @@
 include <screws.scad>
 include <spades.scad>
 
-fused_spades = [[spade6p4, 14,  -7,  0, 0],
+fused_spades = [[spade4p8, 8.5,  7,  3, 90],
-                [spade6p4, 14,   7,  0, 0],
+                [spade4p8, 8.5,  0,  7, 90],
-                [spade6p4, 14,   0, 11, 0],
+                [spade4p8, 8.5,  5, -7, 90]];
+
+fused_spades2 = [[spade6p4, 13,  -7,  0, 0],
+                [spade6p4, 13,   7,  0, 0],
+                [spade6p4, 13,   0, 11, 0],
                 [spade4p8, 8.5, -7, -9, 90],
                 [spade4p8, 8.5,  7, -9, 90]];
 
 inlet_spades = [[spade6p4, 9, -7,  -5.5, 0],
                 [spade6p4, 9,  7,  -5.5, 0],
                 [spade6p4, 9,  0,   5.5, 0]];
-//
-//                                    p                    s                p   s     s     s  b   b     b  b    f   f   f  f    w   d   s            m
-//                                    a                    c                i   l     l     l  e   e     e  e    l   l   l  l    i   e   p            a
-//                                    r                    r                t   o     o     o  z   z     z  z    a   a   a  a    d   p   a            l
-//                                    t                    e                c   t     t     t  e   e     e  e    n   n   n  n    t   t   d            e
-//                                                         w                h                  l   l     l  l    g   g   g  g    h   h   e
-//                                                                              w     h     r                    e   e   e  e            s
-//                                                                                             w   h     r  t
-//                                                                                                               w   h   r  t
-//
-IEC_fused_inlet = ["IEC_fused_inlet", "IEC fused inlet",   M3_cs_cap_screw, 36, 27.3, 31.2, 3, 28, 31,   2, 2.5, 30, 33, 4, 2.5, 44, 21, fused_spades, false ];
-IEC_inlet       = ["IEC_inlet",       "IEC inlet",         M3_cs_cap_screw, 40, 28.2, 20.2, 3, 28, 20.5, 4, 2.5, 37, 23, 1, 2.5, 48, 14, inlet_spades, false ];
-IEC_inlet_atx   = ["IEC_inlet_atx",   "IEC inlet for ATX", M3_cs_cap_screw, 40, 27.0, 19.0, 3, 30, 22,   2, 2.0, 30, 22, 2, 4.0, 50, 13, inlet_spades, false ];
-IEC_outlet      = ["IEC_outlet",      "IEC outlet",        M3_cs_cap_screw, 40, 32,   24,   3, 28, 20.5, 2, 0.0, 29, 29, 2, 2.9, 50, 23, inlet_spades, true ];
 
-iecs = [IEC_inlet, IEC_inlet_atx, IEC_fused_inlet, IEC_outlet];
+atx_spades = [[spade3p5, 8, -7,  -3, 90],
+              [spade3p5, 8,  7,  -3, 90],
+              [spade3p5, 8,  0,   3, 90]];
+
+outlet_spades = [[spade4p8ll, 8, -7,  -2, 90],
+                 [spade4p8ll, 8,  7,  -2, 90],
+                 [spade4p8ll, 8,  0,   2, 90]];
+
+//
+//                                    p                              s                p    b   b   b  b   b     b    b    b   f     f  f    f   w   d   s            m
+//                                    a                              c                i    o   o   o  o   e     e    e    e   l     l  l    l   i   e   p            a
+//                                    r                              r                t    d   d   d  d   z     z    z    z   a     a  a    a   d   p   a            l
+//                                    t                              e                c    y   y   y  y   e     e    e    e   n     n  n    n   t   t   d            e
+//                                                                   w                h                   l     l    l    l   g     g  g    g   h   h   e
+//                                                                                         w   w   h  r                       e     e  e    e           s
+//                                                                                             2          w     h    r    t
+//                                                                                                                            w     h  r    t
+IEC_fused_inlet = ["IEC_fused_inlet", "IEC fused inlet JR-101-1F",   M3_cs_cap_screw, 36, 27, 16, 31, 3, 28,   31,   2, 2.0, 30,   33, 4, 3.0, 44, 15, fused_spades,  false ];
+IEC_fused_inlet2= ["IEC_fused_inlet2","IEC fused inlet old",         M3_cs_cap_screw, 36, 27, 14, 31, 3, 28,   31,   2, 2.5, 30,   33, 4, 2.5, 44, 18, fused_spades2, false ];
+
+IEC_inlet       = ["IEC_inlet",       "IEC inlet",                   M3_cs_cap_screw, 40, 28, 18, 20, 3, 28,   20.5, 4, 2.5, 37,   23, 1, 2.5, 48, 14, inlet_spades,  false ];
+IEC_inlet_atx   = ["IEC_inlet_atx",   "IEC inlet for ATX",           M3_cs_cap_screw, 40, 27, 18, 19, 3, 30.5, 22,   2, 2.0, 30.5, 22, 2, 4.0, 50, 15, atx_spades,    false ];
+IEC_outlet      = ["IEC_outlet",      "IEC outlet RS 811-7193",      M3_cs_cap_screw, 40, 32, 18, 24, 3, 28,   20.5, 2, 0.0, 29,   29, 2, 2.8, 50, 23, outlet_spades, true ];
+
+iecs = [IEC_inlet, IEC_inlet_atx, IEC_fused_inlet, IEC_fused_inlet2, IEC_outlet];
 use <iec.scad>

vitamins/spades.scad

@@ -18,11 +18,12 @@
 //
 
 spade3     = [3.8, 3.0, 0.4, 1.0,  3.9];
+spade3p5   = [7.0, 3.5, 0.8, 1.75, 6.8];
 spade6p4   = [8.3, 6.4, 0.8, 1.8,  8];
 spade4p8   = [6.4, 4.8, 0.5, 1.8,  8];
 spade4p8l  = [7.0, 4.8, 0.5, 1.8,  8];
 spade4p8ll = [8.0, 4.8, 0.5, 1.8,  4.8];
 
-spades = [spade3, spade6p4, spade4p8, spade4p8l, spade4p8ll];
+spades = [spade3, spade3p5, spade6p4, spade4p8, spade4p8l, spade4p8ll];
 
 use <spade.scad>