lianshroud/fan_mount.scad

/* */

include <BOSL/shapes.scad>
include <BOSL/transforms.scad>
include <inserts/inserts.scad>

/* [Mount Dimensions] */
CASE_HOLE_X =   5.6;
CASE_HOLE_Z =  11.00;
CASE_HOLE_Y =   1.4;

TAB_YOUT = 3.9;
TAB_THICK = 3;
TAB_Z = 9.6;

SCREEN_Y = 19.0; // Saggitta of mesh path
SCREEN_X = 131.6;

FAN_MOUNT_X = 128.6;
FAN_MOUNT_Z =  69.4;

/* [Render Options] */
render_show="none"; // [both, bottom, top, washer]
render_fs=.4;
render_fn=0;
render_fa=.4;

// Set Render Options
$fs= ($preview) ? $fs : render_fs;
$fn= ($preview) ? $fn : render_fn;
$fa= ($preview) ? $fa : render_fa;

module case_washer(align=V_CENTER, orient=ORIENT_Z) {
	size=[CASE_HOLE_X+5, 3, CASE_HOLE_Z+5];
	orient_and_align(size,align=align,orient=orient,orig_align=V_CENTER, orig_orient=ORIENT_Z)
	difference() {
		cuboid(size);
		left(3) {
			cyl(d=3.5, h=4, orient=ORIENT_Y);
			cyl(d=7, h=4, align=V_BACK, orient=ORIENT_Y);
		}
	}
}

module case_hole(x=CASE_HOLE_X, y=CASE_HOLE_Y, z=CASE_HOLE_Z, align=V_FRONT)
{
	cuboid([x,y,z], align=V_FRONT);
}



module snap(top=true)
{
	cut_align= top ? V_BOTTOM : V_TOP;
	zi = top ? 1 : -1;
	down(zi*2.2)up(zi*(.2+CASE_HOLE_Z/2)) {
		difference() {
			union() {
				cuboid([CASE_HOLE_X-.2, CASE_HOLE_Y+.3, 3], align=V_FRONT);
				fwd(CASE_HOLE_Y+1+.2) {
					cuboid([CASE_HOLE_X-.2, 2, 4], chamfer=1, edges=EDGES_X_FR);
				}		
			}
			up(zi*.6)cuboid([CASE_HOLE_X, 6+CASE_HOLE_Y, 4], align=cut_align);
		}
	
	}
	%case_hole();
}

module snap_base()
{
	difference() {
		cuboid([CASE_HOLE_X-.2, CASE_HOLE_Y/4, CASE_HOLE_Z-1.2], align=V_FRONT);
		zspread(n=5,l=CASE_HOLE_Z-4) fwd((CASE_HOLE_Y)/2)cyl(h=CASE_HOLE_X, d=1, orient=ORIENT_X);
	}
}

function mesh_radius(s,l) = (s^2 + (l^2)/4) / (2 * s);
SCREEN_R = mesh_radius(s=SCREEN_Y, l=SCREEN_X);
echo ("MESHR: ", SCREEN_R);
function mesh_theta(l,r) = PI * 2*asin(l/(2*r)) / 180;
echo("Mesh_Theta", mesh_theta(SCREEN_X,SCREEN_R), "radians");

echo("mesh Width = ", SCREEN_R * mesh_theta(SCREEN_X-4, SCREEN_R));

module meshpath(s = SCREEN_Y, l= SCREEN_X, w=2, h=130) {
	r = mesh_radius(s=s, l=l);
	intersection() {
		fwd(r-21) difference() {
			cyl(r=r+w/2, h=h); 
			cyl(r=r-w/2, h=h+w/2); 
		}
		back(1) cuboid([128.6,30,h], align=V_BACK);
	}
}

module rail(left=true, h=265, align=V_BACK, orient=ORIENT_Z) {
	lr = left ? 1 : -1;
	size = [CASE_HOLE_X+2,9,h];
	orient_and_align(size, orient=orient, align=align, orig_align=V_BACK)
	difference() {
		back(0)cuboid(size, chamfer=1.5, edges=EDGES_Z_BK, align=V_BACK);
		back(2)left(lr*FAN_MOUNT_X/2) meshpath(h=h+2);
	}
}

module endcap(orient=ORIENT_Z, align=V_BACK, s=SCREEN_Y, l=SCREEN_X, h=5) {
	r = mesh_radius(s=s, l=l);
	orient_and_align([99*2,25,h], orient=orient, align=align, orig_align=V_BACK)
	difference() {
		intersection() {
			fwd(r-23)cyl(r=r+1, h=h); 
			cuboid([66*2,200,131], align=V_BACK);
		}
		back(2)up(2) meshpath(h=h, w=2.1);
		//fwd(94-25)cyl(r=92, h=11); 
	}
}


//%meshpath(h=265-5);
module mesh_mount(h=265, align=V_FRONT,orient=ORIENT_Z,top=true, bottom=true) {
	parts =  (top && bottom)
		?  [-1,1]
		:  top ? [1] : [-1];
		
	echo("parts: ", len(parts));
	rh = len(parts) * h/2;
	orient_and_align([2*128.6, 9, 265], orient=orient,align=align) union() {
	difference() {
		union() {
			right(128.6/2) rail(left=true, h=rh, align=V_BACK);
			left(128.6/2) rail(left=false, h=rh, align=V_BACK);
			if (bottom) down(rh/2) endcap(align=V_BACK+V_TOP);
			if (top) up(rh/2) endcap(align=V_BACK+V_BOTTOM, orient=ORIENT_ZNEG);
		}
		hoff = (len(parts) == 2) ? 0 : rh/2;
		if (top) up(59.6/2-hoff)mount_holes(align=V_TOP);
		if (bottom)down(59.6/2-hoff)mount_holes(align=V_BOTTOM);
	}
	brace_z = len(parts) * 10/2;
	brace_off = (len(parts) == 2)
		? 0
		: top ? -(rh-brace_z)/2 : (rh-brace_z)/2;
	up(brace_off) cuboid([125, 1, brace_z], align=V_BACK);
	}
}

module mount_holes(align=V_TOP) {
	orient_and_align(size=[FAN_MOUNT_X,0,FAN_MOUNT_Z+CASE_HOLE_Z], align=align)
	zspread(l=FAN_MOUNT_Z) { 
		xspread(l=FAN_MOUNT_X) {
			back(0) xrot(90) thread_insertM3(bl=10,bz=-5,$die=true);
			%back(0) xrot(90) thread_insertM3(bl=10,bz=-5,$die=false);
		}
	}
}

module fdm_anchor(r=3, d=.4, h=.2) {
	union() {
		//back(d+r)
		zrot(45) back(r) {
			cyl(r=r, h=h, align=V_TOP);	
			fwd(r/2)cuboid([.5,r,h], align=V_FRONT+V_TOP);
		}
	}
}


module print_washer() {
	back((CASE_HOLE_Z+5)/2)left((CASE_HOLE_X+5)/2) fdm_anchor();
	fwd((CASE_HOLE_Z+5)/2)left((CASE_HOLE_X+5)/2) zrot(90) fdm_anchor();
	back((CASE_HOLE_Z+5)/2)right((CASE_HOLE_X+5)/2) zrot(-90) fdm_anchor();
	fwd((CASE_HOLE_Z+5)/2)right((CASE_HOLE_X+5)/2) zrot(180) fdm_anchor();
	case_washer(orient=ORIENT_Y, align=V_TOP);
}

if (render_show == "both") mesh_mount(top=true);