encradio-10-support.scad

use <fake-clip-plane.scad>

{ // Part parameters
  // - Overall dimensions
  height_z = 100;
  width_x = 51;
  depth_y = 42;
  // The part extends on the back (width_x x depth_y is the base of the
  // device)
  depth_negative_offset_y = 2;

  bottom_plate_height_z = 1;
  side_plate_width = 3;

  // This is the width of the from wall
  return_wall_width_x = 5.25;

  banana_diameter = 10.75;
  red_banana_x = 11.25 + (banana_diameter/2);
  red_banana_y = 20.50 + (banana_diameter/2);
  green_banana_x = width_x - red_banana_x;
  green_banana_y = 20.50 + (banana_diameter/2);
  black_banana_x = width_x/2;
  black_banana_y = 27.5 + (banana_diameter/2);

  strap_1_z = 15;
  strap_2_z = 55;
  strap_height_z = 22;
  strap_width_y = depth_negative_offset_y + 1;
  start_stop = "Start";

  // Clip piece
  pole_diameter_xy = 28;
  clip_height_z = 20;
  clip_thickness_xy = 7.5;
  clip_angle = 40;
  termination_offset_x = 2;
  termination_stretch_y = 1.15;
  termination_diameter = 4.2;

  // Set display to one of: 
  // (support|clip|support_and_clip|
  //  polifemo_clip|support_and_polifemo_clip|
  //  washer)
  //
  // display = "washer";
  // display = "polifemo_clip";
  // display = "support_and_polifemo_clip";
  // display="clip";
  // display = "support_and_clip";
  // display = "support";
  display = "racetime_holder";
  // display = "";

  $fn = 200;
}

// Display what you need

if (display == "support_and_clip") {
  encradio10_holder();
  rotate([180, 0, 0]) {
    translate([width_x/2, 25, -clip_height_z-16]) {
      encoder10_antenna_clip(false);
    }
  }
}
if (display == "support") {
  encradio10_holder();
}
if (display == "racetime_holder") {
  // what = "box_and_clip";
  what = "clip";
  // what = "box";
  racetime_holder(what);
}
if (display == "clip") {
  encoder10_antenna_clip(true);
}
if (display == "polifemo_clip") {
  polifemo_clip();
}
if (display == "support_and_polifemo_clip") {
  encradio10_holder();
  rotate([90, 0, -90]) {
    translate([38, 106, -width_x + 1]) {
      polifemo_clip();
    }
  }
}
if (display == "washer") {
  washer();
}

// Holder for the EncRadio10

module bottom_plate() {
  difference() {
    translate([0, 0, -bottom_plate_height_z]) {
      cube([width_x, depth_y, bottom_plate_height_z]);
    }
    translate([red_banana_x, red_banana_y, -bottom_plate_height_z]) {
      cylinder(d=banana_diameter, h=bottom_plate_height_z);
    }
    translate([green_banana_x, green_banana_y, -bottom_plate_height_z]) {
      cylinder(d=banana_diameter, h=bottom_plate_height_z);
    }
    translate([black_banana_x, black_banana_y, -bottom_plate_height_z]) {
      cylinder(d=banana_diameter, h=bottom_plate_height_z);
    }
  }
}

module side_plate_grooved() {
  side_plate_width_x = side_plate_width;
  side_plate_depth_y = side_plate_width + depth_y + side_plate_width;
  side_plate_height_z = height_z + bottom_plate_height_z;

  groove_width = banana_diameter + 0.5;

  // Groove to remove: width along the x and y.
  groove_size_x = side_plate_width_x;
  groove_size_y = groove_width;

  // Groove to remove: y and z position - where to start to remove.
  groove_y = 10.5;
  
  //  |  |  ..........................| 
  //  \__/  ..| <- groove_width/2     | ^
  //          | <- 10                 | | groove_z
  // ______ ..|.......................| v
  
  groove_z = 10 + groove_width/2;
  
  groove_y_center = groove_y + (groove_width/2);
  groove_height_z = side_plate_height_z - groove_z;

  difference() {
    translate([-side_plate_width, -side_plate_width, -bottom_plate_height_z]) {
      cube([side_plate_width_x, side_plate_depth_y, side_plate_height_z]);
    }
    translate([-side_plate_width, groove_y, groove_z]) {
      cube([groove_size_x, groove_size_y, groove_height_z]);
    }
    translate([-side_plate_width, groove_y_center, groove_z]) {
      rotate([00, 90, 0]) {
        cylinder(d=groove_width, h=side_plate_width);
      }
    }
  }
}

module side_plate_not_grooved() {
  side_plate_width_x = side_plate_width;
  side_plate_depth_y = side_plate_width + depth_y + side_plate_width;
  side_plate_height_z = height_z + bottom_plate_height_z;
  extrusion_width_x = 1;

  difference() {
    union() {
      translate([width_x, -side_plate_width, -bottom_plate_height_z]) {
        cube([side_plate_width_x, side_plate_depth_y, side_plate_height_z]);
      }
    }
    union() {
      translate([width_x + side_plate_width-extrusion_width_x, 20, 60]) {
        rotate([90,0,90]) {
          linear_extrude(height=extrusion_width_x, convexity=5) {
            text("SCA", size=11, halign="center", font="Impact");
          }
	}
      }
      translate([width_x + side_plate_width-extrusion_width_x, 20, 20]) {
        rotate([90,0,90])
        linear_extrude(height=extrusion_width_x, convexity=5) {
          text(start_stop, size=11, halign="center", font="Impact");
        }
      }
    }
  }  
}

module front_plate() {
  fp_height_z = 15;
  fp_y = depth_y;
  fp_x = 0;
  fp_z = -bottom_plate_height_z;
  extrusion_width_y = 1;
  difference() {
    translate([fp_x, fp_y, fp_z]) {
     cube([width_x, side_plate_width, fp_height_z]);
    }
    translate([green_banana_x+4.25, fp_y + side_plate_width-1, 5]) {
      rotate([0, 90, 90]) {
        linear_extrude(height=extrusion_width_y, convexity=5) {
          text("►", size=6, halign="center", font="Impact");
        }
      }
    }
    translate([black_banana_x+2.75, fp_y + side_plate_width-1, 5]) {
      rotate([0, 90, 90]) {
        linear_extrude(height=extrusion_width_y, convexity=5) {
          text("►", size=6, halign="center", font="Impact");
        }
      }
    }
    translate([red_banana_x-0.5, fp_y + side_plate_width-1, 7.75]) {
      rotate([-90, 0, 0]) {
        linear_extrude(height=extrusion_width_y, convexity=5) {
          text("X", size=6, halign="center", font="Fixed:style=Bold");
        }
      }
    }
  }
}

module side_wall(x, y) {
  fsw_x = x;
  fsw_y = y;
  fsw_z = 0;
  translate([fsw_x, fsw_y, fsw_z]) {
    cube([return_wall_width_x, side_plate_width, height_z]);
  }
}

module back_wall() {
  // We extend things back by depth_negative_offset_y.
  translate([0, -depth_negative_offset_y, -bottom_plate_height_z]) {
    cube([width_x, depth_negative_offset_y, bottom_plate_height_z]);
  }
  translate([-side_plate_width, -depth_negative_offset_y - side_plate_width,
             -bottom_plate_height_z]) {
    cube([width_x + 2*side_plate_width, side_plate_width,
          height_z + bottom_plate_height_z]);	     
  }
}

module main_piece() {
  color("green")  bottom_plate();
  color("cyan")   side_plate_grooved();
  color("cyan")   side_plate_not_grooved();
  color("red")    front_plate();
  color("yellow") side_wall(0, depth_y);
  color("yellow") side_wall(width_x - return_wall_width_x, depth_y);
  color("orange") back_wall();
}

module straps() {
  // Four grooves for straps to be passed through.
  translate([-side_plate_width, -depth_negative_offset_y, strap_1_z]) {
    cube([side_plate_width, strap_width_y, strap_height_z]);
  }
  translate([-side_plate_width, -depth_negative_offset_y, strap_2_z]) {
    cube([side_plate_width, strap_width_y, strap_height_z]);
  }
  translate([width_x, -depth_negative_offset_y, strap_1_z]) {
    cube([side_plate_width, depth_negative_offset_y, strap_height_z]);
  }
  translate([width_x, -depth_negative_offset_y, strap_2_z]) {
    cube([side_plate_width, strap_width_y, strap_height_z]);
  }
}

module encradio10_holder() {
  difference() {
    main_piece();
    straps();
  }
}

// A holder for the entire racetime

module main_racetime_holder_piece(length_x, length_y, length_z,
                                  bottom_offset, wall_width, bottom_plate_width) {
  difference() {
    cube([length_x+2*wall_width, length_y+2*wall_width, bottom_offset]);
    translate([bottom_plate_width+wall_width, bottom_plate_width+wall_width, 0]) {
      cube([length_x - 2 * bottom_plate_width,
            length_y - 2 * (bottom_plate_width - 3),
            bottom_offset]);
    }
  }
  cube([wall_width, length_y + 2*wall_width, length_z]);

  difference() {
    translate([length_x + wall_width, 0, 0]) {
      cube([wall_width, length_y + 2*wall_width, length_z]);
    }
    translate([length_x+ 1.5*wall_width, 3+length_y/2, 10]) {
      rotate([90,0,90])
      linear_extrude(height=3, convexity=5) {
        text("SCA", size=20, halign="center", font="Impact");
      }
    }
  }
  cube([wall_width, length_y, length_z]);
  cube([length_x + 2*wall_width, wall_width, length_z]);
  translate([0, length_y + wall_width, 0]) {
    difference() {
      cube([length_x + 2*wall_width, wall_width, length_z]);
      translate([10-wall_width, 0, 10]) {
        cube([length_x - 3*wall_width, wall_width, length_z-20]);
      }
    }
  }
}

module racetime_holder_straps(length_x, length_z, wall_width) {
  translate([0, wall_width, length_z - strap_height_z - 5]) {
    cube([wall_width, strap_width_y, strap_height_z]);
  }
  translate([length_x + wall_width, wall_width, length_z - strap_height_z - 5]) {
    cube([wall_width, strap_width_y, strap_height_z]);
  }
}

module racetime_holder(what) {
  // Next 3 dimensions are the ones of the racetime2
  // Do not include the wall sizes
  length_x = 95;
  length_y = 48;
  length_z = 75;
  // Thickness of the holder's walls
  wall_width = 3;

  // Bottom plate measures
  bottom_plate_thickness = 3;
  bottom_plate_recess = 13;

  if (search(what, "box")) {
    translate([-(length_x + 2*wall_width)/2, 0, 0]) {
      difference() {
        main_racetime_holder_piece(length_x, length_y, length_z,
                                   bottom_plate_thickness, wall_width,
				   bottom_plate_recess);
        racetime_holder_straps(length_x, length_z, wall_width);
      }
    }
  }
  if (search(what, "clip")) {
    translate([0, -35, clip_height_z]) {
      rotate([180, 0, 0]) {
        clip(length_x, 2, false);
      }
    }
  }
}

// Clip to attach clip the EncRadio10 or the racetime2 to a pole of a
// given diameter

module clip(clip_width, clip_plate_width, closed_loop) {
  pole_radius_xy = pole_diameter_xy/2;
  dy = pole_radius_xy * sin(clip_angle);
  x = pole_radius_xy * cos(clip_angle);
  difference() {
    dx = (pole_diameter_xy + clip_thickness_xy)/2;
    cylinder(d=pole_diameter_xy + clip_thickness_xy, clip_height_z);
    translate([0, 0,-0.1]) {
      cylinder(d=pole_diameter_xy, clip_height_z+0.2);
    }
    translate([-dx, dy, -0.1]) {
      cube([pole_diameter_xy + clip_thickness_xy,
            pole_diameter_xy + clip_thickness_xy-dy, clip_height_z+0.2]);
    }
  }
  translate([x+termination_offset_x,dy,0]) {
    scale([1, termination_stretch_y]) {
      cylinder(d=termination_diameter, h=clip_height_z);
    }
  }
  translate([-(x+termination_offset_x),dy,0]) {
    scale([1, termination_stretch_y]) {
      cylinder(d=termination_diameter, h=clip_height_z);
    }
  }
  base_length_x = 45;
  base_width_y = 5;
  base_width_offset_x = base_length_x / 2;
  difference() {
    union() {
      translate([-base_width_offset_x, -pole_radius_xy - base_width_y, 0]) {
        cube([base_length_x, base_width_y, clip_height_z]);
      }
      translate([-base_width_offset_x, -pole_radius_xy, 0]) {
        cube([base_length_x, base_width_y, clip_height_z]);
      }
    }
    translate([0, 0,-0.1]) {
      cylinder(d=pole_diameter_xy, clip_height_z+0.2);
    }      
  }
  
  // The width of the clip back plate
  clip_plate_width_y = clip_plate_width;
  clip_plate_width_x = clip_plate_width;

  // Hook dimensions:                 
  //                                  \
  //     hook_play_x _.            ____\           __ clip_plate_width_y
  //                  v  |        |     \____     /
  //                .-----------+----------   +--
  //                |----------------------   +--
  // hook_width ->  |
  //                `-----
  //                  ^-------- hook_return
  //
  // How far the plate extend past the dimensions of the holder.
  hook_play_x = 2;
  strap_width_y = strap_width_y + (closed_loop ? 2 : 0);
  hook_return_x = (closed_loop ? clip_width : 6);
  hook_width_y = 1;
  
  clip_plate_length_x = clip_width + 2*side_plate_width + 2*hook_play_x;
  clip_plate_offset_y = -pole_radius_xy - base_width_y;
  clip_plate_offset_x = clip_plate_length_x/2;

  // Clip support plate
  translate([-clip_plate_offset_x, clip_plate_offset_y]) {
    cube([clip_plate_length_x, clip_plate_width_y, clip_height_z]);
  }

  // First/left hook
  translate([-clip_plate_offset_x - clip_plate_width_x,
             clip_plate_offset_y - side_plate_width - strap_width_y]) {
    cube([clip_plate_width_x,
          side_plate_width + clip_plate_width_y + strap_width_y,
	  clip_height_z]);
  }
  translate([-clip_plate_offset_x - clip_plate_width_x,
             clip_plate_offset_y - side_plate_width - strap_width_y]) {
    cube([hook_return_x, hook_width_y, clip_height_z]);    	     
  }

  // Second/right hook
  translate([clip_plate_offset_x,
             clip_plate_offset_y - side_plate_width - strap_width_y]) {
    cube([clip_plate_width_x,
          side_plate_width + clip_plate_width_y + strap_width_y,
	  clip_height_z]);
  }
  translate([clip_plate_offset_x - hook_return_x,
             clip_plate_offset_y - side_plate_width - strap_width_y]) {
    cube([hook_return_x, hook_width_y, clip_height_z]);    	     
  }
}

module encoder10_antenna_clip(closed_loop) {
  clip(width_x, 1, false);
}

// Clip to attach the EncRadio10 to a Polifemo cell.
module polifemo_clip() {
  thickness = 3;
  inside_diameter = 53 + 4*2;
  outside_diameter = inside_diameter + 2*thickness;
  pf_height_z = width_x - 2;
  
  right_flank_length_y = 88 - 53/2;
  right_flank_groove_width_y = 15;
  right_flank_groove_y = 10;
  right_flank_groove_pf_height_z = 25;
  
  left_flank_length_y = height_z + bottom_plate_height_z + 2*side_plate_width;
  left_flank_bottom_x = depth_y+3*side_plate_width + depth_negative_offset_y;
  left_flank_bottom_openning_xy = 5;
 
  // Top arc
  difference() {
    cylinder(d=outside_diameter, h=pf_height_z);
    translate([0, 0, -0.1]) {
      cylinder(d=inside_diameter, h=pf_height_z+0.2);
    }
    translate([-outside_diameter, -outside_diameter, -0.1]) {
      cube([outside_diameter*2, outside_diameter, pf_height_z+0.2]);
    }
  }

  // Top cover with holes for the banana jacks
  translate([0, 0, pf_height_z - thickness]) {
    difference() {
      cylinder(d=outside_diameter, h=thickness);
      translate([-outside_diameter, -outside_diameter, -0.1]) {
        cube([outside_diameter*2, outside_diameter, thickness+0.2]);
      }
      mirror([1,0,0]) {
        translate([4, 18, -0.1]) {
          cylinder(d=banana_diameter, h=thickness+0.2);
        }
        translate([14, 8.5, -0.1]) {
          cylinder(d=banana_diameter, h=thickness+0.2);
        }
      }
    }
  }
  
  // Visor
  translate([0, 0, pf_height_z]) {
    difference() {
      union() {
        difference() {
          cylinder(d=outside_diameter, h=50);
          cylinder(d=inside_diameter, h=50);
        }
      }
     FakeClipPlane([0,-1,1],0,120);
    }
  }
  
  // Right side flank
  difference() {
    translate([inside_diameter/2, -right_flank_length_y, 0]) {
      cube([thickness, right_flank_length_y, pf_height_z]);
    }
    translate([(inside_diameter/2)-0.1,
               -right_flank_length_y + right_flank_groove_y,
	       pf_height_z - right_flank_groove_pf_height_z]) {
      cube([thickness+0.2, right_flank_groove_width_y,
            right_flank_groove_pf_height_z + 0.2]);
    }
    translate([(inside_diameter/2)-0.1,
               (-right_flank_length_y + right_flank_groove_y +
	        right_flank_groove_width_y/2),
	       pf_height_z - right_flank_groove_pf_height_z]) {
      rotate([0, 90, 0]) {	       
        cylinder(d=right_flank_groove_width_y, h=thickness+0.2);
      }
    }
  }
  
  // Left side flank
  translate([-inside_diameter/2 - thickness, -left_flank_length_y, 0]) {
    cube([thickness, left_flank_length_y, pf_height_z]);
  }
  
  // Bottom plate, with room to let the cables go through
  difference() {
    translate([-inside_diameter/2 - thickness - left_flank_bottom_x,
               -left_flank_length_y-side_plate_width, 0]) {
      cube([left_flank_bottom_x + thickness, side_plate_width, pf_height_z]);
    }
    translate([(-inside_diameter/2 - thickness
                - left_flank_bottom_x + left_flank_bottom_openning_xy),
               -left_flank_length_y-side_plate_width - 0.1,
	       left_flank_bottom_openning_xy]) {
      cube([left_flank_bottom_x - 2*left_flank_bottom_openning_xy,
            side_plate_width + 0.2,
            pf_height_z - 2*left_flank_bottom_openning_xy]);
    }
  }

  // Bottom plate return
  translate([
	-inside_diameter/2 - thickness - left_flank_bottom_x - side_plate_width,
        -left_flank_length_y-side_plate_width, 0]) {
    cube([side_plate_width, 10, pf_height_z]);
  }

  // Left side flank to return
  translate([
	-inside_diameter/2 - thickness - 2.5*side_plate_width,
        (-left_flank_length_y + height_z +
         bottom_plate_height_z), 0]) {
    cube([2.5*side_plate_width, side_plate_width, pf_height_z]);
  }
  translate([
	-inside_diameter/2 - thickness - 2.5*side_plate_width,
        (-left_flank_length_y + height_z +
         bottom_plate_height_z - 2*side_plate_width), 0]) {
    cube([side_plate_width, 2*side_plate_width, pf_height_z]);
  }

}

// Simple washer to secure the holder on the polifemo.
module washer() {
  right_flank_groove_width_y = 15;
  height = 3.5;
  difference() {
    cylinder(d=right_flank_groove_width_y*2, h=height);
    translate([0,0,-0.1]) {
      cylinder(d=right_flank_groove_width_y, h=height+0.2);
    }
  }
}