h2n: major reorganization of the code, factor blocks into several modules, make everything tilt according to the angle of the support columns, clean up all the major and minor junctures between pieces, almost everything seems to fall into place automatically

TinySpHEAR_H2N_common.scad

@@ -46,6 +46,40 @@ h2n_depth = 42.66;
 
 h2n_width_up = 57.0;
 
+h2n_column_height = 40;
+transition_height = 30;
+
+// measured = 11.50, should be 13.1 -> ratio = 
+
+// h2n_side_radius = 18.2;
+h2n_side_radius = 18.4;
+h2n_side_band = 1.5;
+h2n_side_band_w = 13.4;
+h2n_width_m = 63.0;
+h2n_depth_m = 36.4;
+
+h2n_band_height = 6.0;
+
+// base band width
+h2n_band_wall = 1.6;
+
+// walls for the columns
+h2n_col_wall = 2 * wall;
+
+// tilt for the columnds
+h2n_col_tilt = 4.0;
+
+// radius of mount stalk
+h2n_mount_radius = mount_radius;
+
+// fit for connector from column to bridge
+h2n_mount_fit = 0.04;
+
+// bridge dimensions
+h2n_bridge_base_height = 10.0;
+h2n_bridge_stalk_height = 20.0;
+
+
 module tube(or, ir, h) {
     difference() {
         cylinder(r = or, h = h, $fn = facets);
@@ -55,27 +89,23 @@ module tube(or, ir, h) {
 
 // main support ring
 
-module h2n_ring(width, depth, radius, height, slot_w, slot_d, band_wall, wall, col_rad, col_wall) {
+module h2n_ring(width, depth, radius, height, tilt, slot_w, slot_d, band_wall, wall, col_rad, col_wall) {
     // main support ring
     difference() {
-        rounded_block(height, width / 2 + band_wall, depth / 2 +  band_wall, radius - thin_mint);
-        rounded_block_relative(height, width / 2 + band_wall, depth / 2 + band_wall, radius - band_wall - thin_mint, - band_wall);
+        conical_rounded_box(height, width / 2 + band_wall, depth / 2 +  band_wall, radius - thin_mint, band_wall, height * tan(tilt));
         for (m = [0, 1]) mirror([m, 0, 0]) {
-            translate([width / 2 + col_rad - col_wall, 0, 0]) {
-                cylinder(r = col_rad, h = height + thin_mint, $fn = facets);
+            translate([-(width / 2 + col_rad - col_wall), 0, 0]) {
+                tilted_cylinder(col_rad, height, height * tan(tilt));
             }
         }
     }
     // inner band
     difference() {
-        difference() {
-            rounded_block(height, width / 2 + wall - h2n_side_band, depth / 2 + band_wall, radius - thin_mint);
-            rounded_block_relative(height, width / 2 + wall - h2n_side_band, depth / 2 + band_wall, radius - wall - thin_mint, - wall);
-        }
+        conical_rounded_box(height, width / 2 + wall - h2n_side_band, depth / 2 + band_wall, radius - thin_mint, wall, height * tan(tilt));
         for (m = [0, 1]) mirror([m, 0, 0]) {
             // cut slots on the sides
             translate([-width / 2, -h2n_side_band_w / 2, 0]) {
-                cube([width / 2, h2n_side_band_w, height]);
+                cube([width / 2, h2n_side_band_w, height + thin_mint]);
             }
         }
     }
@@ -83,32 +113,92 @@ module h2n_ring(width, depth, radius, height, slot_w, slot_d, band_wall, wall, c
 
 // side columns
 
-module h2n_columns(width, height, ring_height, tilt, band, transition, radius, wall) {
+module tilted_cylinder(radius, height, offset) {
+    hull() {
+        cylinder(r = radius, h = thin_mint, $fn = facets);
+        translate([offset, 0, height]) {
+            cylinder(r = radius, h = thin_mint, $fn = facets);
+        }
+    }
+}
+
+module tilted_rounded_box(height, width, depth, radius, wall, offset) {
+    difference() {
+        hull() {
+            rounded_block(thin_mint, width, depth, radius);
+            translate([offset, 0, height]) {
+                rounded_block(thin_mint, width, depth, radius);
+            }
+        }
+        hull() {
+            rounded_block_relative(thin_mint, width, depth, radius, -wall);
+            translate([offset, 0, height]) {
+                rounded_block_relative(thin_mint, width, depth, radius, -wall);
+            }
+        }
+    }
+}
+
+module conical_rounded_box(height, width, depth, radius, wall, inset) {
+    difference() {
+        hull() {
+            rounded_block(thin_mint, width, depth, radius);
+            translate([0, 0, height]) {
+                rounded_block_relative(thin_mint, width, depth, radius, -inset);
+            }
+        }
+        hull() {
+            rounded_block_relative(thin_mint, width, depth, radius, -wall);
+            translate([0, 0, height]) {
+                rounded_block_relative(thin_mint, width, depth, radius, -(wall + inset));
+            }
+        }
+    }
+}
+
+module tilted_cube(height, width, depth, offset) {
+    hull() {
+        cube([width, depth, thin_mint]);
+        translate([offset, 0, height]) {
+            cube([width, depth, thin_mint]);
+        }
+    }
+}
+
+module tilted_half_rounded_box(height, width, depth, radius, wall, offset, e = 0.1) {
+    difference() {
+        tilted_rounded_box(height, width, depth, radius, wall, offset);
+        translate([0, -(depth + e), 0]) {
+            tilted_cube(height, width + e, (depth + e) * 2, offset);
+        }
+    }
+}
+
+module half_rounded_box(height, width, depth, radius, wall, e = 0.1) {
+    difference() {
+        rounded_box(height, width , depth, radius, wall);
+        translate([0, -(depth + e), 0]) {
+            cube([width + e, 2 * (depth + e), height]);
+        }
+    }
+}
+
+module h2n_columns(width, height, ring_height, tilt, transition, radius, col_wall, wall) {
     // side tubes for cables
+    slot_height = 25.0;
     for (m = [0, 1]) mirror([m, 0, 0]) {
-        translate([-(width / 2 + mount_radius - wall), 0, 0]) {
+        translate([-(width / 2 + radius - col_wall), 0, 0]) {
             difference() {
-                // angled column (4 degrees inward tilt)
-                hull() {
-                    cylinder(r = radius, h = thin_mint, $fn = facets);
-                    translate([height * tan(tilt) - wall/2, 0, height]) {
-                        cylinder(r = radius, h = thin_mint, $fn = facets);
-                    }
-                }
-                hull() {
-                    cylinder(r = radius - wall, h = thin_mint, $fn = facets);
-                    translate([height * tan(tilt) - wall/2, 0, height]) {
-                        cylinder(r = radius - wall, h = thin_mint, $fn = facets);
-                    }
-                }
+                // angled column
+                tilted_cylinder(radius + col_wall, height, height * tan(tilt));
+                tilted_cylinder(radius, height, height * tan(tilt));
                 // slots in the columns for cables
-                translate([mount_radius - wall - ring_height * tan(tilt), - mount_radius * 2, -ring_height]) {
-                    slot_height = 25.0;
+                translate([radius - col_wall - ring_height * tan(tilt), - radius * 2, -ring_height]) {
                     rotate([0, tilt, 0]) {
-                        cube([5.0, mount_radius * 4, slot_height]);
-                        translate([mount_radius + wall, mount_radius - wall, slot_height]) {
+                        cube([5.0, radius * 4, slot_height]);
+                        translate([radius + col_wall, radius - col_wall, slot_height]) {
                             rotate([0, 90, 90]) {
-                                cylinder(r = mount_radius + wall, h = 15.0, $fn = facets);
+                                cylinder(r = radius + col_wall, h = 15.0, $fn = facets);
                             }
                         }
                     }
@@ -116,29 +206,43 @@ module h2n_columns(width, height, ring_height, tilt, band, transition, radius, w
             }
         }
         // connector to bridge
-        translate([-(width / 2 + mount_radius - wall / 2 - height * tan(tilt)), 0, height]) {
-            tube(mount_radius + wall / 2 - h2n_mount_fit, mount_radius, 5.0);
+        translate([-(width / 2 + radius - col_wall - height * tan(tilt)), 0, height]) {
+            tube(radius + wall - h2n_mount_fit, radius, 5.0);
+        }
+        // side sleeves
+        sleeve_height = slot_height - mount_radius - col_wall;
+        for (m = [0, 1]) mirror([m, 0, 0]) {
+            // we should derive the geometry for the aligment magic below...
+            side_fit = 1.05;
+            translate([-(width / 2 - (radius + col_wall) / 2 + wall - side_fit), 0, 0]) {
+                difference() {
+                    tilted_half_rounded_box(sleeve_height, 3.8, h2n_side_band_w / 2 + wall, 2.0, wall, sleeve_height * tan(tilt));
+                    translate([col_wall / 2 + wall - radius * 3 / 2 - side_fit, 0, 0]) {
+                        tilted_cylinder(radius, height, height * tan(tilt));
+                    }
+                }
+            }
         }
     }
 }
 
 // bridge that connects to capsule array
 
-module semi_cylinder(r, h) {
+module semi_cylinder(r, h, e = thin_mint) {
     difference() {
         cylinder(h, r, r, $fn = facets);
-        translate ([-r*2, -r, 0])
-            cube([2*r, 2*r, h]);
+        translate ([-(r+e)*2, -r, 0])
+            cube([2*(r+e), 2*(r+e), h]);
     }
 }
 
-module quarter_sphere(r) {
+module quarter_sphere(r, e = thin_mint) {
     difference() {
         sphere(r, $fn = facets);
-        translate([-r, -r, -r])
-            cube([2*r, 2*r, r]);
-        translate([-r, -r, 0])
-            cube([r, 2*r, r]);
+        translate([-(r+e), -(r+e), -(r+e)])
+            cube([2*(r+e), 2*(r+e), r+e]);
+        translate([-(r+e), -(r+e), -e])
+            cube([r, 2*(r+e), (r+e)]);
     }
 }
 
@@ -157,15 +261,15 @@ module cylcube(width, depth, height, wall) {
     }
 }
 
-module h2n_bridge(width, height, ring_height, ring_wall, tilt, band, transition, radius, col_wall, wall) {
+module h2n_bridge(width, base_height, stalk_height, radius, col_wall, wall) {
     // capsule array mount
-    translate([0, 0, band + 20.0]) {
+    translate([0, 0, base_height + stalk_height]) {
         tetra_capsule_array_mount([-45, 135]);
     }
     // stalk
-    translate([0, 0, band]) {
+    translate([0, 0, base_height]) {
         difference() {
-            tube(mount_radius + wall, mount_radius, 20.0 + 1.0);
+            tube(radius + wall, radius, stalk_height);
             // remove stalk segment that is inside the bridge
             translate([width / 2, 0, -1.0]) {
                 rotate([0, -90, 0]) {
@@ -175,16 +279,16 @@ module h2n_bridge(width, height, ring_height, ring_wall, tilt, band, transition,
         }
     }
     // top of bridge
-    translate([width / 2 + wall, 0, band]) {
+    translate([width / 2, 0, base_height]) {
         rotate([0, -90, 0]) {
             difference() {
                 // curvy ceiling
-                semi_cylinder(r = radius + col_wall, h = width + 2 * wall);
-                semi_cylinder(r = radius + col_wall - wall, h = width + 2 * wall);
+                semi_cylinder(r = radius + col_wall, h = width);
+                semi_cylinder(r = radius + col_wall - wall, h = width);
                 // make a hole for the cables
                 translate([0, 0, width / 2]) {
                     rotate([0, 90, 0]) {
-                        cylinder(r = mount_radius, h = 10, $fn = facets);
+                        cylinder(r = radius, h = 10, $fn = facets);
                     }
                 }
             }
@@ -192,7 +296,7 @@ module h2n_bridge(width, height, ring_height, ring_wall, tilt, band, transition,
     }
     // caps at ends
     for (m = [0, 1]) mirror([m, 0, 0]) {
-        translate([width / 2 + wall, 0, band]) {
+        translate([width / 2, 0, base_height]) {
             difference() {
                 quarter_sphere(r = radius + col_wall);
                 quarter_sphere(r = radius + col_wall - wall);
@@ -202,8 +306,8 @@ module h2n_bridge(width, height, ring_height, ring_wall, tilt, band, transition,
     // base of bridge
     translate([0, 0, 0]) {
         for (m = [0, 1]) mirror([m, 0, 0]) {
-            translate([width / 2 + wall, 0, 0]) {
-                cylcube(width / 2 + wall, radius + col_wall, band, wall);
+            translate([width / 2, 0, 0]) {
+                cylcube(width / 2, radius + col_wall, base_height, wall);
             }
         }
     }
@@ -212,62 +316,38 @@ module h2n_bridge(width, height, ring_height, ring_wall, tilt, band, transition,
         cube([col_wall, (radius + wall) * 2, col_wall]);
     }
     for (m = [0, 1]) mirror([m, 0, 0]) {
-        translate([-width / 2 + radius, -(radius + wall), 0]) {
+        translate([-width / 2 + radius + wall, -(radius + wall), 0]) {
             cube([col_wall, (radius + wall) * 2, col_wall]);
         }
     }
 }
 
-connector_height = 40;
-transition_height = 30;
-
-// measured = 11.50, should be 13.1 -> ratio = 
-
-// h2n_side_radius = 18.2;
-h2n_side_radius = 18.4;
-h2n_side_band = 1.5;
-h2n_side_band_w = 13.1;
-h2n_width_m = 63.0;
-h2n_depth_m = 36.4;
-
-h2n_band_height = 6.0;
-
-// base band width
-h2n_band_wall = 1.6;
-
-// walls for the columns
-h2n_col_wall = 2 * wall;
-
-// tilt for the columnds
-h2n_col_tilt = 4.0;
-
-// fit for connector from column to bridge
-h2n_mount_fit = 0.1;
-
 // render the whole thing
 
 difference() {
 union() {
 
-h2n_ring(h2n_width_m, h2n_depth_m, h2n_depth * 0.425, h2n_band_height, h2n_side_band_w, h2n_side_band, h2n_band_wall, wall, mount_radius, h2n_col_wall);
+h2n_ring(h2n_width_m, h2n_depth_m, h2n_depth * 0.425, h2n_band_height, h2n_col_tilt, 
+         h2n_side_band_w, h2n_side_band, h2n_band_wall, wall, mount_radius, h2n_col_wall);
 
-h2n_columns(h2n_width_m, connector_height, h2n_band_height, h2n_col_tilt, 10.0, transition_height, mount_radius + h2n_col_wall, h2n_col_wall);
+h2n_columns(h2n_width_m, h2n_column_height, h2n_band_height, h2n_col_tilt, 
+            transition_height, h2n_mount_radius, h2n_col_wall, wall);
 
-translate([0, 0, connector_height]) {
-    h2n_bridge(h2n_width_m - connector_height * tan(h2n_col_tilt), connector_height, 
-               h2n_band_height, h2n_band_wall, h2n_col_tilt, 10.0, transition_height, mount_radius, h2n_col_wall, wall);
+translate([0, 0, h2n_column_height]) {
+    h2n_bridge((h2n_width_m / 2 + mount_radius - h2n_col_wall - h2n_column_height * tan(h2n_col_tilt)) * 2, 
+               h2n_bridge_base_height, h2n_bridge_stalk_height, mount_radius, h2n_col_wall, wall);
 }
 
+rotate([0, 0, 0]) {
+    render_tetra_capsule_array(h2n_column_height + h2n_bridge_base_height + h2n_bridge_stalk_height + 27);
 }
-translate([-40, -50, 0]) {
+
+}
+*translate([-40, -50, 0]) {
     cube([80, 50, 80]);
 }
 }
 
-// capsule holders and connector to main body
-*rotate([0, 0, 0]) {
-    render_tetra_capsule_array(connector_height + transition_height + 30);
-}
 
 // make sure dimensions are fine
 *translate([-(h2n_width_m - 0.1) / 2, - 0.5, 0]) {