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Make connector less fragile, move inside top/bottom enclosure #248

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Make connector less fragile, move inside top/bottom enclosure #248

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41 changes: 31 additions & 10 deletions 3d/splitflap.scad
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Original file line number Diff line number Diff line change
Expand Up @@ -222,21 +222,21 @@ motor_backpack_extent = 28byj48_backpack_extent() + 2; // Add 2mm to make sure t
motor_hole_slop = 1;
motor_window_radius = 5;

connector_bracket_length_outer = 14;
connector_bracket_length_inner = enclosure_length_right / 2 - m4_button_head_diameter/2 - 1;
connector_bracket_thickness = captive_nut_inset - thickness - 0.2;
connector_bracket_length_outer = enclosure_length_right / 2 - max(m4_button_head_diameter/2, m4_nut_width_flats/2) - 1;
connector_bracket_length_inner = connector_bracket_length_outer;
connector_bracket_thickness = 5;
connector_bracket_width = enclosure_width - enclosure_wall_to_wall_width + thickness*2 + connector_bracket_thickness*2;
connector_bracket_overlap = 4;
connector_bracket_overlap = connector_bracket_length_inner/2;
connector_bracket_clearance = 0.40;
connector_bracket_depth_clearance = 0.20;
connector_bracket_depth_clearance = 0;

mounting_hole_inset = m4_button_head_diameter/2 + 2;

enclosure_indicator_inset = 3.0; // inset on both X and Y
enclosure_indicator_size = 1.75; // symbol size
enclosure_indicator_arrow_width = 2.25;
enclosure_indicator_arrow_height = enclosure_indicator_arrow_width * 2;
enclosure_indicator_position_y = (enclosure_height - enclosure_vertical_inset - thickness) - enclosure_indicator_inset;
enclosure_indicator_position_y = (enclosure_height - enclosure_vertical_inset - thickness * 2) - enclosure_indicator_inset;

zip_tie_height = 3.0; // height of the zip-tie hole
zip_tie_width = 2.0; // width of the zip-tie holes
Expand Down Expand Up @@ -514,17 +514,35 @@ module front_tabs_negative(upper, tool_diameter=0) {
}

module connector_bracket_2d() {
fillet_r = 3;
difference() {
square([connector_bracket_width, connector_bracket_length_outer]);
hull() {
translate([0, fillet_r]) {
square([connector_bracket_width, connector_bracket_length_outer - fillet_r]);
}
translate([fillet_r, fillet_r]) {
circle(r=fillet_r, $fn=30);
}
translate([connector_bracket_width - fillet_r, fillet_r]) {
circle(r=fillet_r, $fn=30);
}
}

translate([connector_bracket_thickness, -eps]) {
square([connector_bracket_width - connector_bracket_thickness*2, connector_bracket_length_outer - connector_bracket_length_inner + eps]);
}
translate([connector_bracket_thickness - connector_bracket_clearance/2, -eps]) {
square([thickness + connector_bracket_clearance, connector_bracket_length_outer - connector_bracket_overlap + connector_bracket_depth_clearance + eps]);
}
translate([connector_bracket_thickness + thickness/2, connector_bracket_length_outer - connector_bracket_overlap + connector_bracket_depth_clearance]) {
circle(d=thickness+connector_bracket_clearance, $fn=30);
}
translate([connector_bracket_width - connector_bracket_thickness - thickness - connector_bracket_clearance/2, -eps]) {
square([thickness + connector_bracket_clearance, connector_bracket_length_outer - connector_bracket_overlap + connector_bracket_depth_clearance + eps]);
}
translate([connector_bracket_width - connector_bracket_thickness - thickness/2, connector_bracket_length_outer - connector_bracket_overlap + connector_bracket_depth_clearance]) {
circle(d=thickness+connector_bracket_clearance, $fn=30);
}
}
}

Expand Down Expand Up @@ -636,9 +654,12 @@ module backstop_bolt_slot(radius) {

module connector_bracket_side_holes() {
// overlap slot
translate([enclosure_vertical_inset - thickness - connector_bracket_clearance/2, -connector_bracket_overlap]) {
translate([enclosure_vertical_inset + thickness + connector_bracket_clearance/2, -connector_bracket_overlap]) {
square([thickness + connector_bracket_clearance, connector_bracket_overlap + eps]);
}
translate([enclosure_vertical_inset + thickness + connector_bracket_clearance/2 + (thickness+connector_bracket_clearance)/2, -connector_bracket_overlap]) {
circle(d=thickness + connector_bracket_clearance, $fn=30);
}
}

module alignment_bar() {
Expand Down Expand Up @@ -988,13 +1009,13 @@ module split_flap_3d(front_flap_index, include_connector, include_front_panel=tr
}

module positioned_top_connector() {
translate([enclosure_wall_to_wall_width - thickness - connector_bracket_thickness, front_forward_offset - connector_bracket_length_outer, enclosure_height_upper - enclosure_vertical_inset]) {
translate([enclosure_wall_to_wall_width - thickness - connector_bracket_thickness, front_forward_offset - connector_bracket_length_outer, enclosure_height_upper - enclosure_vertical_inset - thickness * 2 - connector_bracket_clearance]) {
connector_bracket();
}
}

module positioned_bottom_connector() {
translate([enclosure_wall_to_wall_width - thickness - connector_bracket_thickness, front_forward_offset - connector_bracket_length_outer, - enclosure_height_lower + enclosure_vertical_inset - thickness]) {
translate([enclosure_wall_to_wall_width - thickness - connector_bracket_thickness, front_forward_offset - connector_bracket_length_outer, - enclosure_height_lower + enclosure_vertical_inset + thickness + connector_bracket_clearance]) {
connector_bracket();
}
}
Expand Down
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