//
// Mendel90
//
// GNU GPL v2
// nop.head@gmail.com
// hydraraptor.blogspot.com
//
// Brackets to fasten the frame together
//
include <conf/config.scad>

slot = 2;
thickness = 5;
thin_wall = filament_width * 2 + eta;
wall = 3;

counter_bore_rad = washer_diameter(screw_washer(base_screw)) / 2 + 0.2;
width = 2 * wall + 2 * thin_wall + 6 * counter_bore_rad;
shear = min(counter_bore_rad - screw_clearance_radius(frame_screw), 2.5);


hole_pitch = 2 * (2 * counter_bore_rad + thin_wall);
depth = 2 * (thickness + counter_bore_rad) + slot - 2 * shear;
height = depth;

hole_offset = depth / 2;
corner_rad = 3;

counter_bore_depth = depth - thickness;

function fixing_block_width() = width;
function fixing_block_height() = height;

module fixing_block_v_hole(h)
    translate([0, hole_offset, h])
        child();

module fixing_block_h_holes(h)
    for(end = [-1, 1])
        translate([end * hole_pitch / 2, h, hole_offset])
            rotate([90, 0, 180])
                child();


module fixing_block_stl() {
    stl("fixing_block");
    difference() {
        translate([-(width - 2 * corner_rad) / 2, 0, 0])
            minkowski() {
                cube([width - 2 * corner_rad, depth- corner_rad, height -corner_rad]);
                intersection() {
                    sphere(r = corner_rad);
                    translate([0, 5, 5])
                        cube([10, 10, 10], center = true);
                }
            }

        translate([-width / 2 - 1, thickness, height + eta])                // diagonal slice of the front
            rotate([-45, 0, 0])
                cube([width + 2, depth * 2, height]);


        fixing_block_v_hole(height - counter_bore_depth)
            rotate([0,0,90])
                union() {
                    slot(h = 100, r = screw_clearance_radius(frame_screw), l = slot, center = true);
                    multmatrix(m = [ [1, 0, shear / counter_bore_depth, 0],
                                     [0, 1, 0, 0],
                                     [0, 0, 1, 0],
                                     [0, 0, 0, 1] ])
                        slot(h = 100, r = counter_bore_rad, l = slot, center = false);
                }


        fixing_block_h_holes(depth - counter_bore_depth)
            rotate([0,0,0])
                union() {
                    vertical_tearslot(h = 100, r = screw_clearance_radius(frame_screw), l = slot, center = true);
                    multmatrix(m = [ [1, 0, 0, 0],
                                     [0, 1, shear / counter_bore_depth, 0],
                                     [0, 0, 1, 0],
                                     [0, 0, 0, 1] ])
                    vertical_tearslot(h = 100, r = counter_bore_rad, l = slot, center = false);
                }
    }
}

module fixing_block_assembly(front = false) {
    color(fixing_block_color) render() fixing_block_stl();
    fixing_block_v_hole(height - counter_bore_depth)
        if(front)
            frame_screw(thickness);
        else
            base_screw();
    fixing_block_h_holes(depth - counter_bore_depth)
        frame_screw(thickness);
}

if(0) {
    fixing_block_stl();
}
else
    fixing_block_assembly();