Mendel90/scad/ATX_PSU_brackets.scad

//
// Mendel90
//
// GNU GPL v2
// nop.head@gmail.com
// hydraraptor.blogspot.com
//
// ATX PSU brackets
//
include <conf/config.scad>
include <positions.scad>

wall = 3;

length = psu == ATX500 ? psu_length(psu) : psu_length(psu) - 138 + 114;
offset = (psu_length(psu) - length) / 2;
width = atx_bracket_width;
thickness = part_base_thickness;
psu_hole_z = 6;
psu_hole_z2 = 16;
psu_hole_x = 6;
tab_length = psu_hole_x + washer_diameter(M4_washer) / 2 + 1;
tab_height = psu_hole_z * 2;
tab_height2 = psu_hole_z * 2 + psu_hole_z2 - psu_hole_z;
tab_thickness = 5;
nut_depth = frame_nut_traps ? nut_trap_depth(frame_nut) : 0;

module atx_long_bracket_stl() {
    stl("atx_long_bracket");

  rotate([0, 0, 180])
    translate([-offset, 0, 0]) difference() {
        union() {
            // base
            linear_extrude(height = thickness)
                hull() {
                    translate([0, -width / 4, 0])
                        square([length - 2 * tab_length, width / 2], center = true);

                    for(end = [-1, 1])
                        translate([end * (length  / 2 - tab_length - width / 2), -width / 2])
                            circle(width / 2);
                }
            // tabs
            for(end = [-1, 1]) {
                height =  end == 1 ? tab_height : tab_height2;
                translate([end * (length / 2 - tab_length / 2 - eta), -tab_thickness / 2, height / 2])
                    cube([tab_length, tab_thickness, height], center = true);
            }
            // nut traps
            if(frame_nut_traps)
                for(end = [-1, 1])
                    translate([end * (length  / 2 - tab_length - width / 2), 0, 0])
                        linear_extrude(height = thickness + nut_depth, convexity = 5)
                            union() {
                                translate([end * width / 4, -tab_thickness / 2])
                                    square([width / 2 + eta, tab_thickness], center = true);

                                translate([2 * end * eta, -width / 2 -eta])
                                    circle(r = width / 2 + eta);
                            }
        }
        rotate([0, 0, 180])
            for(end = [-1, 1])
                translate([end * (length / 2 - tab_length - width / 2), width / 2, thickness + nut_depth + eta])
                    if(frame_nut_traps)
                        nut_trap(screw_clearance_radius(frame_screw), nut_radius(frame_nut), nut_depth);
                    else
                        poly_cylinder(r = screw_clearance_radius(frame_screw), h = 100, center = true);

        for(end = [-1, 1])
            translate([end * (length / 2 - psu_hole_x), 0, end == 1 ? psu_hole_z : psu_hole_z2])
                rotate([90, 0, 0])
                    teardrop_plus(r = screw_clearance_radius(No632_pan_screw), h = 100, center = true);
    }
}


sb_wall = 4;
sb_frame_offset = psu_y - psu_width(psu) / 2 - gantry_Y - sheet_thickness(frame);
sb_corner_offset = max(5, fixing_block_height() - sb_frame_offset + base_clearance);
sb_clearance = 0.5;
sb_frame_width = 1 + 2 * sb_wall + (frame_nut_traps ? nut_radius(frame_nut) * 2 : washer_diameter(frame_washer));
sb_base_width  = 1 + 2 * sb_wall + ( base_nut_traps ? nut_radius(base_nut)  * 2 : washer_diameter(base_washer));
sb_height = max(sb_base_width, sb_frame_width);
sb_frame_thickness = part_base_thickness + (frame_nut_traps ? nut_trap_depth(frame_nut) : 0);
sb_base_thickness  = part_base_thickness + ( base_nut_traps ? nut_trap_depth(base_nut) : 0);
sb_base_offset  = psu_z - psu_length(psu) / 2;
sb_frame_screw = sb_frame_offset > (frame_nut_traps ? sb_frame_thickness
                                                : sb_frame_thickness + washer_thickness(frame_washer) + screw_head_height(frame_screw));

module atx_short_bracket_stl() {
    stl("atx_short_bracket");

    difference() {
        linear_extrude(height = sb_height, convexity = 10) {
            translate([-sb_base_offset, sb_corner_offset])
                square([sb_base_offset - sb_clearance, sb_base_width]);

            translate([sb_corner_offset, -sb_frame_offset])
                square([sb_frame_width, sb_frame_offset - sb_clearance]);

            polygon([[sb_corner_offset, -sb_clearance],
                     [ - sb_clearance, sb_corner_offset],
                     [ - sb_clearance, sb_corner_offset + sb_base_width],
                     [sb_corner_offset + sb_frame_width,  - sb_clearance]]);

        }
        translate([-sb_clearance,  -sb_clearance, sb_wall])             // space for PSU
            cube([100, 100, sb_height]);

        translate([sb_corner_offset + sb_wall, -sb_frame_offset + sb_frame_thickness, sb_wall])        // Recess for screw
            cube([sb_frame_width - 2 * sb_wall, sb_frame_offset, sb_height - 2 * sb_wall]);

        if(sb_frame_screw)
            translate([sb_corner_offset + sb_frame_width / 2, -sb_frame_offset + sb_frame_thickness, sb_height / 2])
                rotate([90, 0, 0])
                    if(frame_nut_traps)
                        nut_trap(screw_clearance_radius(frame_screw), nut_radius(frame_nut), nut_trap_depth(frame_nut), true);
                    else
                        teardrop(r = screw_clearance_radius(frame_screw), h = 100, center = true);

        translate([-sb_base_offset + sb_base_thickness, sb_corner_offset + sb_wall, sb_wall])       // Recess for screw
            cube([sb_base_offset, sb_base_width - 2 * sb_wall, sb_height - 2 * sb_wall - layer_height]);

        translate([-sb_base_offset + sb_base_thickness, sb_corner_offset + sb_base_width / 2, sb_height / 2 - layer_height])
            rotate([90, 0, 90])
                if(frame_nut_traps)
                    nut_trap(screw_clearance_radius(base_screw), nut_radius(base_nut), nut_trap_depth(base_nut), true);
                else
                    teardrop(r = screw_clearance_radius(base_screw), h = 100, center = true);
    }
}

module atx_screw_positions(psu, base = false) {
    if(base)
        translate([-psu_length(psu) / 2 - sb_base_offset + sb_base_thickness - (base_nut_traps ? nut_trap_depth(base_nut) : 0),
                    psu_width(psu) / 2 - sb_corner_offset - sb_base_width / 2,
                    psu_height(psu) + sb_wall - sb_height / 2 + layer_height + sb_clearance])
            rotate([90, 0, 90])
                children();

    else {
        for(end = [-1, 1])
            translate([end * (length  / 2 - tab_length - width / 2) - offset, -psu_width(psu) / 2 - width / 2, thickness])
                children();

        if(sb_frame_screw)
            translate([-psu_length(psu) / 2 + sb_corner_offset + sb_frame_width / 2,
                        psu_width(psu) / 2 + sb_frame_offset - sb_frame_thickness + (frame_nut_traps ? nut_trap_depth(frame_nut) : 0),
                        psu_height(psu) + sb_wall - sb_height / 2 + sb_clearance])
                rotate([90, 0, 0])
                    children();
    }
}

res = THS15;
second_resistor_pos = controller == Melzi ?
        [psu_length(psu) / 2 + 3 * al_clad_wire_length(res) / 2 + 30, -psu_width(psu) / 2 +     al_clad_width(res) / 2, 0]
      : [psu_length(psu) / 2 +     al_clad_wire_length(res) / 2 + 15, -psu_width(psu) / 2 + 4 * al_clad_width(res) / 2, 0];

sleeving = [
    [HSHRNK24,  3],         // -5V, -12V and PWRGOOD
    [HSHRNK32,  1],         // 3 * 3.3V
    [HSHRNK64,  2],         // 6 * 5V, 6 * 12V
    [HSHRNK100, 1],         // 12 * 0V
];

function sleeve_pos(i) = i > 0 ? sleeve_pos(i - 1) + tubing_od(sleeving[i][0]) /2 + 1 + tubing_od(sleeving[i - 1][0]) / 2 : 0;

module atx_bracket_assembly(show_psu = false) {
    rotate([0, 0, 180]) {
        translate([0, psu_width(psu) / 2, 0]) {
            color(plastic_part_color("lime")) render() atx_long_bracket_stl();
            for(end = [-1, 1])
                translate([end * (length / 2 - psu_hole_x) + offset, tab_thickness, end == -1 ? psu_hole_z : psu_hole_z2])
                    rotate([-90, 0, 0])
                        screw_and_washer(No632_pan_screw, 9.5, true);
        }
    }
    translate([-psu_length(psu) / 2, psu_width(psu) / 2, psu_height(psu) + sb_wall + sb_clearance])
        rotate([180, 0, 0])
            color(plastic_part_color("lime")) render() atx_short_bracket_stl();

    atx_screw_positions(psu, false)
        frame_screw(thickness);

    atx_screw_positions(psu, true)
        frame_screw(thickness);

    if(show_psu)
        psu(psu);

    for(j = [0 : len(sleeving) - 1])
        for(i = [0 : sleeving[j][1] - 1]) {
            od = tubing_od(sleeving[j][0]);
            translate([psu_length(psu) / 2 + 8,  psu_width(psu) / 2 - 15 - sleeve_pos(j), 12 + i * (od + 1) + od / 2])
                rotate([0, 90, 0])
                    tubing(sleeving[j][0]);
        }

    translate([psu_length(psu) / 2 + 10, -psu_width(psu) / 2 + 20, 20])
        rotate([90, 0, 0])
            ziptie(small_ziptie, 5);

    translate([psu_length(psu) / 2 + 10, psu_width(psu) / 2, 20])
        rotate([0, 90, 0])
            ziptie(small_ziptie, 10);

    translate([psu_length(psu) / 2 + al_clad_wire_length(res) / 2 + 15, -psu_width(psu) / 2 + al_clad_width(res) / 2, 0])
        al_clad_resistor_assembly(res, "10R");

    translate(second_resistor_pos)
        al_clad_resistor_assembly(res, "4R7");
}

module atx_resistor_holes(psu) {
    translate([psu_length(psu) / 2 + al_clad_wire_length(res) / 2 + 15, -psu_width(psu) / 2 + al_clad_width(res) / 2, 0])
        al_clad_resistor_holes(res);

    translate(second_resistor_pos)
        al_clad_resistor_holes(res);
}

module atx_brackets_stl() {
    rotate([0, 0, 180])
        atx_long_bracket_stl();

    translate([-length / 2 - offset + sb_corner_offset - 2, sb_base_offset - width + 2, 0])
        rotate([0, 0, 90])
            atx_short_bracket_stl();
}

module atx_brackets_x4_stl() {
    squeeze = 2 * (sb_base_width - sb_frame_offset - 1);
    for(i = [0: 1]) {
        translate([0, i * 2 * (atx_bracket_width + 2), 0]) {
            translate([offset, 0, 0])
                rotate([0, 0, 180])
                    atx_long_bracket_stl();
            translate([-offset, 2, 0])
                atx_long_bracket_stl();
        }
        translate([sb_corner_offset + sb_frame_width - i * (2 * sb_corner_offset + 2 * sb_frame_width + sb_base_offset + 1 - squeeze) - squeeze / 2,
                  -(atx_bracket_width + 2), 0]) {
            translate([0, sb_corner_offset - sb_base_width - 2, 0])
                rotate([0, 0, 180])
                    atx_short_bracket_stl();

            translate([sb_base_offset + 1, -sb_corner_offset - sb_base_width , 0])
                atx_short_bracket_stl();
        }
    }
}

if(1)
    atx_bracket_assembly(true);
else
    if(0)
        atx_brackets_x4_stl();
    else
        atx_brackets_stl();