IEC mains connector models more accurate.

JSON BOM now simplified and in required order.

examples/MainsBreakOutBox/bom/bom.json

@@ -1,64 +1,69 @@
-{
-    "name": "main_assembly",
-    "count": 1,
-    "assemblies": [
-        {
-            "name": "mains_in_assembly",
-            "count": 1,
-            "assemblies": [
-                {
-                    "name": "feet_assembly",
-                    "count": 1,
-                    "assemblies": [
-                        {
-                            "name": "base_assembly",
-                            "count": 1,
-                            "assemblies": [],
-                            "vitamins": {
-                                "insert(F1BM3): Heatfit insert M3": 2
-                            },
-                            "printed": {
-                                "socket_box.stl": 1
-                            },
-                            "routed": {}
-                        }
-                    ],
-                    "vitamins": {
-                        "washer(M3_washer): Washer  M3 x 7mm x 0.5mm": 8,
-                        "screw(M3_dome_screw, 10): Screw M3 dome x 10mm": 4,
-                        "nut(M3_nut, nyloc = true): Nut M3 nyloc": 4
-                    },
-                    "printed": {
-                        "foot.stl": 4
-                    },
-                    "routed": {}
-                }
-            ],
-            "vitamins": {
-                ": Wire green & yellow 30/0.25mm strands, length 150mm - not shown": 1,
-                ": Wire blue 30/0.25mm strands, length 150mm - not shown": 1,
-                ": Wire brown 30/0.25mm strands, length 150mm - not shown": 2,
-                "tubing(HSHRNK32): Heatshrink sleeving ID 3.2mm x 15mm - not shown": 3,
-                "iec(IEC_inlet_atx): IEC inlet for ATX": 1,
-                "screw(M3_cs_cap_screw, 12): Screw M3 cs cap x 12mm": 2,
-                "washer(M3_washer): Washer  M3 x 7mm x 0.5mm": 2,
-                "nut(M3_nut, nyloc = true): Nut M3 nyloc": 2
-            },
-            "printed": {},
-            "routed": {}
-        }
-    ],
-    "vitamins": {
-        ": Wire green & yellow 30/0.25mm strands, length 150mm - not shown": 1,
-        ": Wire blue 30/0.25mm strands, length 150mm - not shown": 1,
-        "tubing(HSHRNK32): Heatshrink sleeving ID 3.2mm x 15mm - not shown": 5,
-        ": Ferrule for 1.5mm^2 wire - not shown": 3,
-        "mains_socket(Contactum): Mains socket 13A": 1,
-        "screw(M3_cs_cap_screw, 20): Screw M3 cs cap x 20mm": 2,
-        "jack_4mm_shielded(\"blue\", 3, \"royalblue\"): 4mm shielded jack socket blue": 2,
-        "jack_4mm_shielded(\"brown\", 3, \"sienna\"): 4mm shielded jack socket brown": 1,
-        "jack_4mm_shielded(\"green\", 3): 4mm shielded jack socket green": 2
+[
+    {
+        "name": "base_assembly",
+        "count": 1,
+        "assemblies": {},
+        "vitamins": {
+            "insert(F1BM3): Heatfit insert M3": 2
+        },
+        "printed": {
+            "socket_box.stl": 1
+        },
+        "routed": {}
     },
-    "printed": {},
-    "routed": {}
-}
+    {
+        "name": "feet_assembly",
+        "count": 1,
+        "assemblies": {
+            "base_assembly": 1
+        },
+        "vitamins": {
+            "washer(M3_washer): Washer  M3 x 7mm x 0.5mm": 8,
+            "screw(M3_dome_screw, 10): Screw M3 dome x 10mm": 4,
+            "nut(M3_nut, nyloc = true): Nut M3 x 2.4mm nyloc": 4
+        },
+        "printed": {
+            "foot.stl": 4
+        },
+        "routed": {}
+    },
+    {
+        "name": "mains_in_assembly",
+        "count": 1,
+        "assemblies": {
+            "feet_assembly": 1
+        },
+        "vitamins": {
+            ": Wire green & yellow 30/0.25mm strands, length 150mm - not shown": 1,
+            ": Wire blue 30/0.25mm strands, length 150mm - not shown": 1,
+            ": Wire brown 30/0.25mm strands, length 150mm - not shown": 2,
+            "tubing(HSHRNK32): Heatshrink sleeving ID 3.2mm x 15mm - not shown": 3,
+            "iec(IEC_inlet_atx): IEC inlet for ATX": 1,
+            "screw(M3_cs_cap_screw, 12): Screw M3 cs cap x 12mm": 2,
+            "washer(M3_washer): Washer  M3 x 7mm x 0.5mm": 2,
+            "nut(M3_nut, nyloc = true): Nut M3 x 2.4mm nyloc": 2
+        },
+        "printed": {},
+        "routed": {}
+    },
+    {
+        "name": "main_assembly",
+        "count": 1,
+        "assemblies": {
+            "mains_in_assembly": 1
+        },
+        "vitamins": {
+            ": Wire green & yellow 30/0.25mm strands, length 150mm - not shown": 1,
+            ": Wire blue 30/0.25mm strands, length 150mm - not shown": 1,
+            "tubing(HSHRNK32): Heatshrink sleeving ID 3.2mm x 15mm - not shown": 5,
+            ": Ferrule for 1.5mm^2 wire - not shown": 3,
+            "mains_socket(Contactum): Mains socket 13A": 1,
+            "screw(M3_cs_cap_screw, 20): Screw M3 cs cap x 20mm": 2,
+            "jack_4mm_shielded(\"blue\", 3, \"royalblue\"): 4mm shielded jack socket blue": 2,
+            "jack_4mm_shielded(\"brown\", 3, \"sienna\"): 4mm shielded jack socket brown": 1,
+            "jack_4mm_shielded(\"green\", 3): 4mm shielded jack socket green": 2
+        },
+        "printed": {},
+        "routed": {}
+    }
+]

examples/MainsBreakOutBox/bom/bom.txt

@@ -17,7 +17,7 @@ Vitamins:
   |  | 1|  |  1 4mm shielded jack socket brown
   |  | 2|  |  2 4mm shielded jack socket green
   |  | 1|  |  1 Mains socket 13A
-  | 4|  | 2|  6 Nut M3 nyloc
+  | 4|  | 2|  6 Nut M3 x 2.4mm nyloc
   |  |  | 2|  2 Screw M3 cs cap x 12mm
   |  | 2|  |  2 Screw M3 cs cap x 20mm
   | 4|  |  |  4 Screw M3 dome x 10mm

examples/MainsBreakOutBox/bom/feet_assembly.txt

@@ -1,6 +1,6 @@
 feet_assembly:
 Vitamins:
-  4 Nut M3 nyloc
+  4 Nut M3 x 2.4mm nyloc
   4 Screw M3 dome x 10mm
   8 Washer  M3 x 7mm x 0.5mm
 

examples/MainsBreakOutBox/bom/mains_in_assembly.txt

@@ -4,7 +4,7 @@ Vitamins:
   2 Wire brown 30/0.25mm strands, length 150mm - not shown
   1 Wire green & yellow 30/0.25mm strands, length 150mm - not shown
   1 IEC inlet for ATX
-  2 Nut M3 nyloc
+  2 Nut M3 x 2.4mm nyloc
   2 Screw M3 cs cap x 12mm
   3 Heatshrink sleeving ID 3.2mm x 15mm - not shown
   2 Washer  M3 x 7mm x 0.5mm

examples/MainsBreakOutBox/readme.md

@@ -39,7 +39,7 @@ Earth leakage can be measured Canadian CSA style by disconnected the neutral lin
 |   .  |   .  |   3  |   5  |    8  |    Heatshrink sleeving ID 3.2mm x 15mm - not shown |
 |   .  |   .  |   1  |   .  |    1  |    IEC inlet for ATX |
 |   .  |   .  |   .  |   1  |    1  |    Mains socket 13A |
-|   .  |   4  |   2  |   .  |    6  |    Nut M3 nyloc |
+|   .  |   4  |   2  |   .  |    6  |    Nut M3 x 2.4mm nyloc |
 |   .  |   .  |   2  |   .  |    2  |    Screw M3 cs cap x 12mm |
 |   .  |   .  |   .  |   2  |    2  |    Screw M3 cs cap x 20mm |
 |   .  |   4  |   .  |   .  |    4  |    Screw M3 dome x 10mm |
@@ -88,7 +88,7 @@ Earth leakage can be measured Canadian CSA style by disconnected the neutral lin
 |--:|:----------|
 |8| Washer  M3 x 7mm x 0.5mm|
 |4| Screw M3 dome x 10mm|
-|4| Nut M3 nyloc|
+|4| Nut M3 x 2.4mm nyloc|
 
 
 ### 3D Printed parts
@@ -129,7 +129,7 @@ Earth leakage can be measured Canadian CSA style by disconnected the neutral lin
 |1| IEC inlet for ATX|
 |2| Screw M3 cs cap x 12mm|
 |2| Washer  M3 x 7mm x 0.5mm|
-|2| Nut M3 nyloc|
+|2| Nut M3 x 2.4mm nyloc|
 
 
 ### Sub-assemblies

examples/MainsBreakOutBox/scad/bob_main.scad

@@ -60,7 +60,7 @@ insert_length = insert_length(insert);
 insert_boss = mains_socket_insert_boss(socket);
 screw_length = screw_longer_than(mains_socket_height(socket) + insert_length(insert));
 
-iec_h = iec_slot_h(iec) + 1;
+iec_h = iec_body_h(iec) + 1;
 
 box_height = socket_depth + iec_h;
 base_thickness = wall;

readme.md

@@ -766,6 +766,10 @@ IEC mains inlets and outlet.
 | ```iec_bezel_r(type)``` | Bezel corner radius |
 | ```iec_bezel_t(type)``` | Bezel thickness |
 | ```iec_bezel_w(type)``` | Bezel width |
+| ```iec_body_h(type)``` | Body height |
+| ```iec_body_r(type)``` | Body corner radius |
+| ```iec_body_w(type)``` | Body width |
+| ```iec_body_w2(type)``` | Body width at the narrow part |
 | ```iec_depth(type)``` | Depth of the body below the flange |
 | ```iec_flange_h(type)``` | Flange height |
 | ```iec_flange_r(type)``` | Flange corner radius |
@@ -775,18 +779,21 @@ IEC mains inlets and outlet.
 | ```iec_part(type)``` | Description |
 | ```iec_pitch(type)``` | Screw hole pitch |
 | ```iec_screw(type)``` | Screw type |
-| ```iec_slot_h(type)``` | Body height |
-| ```iec_slot_r(type)``` | Body corner radius |
-| ```iec_slot_w(type)``` | Body width |
 | ```iec_spades(type)``` | Spade type |
 | ```iec_width(type)``` | Widest part including the lugs |
 
+### Functions
+| Function | Description |
+|:--- |:--- |
+| ```iec_insert_screw_length()``` | Screw length used for inserts |
+
 ### Modules
 | Module | Description |
 |:--- |:--- |
 | ```iec(type)``` | Draw specified IEC connector |
 | ```iec_assembly(type, thickness)``` | Assembly with fasteners given panel thickness |
 | ```iec_holes(type, h = 100, poly = false, horizontal = false, insert = false)``` | Drill the required panel holes |
+| ```iec_inserts(type)``` | Place the inserts |
 | ```iec_screw_positions(type)``` | Position children at the screw holes |
 
 ![iecs](tests/png/iecs.png)
@@ -794,14 +801,15 @@ IEC mains inlets and outlet.
 ### Vitamins
 | Qty | Module call | BOM entry |
 | ---:|:--- |:---|
-|   1 | ```iec(IEC_fused_inlet)``` |  IEC fused inlet |
+|   1 | ```iec(IEC_fused_inlet)``` |  IEC fused inlet JR-101-1F |
+|   1 | ```iec(IEC_fused_inlet2)``` |  IEC fused inlet old |
 |   1 | ```iec(IEC_inlet)``` |  IEC inlet |
 |   1 | ```iec(IEC_inlet_atx)``` |  IEC inlet for ATX |
-|   1 | ```iec(IEC_outlet)``` |  IEC outlet |
-|   8 | ```nut(M3_nut, nyloc = true)``` |  Nut M3 x 2.4mm nyloc |
+|   1 | ```iec(IEC_outlet)``` |  IEC outlet RS 811-7193 |
+|  10 | ```nut(M3_nut, nyloc = true)``` |  Nut M3 x 2.4mm nyloc |
 |   4 | ```screw(M3_cs_cap_screw, 10)``` |  Screw M3 cs cap x 10mm |
-|   4 | ```screw(M3_cs_cap_screw, 12)``` |  Screw M3 cs cap x 12mm |
-|   8 | ```washer(M3_washer)``` |  Washer  M3 x 7mm x 0.5mm |
+|   6 | ```screw(M3_cs_cap_screw, 12)``` |  Screw M3 cs cap x 12mm |
+|  10 | ```washer(M3_washer)``` |  Washer  M3 x 7mm x 0.5mm |
 
 
 <a href="#top">Top</a>
@@ -4118,9 +4126,10 @@ Global constants, functions and modules. This file is used directly or indirectl
 | ```circle4n(r, d = undef)``` | Circle with multiple of 4 vertices |
 | ```ellipse(xr, yr)``` | Draw an ellipse |
 | ```extrude_if(h, center = true)``` | Extrudes 2D object to 3D when ```h``` is nonzero, otherwise leaves it 2D |
+| ```hflip()``` | Invert children by doing a 180&deg; flip around the Y axis |
 | ```semi_circle(r, d = undef)``` | A semi circle in the positive Y domain |
 | ```translate_z(z)``` | Shortcut for Z only translations |
-| ```vflip()``` | Invert children by doing a 180 flip around the X axis |
+| ```vflip()``` | Invert children by doing a 180&deg; flip around the X axis |
 
 ![global](tests/png/global.png)
 

scripts/bom.py

@@ -54,21 +54,13 @@ class BOM:
         self.routed = {}
         self.assemblies = {}
 
-    def data(self, main):
-        return {
-             "name"       : self.name,
-             "count"      : self.count,
-             "assemblies" : [main.assemblies[ass].data(main) for ass in self.assemblies],
-             "vitamins"   : self.vitamins,
-             "printed"    : self.printed,
-             "routed"     : self.routed
-        }
-
     def flat_data(self):
         assemblies = {}
         for ass in self.assemblies:
             assemblies[ass] = self.assemblies[ass].count
         return {
+             "name"       : self.name,
+             "count"      : self.count,
              "assemblies" : assemblies,
              "vitamins"   : self.vitamins,
              "printed"    : self.printed,
@@ -167,6 +159,7 @@ class BOM:
 
 def parse_bom(file = "openscad.log", name = None):
     main = BOM(name)
+    main.ordered_assemblies = []
     stack = []
 
     for line in open(file):
@@ -179,6 +172,9 @@ def parse_bom(file = "openscad.log", name = None):
                     main.assemblies[stack[-1]].add_assembly(ass)    #add to nested BOM
                 stack.append(ass)
                 main.add_assembly(ass)                              #add to flat BOM
+                if ass in main.ordered_assemblies:
+                    main.ordered_assemblies.remove(ass)
+                main.ordered_assemblies.insert(0, ass)
             else:
                 if s[0] == '}':
                     if s[1:] != stack[-1]:
@@ -227,14 +223,15 @@ def boms(target = None, assembly = None):
     if assembly == "main_assembly":
         main.print_bom(True, open(bom_dir + "/bom.txt","wt"))
 
-    for ass in sorted(main.assemblies):
+    for ass in main.assemblies:
         with open(bom_dir + "/" + ass + ".txt", "wt") as f:
             bom = main.assemblies[ass]
             print(bom.make_name(ass) + ":", file=f)
             bom.print_bom(False, f)
 
+    data = [main.assemblies[ass].flat_data() for ass in main.ordered_assemblies]
     with open(bom_dir + "/bom.json", 'w') as outfile:
-        json.dump(main.assemblies[assembly].data(main), outfile, indent = 4)
+        json.dump(data, outfile, indent = 4)
 
     print("done")
 

scripts/deps.py

@@ -33,7 +33,7 @@ def read_deps(dname):
     for line in lines:
         if line.startswith('\t'):
             dep = line[1 : -1].rstrip(' \\')
-            if not dep in ['stl.scad', 'dxf.scad', 'svf.scad', 'png.scad']:
+            if not os.path.basename(dep) in ['stl.scad', 'dxf.scad', 'svf.scad', 'png.scad', 'target.scad']:
                 deps.append(dep)
     return deps
 

scripts/render.py

@@ -28,6 +28,7 @@ import os
 import openscad
 from tests import do_cmd, update_image, colour_scheme, background
 from deps import mtime
+from colorama import init
 
 def render(target, type):
     #
@@ -69,6 +70,7 @@ def render(target, type):
             os.remove(png_maker_name)
 
 if __name__ == '__main__':
+    init()
     target =  sys.argv[1] if len(sys.argv) > 1 else None
     render(target, 'stl')
     render(target, 'dxf')

scripts/views.py

@@ -39,13 +39,25 @@ from colorama import Fore
 def is_assembly(s):
     return s[-9:] == '_assembly' or s[-11:] == '_assemblies'
 
-def add_assembly(flat_bom, bom, bounds_map):
-    if not bom in flat_bom:
+def bom_to_assemblies(bom_dir, bounds_map):
+    global flat_bom
+    #
+    # Make a list of all the parts in the BOM
+    #
+    bom_file = bom_dir + "/bom.json"
+    with open(bom_file) as json_file:
+        flat_bom = json.load(json_file)
+    #
+    # Decide if we need big or small assembly pictures
+    #
+    for bom in flat_bom:
         big = False
         for ass in bom["assemblies"]:
-            add_assembly(flat_bom, ass, bounds_map)
-            if ass["big"]:
-                big = True
+            for b in flat_bom:
+                if b["name"] == ass:
+                    if b["big"]:
+                        big = True
+                    break
         if not big:
             for stl in bom["printed"]:
                 bounds = bounds_map[stl]
@@ -54,21 +66,10 @@ def add_assembly(flat_bom, bom, bounds_map):
                 if max(width, depth) > 80:
                     big = True
                     break
-
         bom["big"] = big or bom["routed"]
-        flat_bom.append(bom)
-
-def bom_to_assemblies(bom_dir, bounds_map):
-    global flat_bom
     #
-    # Make a list of all the parts in the BOM
+    # Remove the main assembly if it is a shell
     #
-    bom  = {}
-    bom_file = bom_dir + "/bom.json"
-    with open(bom_file) as json_file:
-        bom = json.load(json_file)
-    flat_bom = []
-    add_assembly(flat_bom, bom, bounds_map)
     ass =  flat_bom[-1]
     if len(ass["assemblies"]) < 2 and not ass["vitamins"] and not ass["printed"] and not ass["routed"]:
         flat_bom = flat_bom[:-1]
@@ -273,49 +274,49 @@ def views(target, do_assemblies = None):
                 printed = ass["printed"]
                 if printed:
                     print('### 3D Printed parts', file = doc_file)
-                    i = 0
-                    for p in printed:
+                    keys = sorted(list(printed.keys()))
+                    for i in range(len(keys)):
+                        p = keys[i]
                         print('%s %d x %s |' % ('\n|' if not (i % 3) else '', printed[p], p), file = doc_file, end = '')
                         if (i % 3) == 2 or i == len(printed) - 1:
                             n = (i % 3) + 1
                             print('\n|%s' % ('--|' * n), file =  doc_file)
                             for j in range(n):
-                                part = list(printed.keys())[i - n + j + 1]
+                                part = keys[i - n + j + 1]
                                 print('| ![%s](stls/%s) %s' % (part, part.replace('.stl','.png'), '|\n' if j == j - 1 else ''), end = '', file = doc_file)
                             print('\n', file = doc_file)
-                        i += 1
                     print('\n', file  = doc_file)
 
                 routed = ass["routed"]
                 if routed:
                     print("### CNC Routed parts", file = doc_file)
-                    i = 0
-                    for r in routed:
+                    keys = sorted(list(routed.keys()))
+                    for i in range(len(keys)):
+                        r = keys[i]
                         print('%s %d x %s |' % ('\n|' if not (i % 3) else '', routed[r], r), file = doc_file, end = '')
                         if (i % 3) == 2 or i == len(routed) - 1:
                             n = (i % 3) + 1
                             print('\n|%s' % ('--|' * n), file =  doc_file)
                             for j in range(n):
-                                part = list(routed.keys())[i - n + j + 1]
+                                part = keys[i - n + j + 1]
                                 print('| ![%s](dxfs/%s) %s' % (part, part.replace('.dxf','.png'), '|\n' if j == j - 1 else ''), end = '', file = doc_file)
                             print('\n', file = doc_file)
-                        i += 1
                     print('\n', file  = doc_file)
 
                 sub_assemblies = ass["assemblies"]
                 if sub_assemblies:
                     print("### Sub-assemblies", file = doc_file)
-                    i = 0
-                    for a in sub_assemblies:
-                        print('%s %d x %s |' % ('\n|' if not (i % 3) else '', a["count"], a["name"]), file = doc_file, end = '')
-                        if (i % 3) == 2 or i == len(sub_assemblies) - 1:
+                    keys = sorted(list(sub_assemblies.keys()))
+                    for i in range(len(keys)):
+                        a = keys[i]
+                        print('%s %d x %s |' % ('\n|' if not (i % 3) else '', sub_assemblies[a], a), file = doc_file, end = '')
+                        if (i % 3) == 2 or i == len(keys) - 1:
                             n = (i % 3) + 1
                             print('\n|%s' % ('--|' * n), file =  doc_file)
                             for j in range(n):
-                                a = sub_assemblies[i - n + j + 1]["name"].replace('_assembly', '_assembled')
+                                a = keys[i - n + j + 1].replace('_assembly', '_assembled')
                                 print('| ![%s](assemblies/%s) %s' % (a, a + '_tn.png', '|\n' if j == j - 1 else ''), end = '', file = doc_file)
                             print('\n', file = doc_file)
-                        i += 1
                     print('\n', file  = doc_file)
 
                 small = not ass["big"]

utils/core/global.scad

@@ -31,7 +31,8 @@ function r2sides(r) = $fn ? $fn : ceil(max(min(360/ $fa, r * 2 * PI / $fs), 5));
 function r2sides4n(r) = floor((r2sides(r) + 3) / 4) * 4;                            //! Round up the number of sides to a multiple of 4 to ensure points land on all axes
 
 module translate_z(z) translate([0, 0, z]) children();                              //! Shortcut for Z only translations
-module vflip() rotate([180, 0, 0]) children();                                      //! Invert children by doing a 180 flip around the X axis
+module vflip() rotate([180, 0, 0]) children();                                      //! Invert children by doing a 180° flip around the X axis
+module hflip() rotate([0, 180, 0]) children();                                      //! Invert children by doing a 180° flip around the Y axis
 module ellipse(xr, yr) scale([1, yr / xr]) circle4n(xr);                            //! Draw an ellipse
 
 module extrude_if(h, center = true)                 //! Extrudes 2D object to 3D when ```h``` is nonzero, otherwise leaves it 2D

utils/core/polyholes.scad

@@ -23,9 +23,9 @@
 //!
 //! The module provides `poly_circle()`, `poly_cylinder()` and `poly_ring()` that is useful for making printed washers and pillars.
 //
-function sides(r) = max(round(4 * r), 3); //! Optimium number of sides for specified radius
-function corrected_radius(r, n = 0)   = r / cos(180 / (n ? n : sides(r))); //! Adjusted radius to make flats lie on the circle
-function corrected_diameter(d, n = 0) = d / cos(180 / (n ? n : sides(d / 2))); //! Adjusted diameter to make flats lie on the circle
+function sides(r) = max(round(4 * r), 3);                                       //! Optimium number of sides for specified radius
+function corrected_radius(r, n = 0)   = r / cos(180 / (n ? n : sides(r)));      //! Adjusted radius to make flats lie on the circle
+function corrected_diameter(d, n = 0) = d / cos(180 / (n ? n : sides(d / 2)));  //! Adjusted diameter to make flats lie on the circle
 
 module poly_circle(r, sides = 0) { //! Make a circle adjusted to print the correct size
     n = sides ? sides : sides(r);
@@ -38,8 +38,8 @@ module poly_cylinder(r, h, center = false, sides = 0) //! Make a cylinder adjust
 
 module poly_ring(or, ir) { //! Make a 2D ring adjusted to have the correct internal radius
     cir = corrected_radius(ir);
-    filaments = floor((or - cir) / extrusion_width);
-    if(filaments > 3)
+    filaments = (or - cir) / extrusion_width;
+    if(filaments > 3 + eps)
         difference() {
             circle(or);
 

vitamins/iec.scad

@@ -30,23 +30,25 @@ include <inserts.scad>
 function iec_part(type)     = type[1];  //! Description
 function iec_screw(type)    = type[2];  //! Screw type
 function iec_pitch(type)    = type[3];  //! Screw hole pitch
-function iec_slot_w(type)   = type[4];  //! Body width
-function iec_slot_h(type)   = type[5];  //! Body height
-function iec_slot_r(type)   = type[6];  //! Body corner radius
-function iec_bezel_w(type)  = type[7];  //! Bezel width
-function iec_bezel_h(type)  = type[8];  //! Bezel height
-function iec_bezel_r(type)  = type[9];  //! Bezel corner radius
-function iec_bezel_t(type)  = type[10]; //! Bezel thickness
-function iec_flange_w(type) = type[11]; //! Flange width not including the lugs
-function iec_flange_h(type) = type[12]; //! Flange height
-function iec_flange_r(type) = type[13]; //! Flange corner radius
-function iec_flange_t(type) = type[14]; //! Flange thickness
-function iec_width(type)    = type[15]; //! Widest part including the lugs
-function iec_depth(type)    = type[16]; //! Depth of the body below the flange
-function iec_spades(type)   = type[17]; //! Spade type
-function iec_male(type)     = type[18]; //! True for an outlet
+function iec_body_w(type)   = type[4];  //! Body width
+function iec_body_w2(type)  = type[5];  //! Body width at the narrow part
+function iec_body_h(type)   = type[6];  //! Body height
+function iec_body_r(type)   = type[7];  //! Body corner radius
+function iec_bezel_w(type)  = type[8];  //! Bezel width
+function iec_bezel_h(type)  = type[9];  //! Bezel height
+function iec_bezel_r(type)  = type[10];  //! Bezel corner radius
+function iec_bezel_t(type)  = type[11]; //! Bezel thickness
+function iec_flange_w(type) = type[12]; //! Flange width not including the lugs
+function iec_flange_h(type) = type[13]; //! Flange height
+function iec_flange_r(type) = type[14]; //! Flange corner radius
+function iec_flange_t(type) = type[15]; //! Flange thickness
+function iec_width(type)    = type[16]; //! Widest part including the lugs
+function iec_depth(type)    = type[17]; //! Depth of the body below the flange
+function iec_spades(type)   = type[18]; //! Spade type
+function iec_male(type)     = type[19]; //! True for an outlet
 
-insert_overlap = 1.1; // chosen to make cap screws 10mm long.
+insert_screw_length = 10;
+function iec_insert_screw_length() = insert_screw_length; //! Screw length used for inserts
 
 module iec(type) { //! Draw specified IEC connector
     vitamin(str("iec(", type[0], "): ", iec_part(type)));
@@ -67,10 +69,10 @@ module iec(type) { //! Draw specified IEC connector
                     cube([pin_w, pin_d, h - pin_chamfer], center = true);
             }
 
-    socket_w  = 24;
+    socket_w  = 24.5;
     socket_w2 = 14;
-    socket_h  = 16.5;
-    socket_h2 = 12;
+    socket_h  = 16.34;
+    socket_h2 = socket_h - (socket_w - socket_w2);
     socket_d  = 17;
     socket_r = 3;
     socket_r2 = 0.5;
@@ -82,7 +84,7 @@ module iec(type) { //! Draw specified IEC connector
                 translate([side * (socket_w / 2 - socket_r), -socket_h / 2 + socket_r])
                     circle(socket_r);
 
-                translate([side * (socket_w / 2 - socket_r2), -socket_h / 2 + socket_h2 + socket_r2])
+                translate([side * (socket_w / 2 - socket_r2), socket_h2 / 2 - socket_r2])
                     circle(socket_r2);
 
                 translate([side * (socket_w2 / 2 - socket_r2), socket_h / 2 - socket_r2])
@@ -93,7 +95,7 @@ module iec(type) { //! Draw specified IEC connector
         translate([0, socket_offset])
             if(iec_male(type))
                 difference() {
-                    offset(3)
+                    offset(2)
                         socket_shape();
 
                     difference() {
@@ -110,6 +112,28 @@ module iec(type) { //! Draw specified IEC connector
             else
                 socket_shape();
 
+    module body_shape() {
+        hull() {
+            bw = iec_body_w(type);
+            bh = iec_body_h(type);
+            br = iec_body_r(type);
+            bw2 = iec_body_w2(type);
+            bh2 = bh - (bw - bw2);
+            br2 = 1;
+
+            for(side = [-1, 1]) {
+                translate([side * (bw / 2 - br), -bh / 2 + br])
+                    circle4n(br);
+
+                translate([side * (bw / 2 - br2), bh2 / 2 - br2])
+                    circle4n(br2);
+
+                translate([side * (bw2 / 2 - br2), bh / 2 - br2])
+                    circle4n(br2);
+            }
+        }
+    }
+
     color(grey20) {
         // Flange
         flange_t = iec_flange_t(type);
@@ -152,12 +176,14 @@ module iec(type) { //! Draw specified IEC connector
         translate_z(-h)
             linear_extrude(height = h)
                 difference() {
-                    rounded_square([iec_slot_w(type), iec_slot_h(type)], iec_slot_r(type));
+                    body_shape();
+
                     oriffice_shape();
                 }
         // Back
         translate_z(-iec_depth(type))
-            rounded_rectangle([iec_slot_w(type), iec_slot_h(type), iec_depth(type) - h], iec_slot_r(type), center = false);
+            linear_extrude(height = iec_depth(type) - h)
+                body_shape();
     }
     if(!iec_male(type))
         translate([0, socket_offset, iec_flange_t(type) + iec_bezel_t(type) - socket_d]) {
@@ -174,6 +200,8 @@ module iec(type) { //! Draw specified IEC connector
                 spade(spade[0], spade[1]);
 }
 
+function iec_spade_depth(type) = iec_depth(type) + max([for(spade = iec_spades(type)) spade[1]]);
+
 module iec_screw_positions(type) //! Position children at the screw holes
     for(side = [-1, 1])
         translate([side * iec_pitch(type) / 2, 0])
@@ -181,36 +209,49 @@ module iec_screw_positions(type) //! Position children at the screw holes
 
 module iec_holes(type, h = 100, poly = false, horizontal = false, insert = false) { //! Drill the required panel holes
     clearance = 0.2;
+    screw = iec_screw(type);
+    insert_type = screw_insert(screw);
+    insert_overlap = max(0, insert_screw_length + clearance - iec_flange_t(type) - insert_hole_length(insert_type));
 
     iec_screw_positions(type)
         if(insert)
-            insert_hole(screw_insert(iec_screw(type)), insert_overlap, horizontal = horizontal);
+            if(h)
+                insert_hole(insert_type, insert_overlap, horizontal = horizontal);
+            else
+                poly_circle(insert_hole_radius(insert_type));
         else
             if(horizontal)
-                teardrop_plus(r = screw_clearance_radius(iec_screw(type)), h = h);
+                teardrop_plus(r = screw_clearance_radius(screw), h = h);
             else
                 if(poly)
-                    poly_cylinder(r = screw_clearance_radius(iec_screw(type)), h = h, center = true);
+                    poly_cylinder(r = screw_clearance_radius(screw), h = h, center = true);
                 else
-                    drill(screw_clearance_radius(iec_screw(type)), h);
+                    drill(screw_clearance_radius(screw), h);
 
     extrude_if(h)
         hull()
             for(x = [-1, 1], y = [-1, 1], sag = horizontal && y > 1 ? layer_height : 0)
-                translate([x * (iec_slot_w(type) / 2 - iec_slot_r(type)), y * (iec_slot_h(type) / 2  - iec_slot_r(type) + sag )])
+                translate([x * (iec_body_w(type) / 2 - iec_body_r(type)), y * (iec_body_h(type) / 2  - iec_body_r(type) + sag )])
                     if(horizontal)
-                        teardrop(0, iec_slot_r(type) + clearance / 2 + layer_height / 4);
+                        teardrop(0, iec_body_r(type) + clearance / 2 + layer_height / 4);
                     else
-                        drill(iec_slot_r(type) + clearance / 2, 0);
+                        drill(iec_body_r(type) + clearance / 2, 0);
 }
 
-module iec_assembly(type, thickness) { //! Assembly with fasteners given panel thickness
+module iec_inserts(type) {              //! Place the inserts
+    insert = screw_insert(iec_screw(type));
+
+    iec_screw_positions(type)
+        insert(insert);
+}
+
+module iec_assembly(type, thickness) {  //! Assembly with fasteners given panel thickness
     screw = iec_screw(type);
     washer = screw_washer(screw);
     nut = screw_nut(screw);
     insert = screw_insert(screw);
     screw_length = thickness ? screw_longer_than(iec_flange_t(type) + thickness + washer_thickness(washer) + nut_thickness(nut, true))
-                             : screw_shorter_than(iec_flange_t(type) + insert_hole_length(insert) + insert_overlap);
+                             : insert_screw_length;
 
     iec(type);
 
@@ -222,7 +263,5 @@ module iec_assembly(type, thickness) { //! Assembly with fasteners given panel t
             translate_z(-thickness)
                 vflip()
                     nut_and_washer(nut, true);
-        else
-            insert(insert);
     }
 }

vitamins/iecs.scad

@@ -19,29 +19,43 @@
 include <screws.scad>
 include <spades.scad>
 
-fused_spades = [[spade6p4, 14,  -7,  0, 0],
-                [spade6p4, 14,   7,  0, 0],
-                [spade6p4, 14,   0, 11, 0],
+fused_spades = [[spade4p8, 8.5,  7,  3, 90],
+                [spade4p8, 8.5,  0,  7, 90],
+                [spade4p8, 8.5,  5, -7, 90]];
+
+fused_spades2 = [[spade6p4, 13,  -7,  0, 0],
+                [spade6p4, 13,   7,  0, 0],
+                [spade6p4, 13,   0, 11, 0],
                 [spade4p8, 8.5, -7, -9, 90],
                 [spade4p8, 8.5,  7, -9, 90]];
 
 inlet_spades = [[spade6p4, 9, -7,  -5.5, 0],
                 [spade6p4, 9,  7,  -5.5, 0],
                 [spade6p4, 9,  0,   5.5, 0]];
-//
-//                                    p                    s                p   s     s     s  b   b     b  b    f   f   f  f    w   d   s            m
-//                                    a                    c                i   l     l     l  e   e     e  e    l   l   l  l    i   e   p            a
-//                                    r                    r                t   o     o     o  z   z     z  z    a   a   a  a    d   p   a            l
-//                                    t                    e                c   t     t     t  e   e     e  e    n   n   n  n    t   t   d            e
-//                                                         w                h                  l   l     l  l    g   g   g  g    h   h   e
-//                                                                              w     h     r                    e   e   e  e            s
-//                                                                                             w   h     r  t
-//                                                                                                               w   h   r  t
-//
-IEC_fused_inlet = ["IEC_fused_inlet", "IEC fused inlet",   M3_cs_cap_screw, 36, 27.3, 31.2, 3, 28, 31,   2, 2.5, 30, 33, 4, 2.5, 44, 21, fused_spades, false ];
-IEC_inlet       = ["IEC_inlet",       "IEC inlet",         M3_cs_cap_screw, 40, 28.2, 20.2, 3, 28, 20.5, 4, 2.5, 37, 23, 1, 2.5, 48, 14, inlet_spades, false ];
-IEC_inlet_atx   = ["IEC_inlet_atx",   "IEC inlet for ATX", M3_cs_cap_screw, 40, 27.0, 19.0, 3, 30, 22,   2, 2.0, 30, 22, 2, 4.0, 50, 13, inlet_spades, false ];
-IEC_outlet      = ["IEC_outlet",      "IEC outlet",        M3_cs_cap_screw, 40, 32,   24,   3, 28, 20.5, 2, 0.0, 29, 29, 2, 2.9, 50, 23, inlet_spades, true ];
 
-iecs = [IEC_inlet, IEC_inlet_atx, IEC_fused_inlet, IEC_outlet];
+atx_spades = [[spade3p5, 8, -7,  -3, 90],
+              [spade3p5, 8,  7,  -3, 90],
+              [spade3p5, 8,  0,   3, 90]];
+
+outlet_spades = [[spade4p8ll, 8, -7,  -2, 90],
+                 [spade4p8ll, 8,  7,  -2, 90],
+                 [spade4p8ll, 8,  0,   2, 90]];
+
+//
+//                                    p                              s                p    b   b   b  b   b     b    b    b   f     f  f    f   w   d   s            m
+//                                    a                              c                i    o   o   o  o   e     e    e    e   l     l  l    l   i   e   p            a
+//                                    r                              r                t    d   d   d  d   z     z    z    z   a     a  a    a   d   p   a            l
+//                                    t                              e                c    y   y   y  y   e     e    e    e   n     n  n    n   t   t   d            e
+//                                                                   w                h                   l     l    l    l   g     g  g    g   h   h   e
+//                                                                                         w   w   h  r                       e     e  e    e           s
+//                                                                                             2          w     h    r    t
+//                                                                                                                            w     h  r    t
+IEC_fused_inlet = ["IEC_fused_inlet", "IEC fused inlet JR-101-1F",   M3_cs_cap_screw, 36, 27, 16, 31, 3, 28,   31,   2, 2.0, 30,   33, 4, 3.0, 44, 15, fused_spades,  false ];
+IEC_fused_inlet2= ["IEC_fused_inlet2","IEC fused inlet old",         M3_cs_cap_screw, 36, 27, 14, 31, 3, 28,   31,   2, 2.5, 30,   33, 4, 2.5, 44, 18, fused_spades2, false ];
+
+IEC_inlet       = ["IEC_inlet",       "IEC inlet",                   M3_cs_cap_screw, 40, 28, 18, 20, 3, 28,   20.5, 4, 2.5, 37,   23, 1, 2.5, 48, 14, inlet_spades,  false ];
+IEC_inlet_atx   = ["IEC_inlet_atx",   "IEC inlet for ATX",           M3_cs_cap_screw, 40, 27, 18, 19, 3, 30.5, 22,   2, 2.0, 30.5, 22, 2, 4.0, 50, 15, atx_spades,    false ];
+IEC_outlet      = ["IEC_outlet",      "IEC outlet RS 811-7193",      M3_cs_cap_screw, 40, 32, 18, 24, 3, 28,   20.5, 2, 0.0, 29,   29, 2, 2.8, 50, 23, outlet_spades, true ];
+
+iecs = [IEC_inlet, IEC_inlet_atx, IEC_fused_inlet, IEC_fused_inlet2, IEC_outlet];
 use <iec.scad>

vitamins/insert.scad

@@ -94,12 +94,14 @@ module insert_hole(type, counterbore = 0, horizontal = false) { //! Make a hole
 }
 
 module insert_boss(type, z, wall = 2 * extrusion_width) { //! Make a boss to take an insert
-    difference() {
-        ir = insert_hole_radius(type);
-        linear_extrude(height = z)
-            poly_ring(corrected_radius(ir) + wall, insert_screw_diameter(type) / 2 + 0.1);
+    render(convexity = 3)
+        difference() {
+            ir = insert_hole_radius(type);
+            linear_extrude(height = z)
+                hull()
+                    poly_ring(corrected_radius(ir) + wall, ir);
 
-        translate_z(z)
-            insert_hole(type, max(0, z - insert_hole_length(type) - 2 * layer_height));
-    }
+            translate_z(z)
+                insert_hole(type, max(0, z - insert_hole_length(type) - 2 * layer_height));
+        }
 }

vitamins/spades.scad

@@ -17,12 +17,13 @@
 // If not, see <https://www.gnu.org/licenses/>.
 //
 
-spade3     = [3.8, 3.0, 0.4, 1.0, 3.9];
-spade6p4   = [8.3, 6.4, 0.8, 1.8, 8];
-spade4p8   = [6.4, 4.8, 0.5, 1.8, 8];
-spade4p8l  = [7.0, 4.8, 0.5, 1.8, 8];
-spade4p8ll = [8.0, 4.8, 0.5, 1.8, 4.8];
+spade3     = [3.8, 3.0, 0.4, 1.0,  3.9];
+spade3p5   = [7.0, 3.5, 0.8, 1.75, 6.8];
+spade6p4   = [8.3, 6.4, 0.8, 1.8,  8];
+spade4p8   = [6.4, 4.8, 0.5, 1.8,  8];
+spade4p8l  = [7.0, 4.8, 0.5, 1.8,  8];
+spade4p8ll = [8.0, 4.8, 0.5, 1.8,  4.8];
 
-spades = [spade3, spade6p4, spade4p8, spade4p8l, spade4p8ll];
+spades = [spade3, spade3p5, spade6p4, spade4p8, spade4p8l, spade4p8ll];
 
 use <spade.scad>