Added PSU shrouds.

Change LED.scad to led.scad

libtest.scad

@@ -87,6 +87,7 @@ use <tests/screw_knob.scad>
 use <tests/socket_box.scad>
 use <tests/strap_handle.scad>
 use <tests/ssr_shroud.scad>
+use <tests/psu_shroud.scad>
 
 x5 = 800;
 
@@ -217,9 +218,11 @@ translate([x0, fans_y]) {
 translate([x0, transformers_y])
     variacs();
 
-translate([x0, psus_y])
+translate([x0, psus_y]) {
     psus();
 
+    psu_shrouds();
+}
 
 x1 = x0 + 100;
 zipties_y = 0;

printed/foot.scad

@@ -28,7 +28,6 @@ include <../vitamins/inserts.scad>
 foot        = [25, 12, 3, 2, M4_cap_screw, 10];
 insert_foot = [20, 10, 0, 2, M3_cap_screw, 10];
 
-function foot() = foot; //! Default foot used unless a list of parameters is passed
 function insert_foot() = insert_foot; //! Default foot with insert
 
 function foot_diameter(type = foot) = type[0]; //! Outside maximum diameter

printed/psu_shroud.scad

@@ -0,0 +1,210 @@
+//
+// NopSCADlib Copyright Chris Palmer 2018
+// nop.head@gmail.com
+// hydraraptor.blogspot.com
+//
+// This file is part of NopSCADlib.
+//
+// NopSCADlib is free software: you can redistribute it and/or modify it under the terms of the
+// GNU General Public License as published by the Free Software Foundation, either version 3 of
+// the License, or (at your option) any later version.
+//
+// NopSCADlib is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY;
+// without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
+// See the GNU General Public License for more details.
+//
+// You should have received a copy of the GNU General Public License along with NopSCADlib.
+// If not, see <https://www.gnu.org/licenses/>.
+//
+
+//
+//! A cover to go over the mains end of a PSU terminal strip to make it safe.
+//! The stl and assembly must be given a name and parameterless wrappers for the stl and assembly added to the project.
+//
+include <../core.scad>
+include <../vitamins/screws.scad>
+include <../vitamins/inserts.scad>
+
+use <../vitamins/wire.scad>
+use <../vitamins/psu.scad>
+use <../utils/round.scad>
+
+wall = 1.8;
+top = 1.5;
+screw = M3_cap_screw;
+insert = screw_insert(screw);
+boss_r = wall + corrected_radius(insert_hole_radius(insert));
+boss_h = insert_hole_length(insert);
+counter_bore = 2;
+boss_h2 = boss_h + counter_bore;
+rad = 2;
+clearance = layer_height;
+overlap = 6;
+
+cable_tie_inset = wall + 4;
+
+function psu_shroud_extent(type) = 15 + wall;                                   //! How far it extends beyond the PSU to clear the connections
+function psu_shroud_depth(type) =                                               //! Outside depth of the shroud
+    psu_left_bay(type) + overlap + psu_shroud_extent(type);
+
+function psu_shroud_width(type)  =                                              //! Outside width of the shroud
+    let(terminals = psu_terminals(type))
+        terminals ?
+            let(y = terminals.y, tb = terminals.z)
+                 wall + clearance / 2 + y + 3 * terminal_block_pitch(tb) + terminal_block_divider(tb) / 2 + wall / 2
+        : psu_width(type) + 2 * wall + clearance;
+
+function psu_shroud_height(type) = psu_height(type) + top + clearance;          //! Outside height
+function psu_shroud_centre_y(type) =                                            //! Shroud centre relative to PSU centre
+    psu_width(type) / 2 + clearance / 2 + wall - psu_shroud_width(type) / 2;
+
+function psu_shroud_pitch(type)  = psu_shroud_width(type) - 2 * boss_r - eps;
+function psu_shroud_screw(type)  = screw;                                       //! Screw used to fasten
+function psu_shroud_cable_pitch(cable_d) = cable_d + 5;                        //! Pitch between cable entries
+
+module psu_shroud_hole_positions(type)                                          //! Place children at the screw hole positions
+    for($side = [-1, 1])
+        translate([-psu_length(type) / 2 - boss_r - 1, psu_shroud_centre_y(type) + $side * psu_shroud_pitch(type) / 2])
+            children();
+
+module psu_shroud_cable_positions(type, cable_d, cables = 1)                    //! Place children at the cable tie positions
+    for(i = [0 : 1 : cables - 1])
+        translate([-psu_length(type) / 2 - psu_shroud_extent(type) + cable_tie_inset,
+                   psu_shroud_centre_y(type) + (i - cables / 2 + 0.5) *  psu_shroud_cable_pitch(cable_d)])
+            children();
+
+module psu_shroud_holes(type, cable_d, cables = 1) {                            //! Drill the screw and ziptie holes
+    psu_shroud_hole_positions(type)
+        drill(screw_clearance_radius(screw), 0);
+
+    psu_shroud_cable_positions(type, cable_d, cables)
+        cable_tie_holes(cable_d / 2, h = 0);
+}
+
+module psu_shroud(type, cable_d, name, cables = 1) { //! Generate the STL file for a specified ssr and cable
+    stl(str("psu_shroud_", name));
+
+    extent = psu_shroud_extent(type);
+    depth = psu_shroud_depth(type);
+    width = psu_shroud_width(type);
+    height = psu_shroud_height(type);
+    centre_x = -psu_length(type) / 2 -  psu_shroud_extent(type) + psu_shroud_depth(type) / 2;
+    centre_y = psu_shroud_centre_y(type);
+    terminal_clearance = 0.5;
+    tb = psu_terminals(type).z;
+
+    module shape() {
+        difference() {
+            round(or = wall / 2 - eps, ir = 0) difference() {
+                rounded_square([depth, width], rad);
+
+                rounded_square([depth - 2 * wall, width - 2 * wall], rad - wall);
+
+                translate([depth / 2, 0])
+                    square([2 * rad, width], center = true);
+
+                translate([depth / 2, width / 2 - 5])
+                    square([2 * (overlap + terminal_clearance), 10], center = true);
+            }
+            for(i = [0 : 1 : cables - 1])
+                translate([0, (i - cables / 2 + 0.5) *  psu_shroud_cable_pitch(cable_d)])
+                    square([depth + 1, cable_d], center = true);
+        }
+    }
+
+    // base and sides
+    translate([centre_x, -centre_y]) {
+        rounded_rectangle([depth - eps, width - eps, top], rad, center = false);
+
+        linear_extrude(height = height)
+            difference() {
+                shape();
+
+                translate([depth / 2, width / 2 - 5])
+                    square([2 * (depth - extent + terminal_clearance), 10], center = true);
+        }
+        linear_extrude(height = height - terminal_block_height(tb) - psu_terminal_block_z(type) - terminal_clearance)
+            shape();
+    }
+    // cable slots
+    for(i = [0 : 1 : cables - 1])
+        translate([centre_x - depth / 2 + wall / 2, -centre_y + (i - cables / 2 + 0.5) *  psu_shroud_cable_pitch(cable_d), height / 2])
+            rotate([90, 0, 90])
+                linear_extrude(height = wall, center = true)
+                    difference() {
+                        square([cable_d + eps, height], center = true);
+
+                        translate([0, height / 2])
+                                vertical_tearslot(h = 0, r = cable_d / 2, l = cable_d);
+                }
+
+    mirror([0, 1, 0]) {
+        // insert boss
+        translate_z(height - boss_h)
+            linear_extrude(height = boss_h)
+                psu_shroud_hole_positions(type)
+                    difference() {
+                        hull() {
+                            circle(boss_r);
+
+                            translate([0, $side * (boss_r - 1)])
+                                square([2 * boss_r, eps], center = true);
+                        }
+                        poly_circle(insert_hole_radius(insert));
+                    }
+
+        // insert boss counter_bore
+        translate_z(height - boss_h2)
+            linear_extrude(height = counter_bore + eps)
+                psu_shroud_hole_positions(type)
+                    difference() {
+                        hull() {
+                            circle(boss_r);
+
+                            translate([0, $side * (boss_r - 1)])
+                                square([2 * boss_r, eps], center = true);
+                        }
+                        poly_circle(insert_screw_diameter(insert) / 2 + 0.1);
+                    }
+        // support cones
+        translate_z(height - boss_h2)
+            psu_shroud_hole_positions(type)
+                hull() {
+                    cylinder(h = eps, r = boss_r - eps);
+
+                    translate([0, $side * (boss_r - 1)])
+                        cube([2 * boss_r, eps, eps], center = true);
+
+                    translate([0, $side * (boss_r - wall), - (2 * boss_r - wall)])
+                        cube(eps);
+                }
+    }
+}
+
+module psu_shroud_assembly(type, cable_d, name, cables = 1) //! The printed parts with inserts fitted
+assembly(str("psu_shroud_", name)) {
+
+    translate_z(psu_shroud_height(type))
+        vflip()
+            color(pp1_colour) psu_shroud(type, cable_d, name, cables);
+
+    psu_shroud_hole_positions(type)
+        vflip()
+            insert(insert);
+}
+
+module psu_shroud_fastened_assembly(type, cable_d, thickness, name, cables = 1) //! Assembly with screws in place
+{
+    washer = screw_washer(screw);
+    screw_length = screw_shorter_than(2 * washer_thickness(washer) + thickness + insert_length(insert) + counter_bore);
+
+    psu_shroud_assembly(type, cable_d, name, cables);
+
+    translate_z(-thickness)
+        psu_shroud_hole_positions(type)
+            vflip()
+                screw_and_washer(screw, screw_length, true);
+
+    psu_shroud_cable_positions(type, cable_d, cables)
+        cable_tie(cable_d / 2, thickness);
+}

printed/ssr_shroud.scad

@@ -147,7 +147,7 @@ module ssr_shroud(type, cable_d, name) {    //! Generate the STL file for a spec
 module ssr_shroud_assembly(type, cable_d, name) //! The printed parts with inserts fitted
 assembly(str("ssr_shroud_", name)) {
 
-    translate_z(ssr_height(type) + top)
+    translate_z(ssr_shroud_height(type))
         vflip()
             color(pp1_colour) ssr_shroud(type, cable_d, name);
 

readme.md

@@ -29,12 +29,12 @@ See [usage](docs/usage.md) for requirements, installation instructions and a usa
 <tr><td> <a href = "#Displays">Displays</a> </td><td> <a href = "#Rockers">Rockers</a> </td><td> <a href = "#Fixing_block">Fixing_block</a> </td><td> <a href = "#Quadrant">Quadrant</a> </td><td></td></tr>
 <tr><td> <a href = "#D_connectors">D_connectors</a> </td><td> <a href = "#Rod">Rod</a> </td><td> <a href = "#Foot">Foot</a> </td><td> <a href = "#Round">Round</a> </td><td></td></tr>
 <tr><td> <a href = "#Fans">Fans</a> </td><td> <a href = "#Screws">Screws</a> </td><td> <a href = "#Handle">Handle</a> </td><td> <a href = "#Rounded_cylinder">Rounded_cylinder</a> </td><td></td></tr>
-<tr><td> <a href = "#Fuseholder">Fuseholder</a> </td><td> <a href = "#Sealing_strip">Sealing_strip</a> </td><td> <a href = "#Ribbon_clamp">Ribbon_clamp</a> </td><td> <a href = "#Rounded_polygon">Rounded_polygon</a> </td><td></td></tr>
-<tr><td> <a href = "#Hot_ends">Hot_ends</a> </td><td> <a href = "#Sheets">Sheets</a> </td><td> <a href = "#Screw_knob">Screw_knob</a> </td><td> <a href = "#Sector">Sector</a> </td><td></td></tr>
-<tr><td> <a href = "#Iecs">Iecs</a> </td><td> <a href = "#Spades">Spades</a> </td><td> <a href = "#Socket_box">Socket_box</a> </td><td> <a href = "#Sweep">Sweep</a> </td><td></td></tr>
-<tr><td> <a href = "#Inserts">Inserts</a> </td><td> <a href = "#Spools">Spools</a> </td><td> <a href = "#Ssr_shroud">Ssr_shroud</a> </td><td> <a href = "#Tube">Tube</a> </td><td></td></tr>
-<tr><td> <a href = "#Jack">Jack</a> </td><td> <a href = "#Springs">Springs</a> </td><td> <a href = "#Strap_handle">Strap_handle</a> </td><td></td><td></td></tr>
-<tr><td> <a href = "#Leadnuts">Leadnuts</a> </td><td> <a href = "#Ssrs">Ssrs</a> </td><td></td><td></td><td></td></tr>
+<tr><td> <a href = "#Fuseholder">Fuseholder</a> </td><td> <a href = "#Sealing_strip">Sealing_strip</a> </td><td> <a href = "#Psu_shroud">Psu_shroud</a> </td><td> <a href = "#Rounded_polygon">Rounded_polygon</a> </td><td></td></tr>
+<tr><td> <a href = "#Hot_ends">Hot_ends</a> </td><td> <a href = "#Sheets">Sheets</a> </td><td> <a href = "#Ribbon_clamp">Ribbon_clamp</a> </td><td> <a href = "#Sector">Sector</a> </td><td></td></tr>
+<tr><td> <a href = "#Iecs">Iecs</a> </td><td> <a href = "#Spades">Spades</a> </td><td> <a href = "#Screw_knob">Screw_knob</a> </td><td> <a href = "#Sweep">Sweep</a> </td><td></td></tr>
+<tr><td> <a href = "#Inserts">Inserts</a> </td><td> <a href = "#Spools">Spools</a> </td><td> <a href = "#Socket_box">Socket_box</a> </td><td> <a href = "#Tube">Tube</a> </td><td></td></tr>
+<tr><td> <a href = "#Jack">Jack</a> </td><td> <a href = "#Springs">Springs</a> </td><td> <a href = "#Ssr_shroud">Ssr_shroud</a> </td><td></td><td></td></tr>
+<tr><td> <a href = "#Leadnuts">Leadnuts</a> </td><td> <a href = "#Ssrs">Ssrs</a> </td><td> <a href = "#Strap_handle">Strap_handle</a> </td><td></td><td></td></tr>
 <tr><td> <a href = "#Leds">Leds</a> </td><td> <a href = "#Stepper_motors">Stepper_motors</a> </td><td></td><td></td><td></td></tr>
 <tr><td> <a href = "#Light_strips">Light_strips</a> </td><td> <a href = "#Toggles">Toggles</a> </td><td></td><td></td><td></td></tr>
 <tr><td> <a href = "#Linear_bearings">Linear_bearings</a> </td><td> <a href = "#Transformers">Transformers</a> </td><td></td><td></td><td></td></tr>
@@ -3410,7 +3410,6 @@ inserts don't grip well in rubber.
 ### Functions
 | Function | Description |
 |:--- |:--- |
-| ```foot()``` | Default foot used unless a list of parameters is passed |
 | ```insert_foot()``` | Default foot with insert |
 
 ### Modules
@@ -3497,6 +3496,64 @@ Printed handle that can be printed without needing support material due to its t
 |   1 | handle_assembly |
 
 
+<a href="#top">Top</a>
+
+---
+<a name="Psu_shroud"></a>
+## Psu_shroud
+A cover to go over the mains end of a PSU terminal strip to make it safe.
+The stl and assembly must be given a name and parameterless wrappers for the stl and assembly added to the project.
+
+
+[printed/psu_shroud.scad](printed/psu_shroud.scad) Implementation.
+
+[tests/psu_shroud.scad](tests/psu_shroud.scad) Code for this example.
+
+### Functions
+| Function | Description |
+|:--- |:--- |
+| ```psu_shroud_cable_pitch(cable_d)``` | Pitch between cable entries |
+| ```psu_shroud_centre_y(type)``` | Shroud centre relative to PSU centre |
+| ```psu_shroud_depth(type)``` | Outside depth of the shroud |
+| ```psu_shroud_extent(type)``` | How far it extends beyond the PSU to clear the connections |
+| ```psu_shroud_height(type)``` | Outside height |
+| ```psu_shroud_screw(type)``` | Screw used to fasten |
+| ```psu_shroud_width(type)``` | Outside width of the shroud |
+
+### Modules
+| Module | Description |
+|:--- |:--- |
+| ```psu_shroud(type, cable_d, name, cables = 1)``` | Generate the STL file for a specified ssr and cable |
+| ```psu_shroud_assembly(type, cable_d, name, cables = 1)``` | The printed parts with inserts fitted |
+| ```psu_shroud_cable_positions(type, cable_d, cables = 1)``` | Place children at the cable tie positions |
+| ```psu_shroud_fastened_assembly(type, cable_d, thickness, name, cables = 1)``` | Assembly with screws in place |
+| ```psu_shroud_hole_positions(type)``` | Place children at the screw hole positions |
+| ```psu_shroud_holes(type, cable_d, cables = 1)``` | Drill the screw and ziptie holes |
+
+![psu_shroud](tests/png/psu_shroud.png)
+
+### Vitamins
+| Qty | Module call | BOM entry |
+| ---:|:--- |:---|
+|   4 | ```insert(F1BM3)``` |  Heatfit insert M3 |
+|   4 | ```screw(M3_cap_screw, 10)``` |  Screw M3 cap x 10mm |
+|   4 | ```washer(M3_washer)``` |  Washer  M3 x 7mm x 0.5mm |
+|   4 | ```star_washer(M3_washer)``` |  Washer star M3 x 0.5mm |
+|   2 | ```ziptie(small_ziptie, 3)``` |  Ziptie 100mm min length |
+
+### Printed
+| Qty | Filename |
+| ---:|:--- |
+|   1 | psu_shroud_PD_150_12.stl |
+|   1 | psu_shroud_S_250_48.stl |
+
+### Assemblies
+| Qty | Name |
+| ---:|:--- |
+|   1 | psu_shroud_PD_150_12_assembly |
+|   1 | psu_shroud_S_250_48_assembly |
+
+
 <a href="#top">Top</a>
 
 ---
@@ -4220,12 +4277,17 @@ Global constants, functions and modules. This file is used directly or indirectl
 | Function | Description |
 |:--- |:--- |
 | ```Len(x)``` | Returns the length of a list or 0 if ```x``` is not a list |
+| ```cm(x)``` | cm to mm conversion |
 | ```echoit(x)``` | Echo expression and return it, useful for debugging |
+| ```foot(x)``` | Foot to mm conversion |
 | ```in(list, x)``` | Returns true if ```x``` is an element in the ```list``` |
-| ```inch(x)``` | Inch to mm conversion |
+| ```inch(x)``` | Inch to mm conversion (For fractional inches, 'inch(1 + 7/8)' will work as expected.) |
+| ```m(x)``` | m to mm conversion |
+| ```mm(x)``` | Explicit mm specified |
 | ```r2sides(r)``` | Replicates the OpenSCAD logic to calculate the number of sides from the radius |
 | ```r2sides4n(r)``` | Round up the number of sides to a multiple of 4 to ensure points land on all axes |
 | ```sqr(x)``` | Returns the square of ```x``` |
+| ```yard(x)``` | Yard to mm conversion |
 
 ### Modules
 | Module | Description |

tests/psu_shroud.scad

@@ -0,0 +1,38 @@
+//
+// NopSCADlib Copyright Chris Palmer 2018
+// nop.head@gmail.com
+// hydraraptor.blogspot.com
+//
+// This file is part of NopSCADlib.
+//
+// NopSCADlib is free software: you can redistribute it and/or modify it under the terms of the
+// GNU General Public License as published by the Free Software Foundation, either version 3 of
+// the License, or (at your option) any later version.
+//
+// NopSCADlib is distributed in the hope that it will be useful, but WITHOUT ANY WARRANTY;
+// without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE.
+// See the GNU General Public License for more details.
+//
+// You should have received a copy of the GNU General Public License along with NopSCADlib.
+// If not, see <https://www.gnu.org/licenses/>.
+//
+include <../core.scad>
+use <../utils/layout.scad>
+
+include <../vitamins/screws.scad>
+include <../vitamins/psus.scad>
+use <../printed/psu_shroud.scad>
+
+thickness = 3;
+
+module psu_shrouds()
+    layout([for(p = psus) psu_width(p)], 10) let(psu = psus[$i])
+        if(psu_terminals(psu))
+            rotate(90) {
+                if($preview)
+                    psu_shroud_fastened_assembly(psu, 6, thickness, psu[0]);
+                else
+                    psu_shroud(psu, 6, psu[0]);
+            }
+
+psu_shrouds();

tests/ssr_shroud.scad

@@ -31,7 +31,7 @@ module ssr_shrouds()
             if($preview)
                 ssr_shroud_fastened_assembly(ssr, 6, thickness, ssr[0]);
             else
-                ssr_shroud(ssrs[$i], 6, ssr[0]);
+                ssr_shroud(ssr, 6, ssr[0]);
         }
 
 ssr_shrouds();

utils/core/global.scad

@@ -22,8 +22,14 @@
 //
 include <../../global_defs.scad>
 
+function inch(x) = x * 25.4;                                                        //! Inch to mm conversion (For fractional inches, 'inch(1 + 7/8)' will work as expected.)
+function foot(x) = x * 25.4 * 12;                                                   //! Foot to mm conversion
+function yard(x) = x * 25.4 * 12 * 3;                                               //! Yard to mm conversion
+function mm(x)   = x;                                                               //! Explicit mm specified
+function cm(x)   = x * 10.0;                                                        //! cm to mm conversion
+function m(x)    = x * 1000.0;                                                      //! m to mm conversion
+
 function sqr(x) = x * x;                                                            //! Returns the square of ```x```
-function inch(x) = x * 25.4;                                                        //! Inch to mm conversion
 function echoit(x) = echo(x) x;                                                     //! Echo expression and return it, useful for debugging
 function in(list, x) = !!len([for(v = list) if(v == x) true]);                      //! Returns true if ```x``` is an element in the ```list```
 function Len(x) = is_list(x) ? len(x) : 0;                                          //! Returns the length of a list or 0 if ```x``` is not a list

vitamins/leds.scad

@@ -31,4 +31,4 @@ LED10mm = ["LED10mm", 10, 11.0, 2.0, 13.5, 2.54, 0.4];
 
 LEDs = [LED3mm, LED5mm, LED10mm];
 
-use <LED.scad>
+use <led.scad>

vitamins/psu.scad

@@ -139,6 +139,8 @@ module psu_grill(width, height) {
     }
 }
 
+function psu_terminal_block_z(type) = psu_face_cutouts(psu_faces(type)[f_left])[0][2].y + psu_height(type) / 2;
+
 module psu(type) { //! Draw a power supply
     vitamin(str("psu(", type[0], "): PSU ", psu_name(type)));
 
@@ -242,7 +244,7 @@ module psu(type) { //! Draw a power supply
         rt = psu_face_thickness(faces[f_right]);
         lt =  psu_face_thickness(faces[f_left]);
         cutout = psu_face_cutouts(faces[f_left])[0];
-        z = cutout[2].y + h / 2;
+        z = psu_terminal_block_z(type);
         pw = w -ft - bt;
         pl = l - right - rt;
         pcb_thickness = 1.6;

vitamins/wire.scad

@@ -38,8 +38,7 @@ function cable_wire_size(cable) = cable[1]; //! Size of each wire in a bundle
 // numbers from http://mathworld.wolfram.com/CirclePacking.html
 function cable_radius(cable) = [0, 1, 2, 2.15, 2.41, 2.7, 3, 3, 3.3][cable_wires(cable)] * cable_wire_size(cable) / 2; //! Radius of a bundle of wires, see <http://mathworld.wolfram.com/CirclePacking.html>.
 
-function wire_hole_radius(cable) = cable_radius(cable) + 0.5; //! Radius of a hole to accept a bundle of wires
-
+function wire_hole_radius(cable) = ceil(2 * cable_radius(cable) +1) / 2; //! Radius of a hole to accept a bundle of wires
 
 function cable_bundle(cable) = //! Arrangement of a bundle in a flat cable clip
     [[0,0], [1,1], [2,1], [2, 0.5 + sin(60)], [2,2], [3, 0.5 + sin(60)], [3,2]][cable_wires(cable)];