usb-pd-bench-supply-housing/power_supply_housing.scad

include <MCAD/units.scad>;

use <pd-buddy-openscad/truncated_teardrop.scad>;
use <pd-buddy-openscad/sink_bracket.scad>;
use <binding_post.scad>;
use <dph.scad>;

/*
 * A wedge to keep overhangs reasonable when putting things on walls.  The
 * slope is at 45 degrees in the X-Z plane.
 *
 * size: [x, y]
 */
module wedge(size) {
	difference() {
		translate([0, size[1]/2, 0])
			rotate([0, 45, 0])
			cube([size[0]*2/sqrt(2), size[1], size[0]*2/sqrt(2)], center=true);

		translate([-size[0], -epsilon, 0])
			cube([2*size[0], size[1] + 2*epsilon, size[0]]);

		translate([-size[0], -epsilon, -size[0]])
			cube([size[0], size[1] + 2*epsilon, size[0] + epsilon]);
	}
}

/*
 * A side of the housing, with ventillation holes
 */
module housing_side(case_thickness, height, depth, slot_r=2*mm, slot_count=3) {
	offset = case_thickness + 2*slot_r;
	spacing = slot_r*3;

	difference() {
		union() {
			/* Wall */
			cube([case_thickness, height, depth]);

			/* Stop for the back */
			translate([case_thickness, case_thickness, depth - case_thickness])
				wedge([2*case_thickness, slot_r]);

			/* Nut traps */
			translate([case_thickness, height - case_thickness - 4*mm, case_thickness])
				nut_trap_bot(thickness=4*mm);
			translate([case_thickness, height - case_thickness - 4*mm, depth - case_thickness - 8*mm])
				nut_trap_top(thickness=4*mm);
		}

		for (i = [0 : 4 : 4*slot_count - 1]) {
			/* First row of slots */
			hull() {
				translate([-epsilon, offset, depth - offset - i*spacing])
					truncated_teardrop(radius = slot_r, length = case_thickness + 2*epsilon);

				translate([-epsilon, offset, depth - offset - (i + 3)*spacing])
					truncated_teardrop(radius = slot_r, length = case_thickness + 2*epsilon);
			}

			/* Second row of slots */
			hull() {
				translate([-epsilon, offset + spacing, depth - offset - i*spacing])
					truncated_teardrop(radius = slot_r, length = case_thickness + 2*epsilon);

				translate([-epsilon, offset + spacing, depth - offset - (i + 3)*spacing])
					truncated_teardrop(radius = slot_r, length = case_thickness + 2*epsilon);
			}
		}
	}
}

/*
 * A nut trap for the bottom pair of nuts
 */
module nut_trap_bot(thickness, nut_tolerance=0.05*mm, nut_depth=4*mm,
		bolt_tolerance=0.3*mm) {
	difference() {
		/* Body */
		translate([0, -2*thickness, 0])
			cube([2*thickness, 2*thickness, 2*thickness]);

		/* Nut trap */
		translate([thickness, -2*thickness - epsilon, thickness])
			rotate([0, 90, 90])
			rotate([0, 0, 30])
			cylinder(r=6.4*mm / 2 + nut_tolerance, h=nut_depth + epsilon, $fn=6);

		/* Bolt hole */
		translate([thickness, -2*thickness - epsilon, thickness])
			rotate([0, 0, 90])
			truncated_teardrop(radius=(3*mm + bolt_tolerance)/2,
					length=2*thickness + 2*epsilon);
	}
}

/*
 * A nut trap for the top pair of nuts
 */
module nut_trap_top(thickness, nut_tolerance=0.05*mm, nut_depth=4*mm,
		bolt_tolerance=0.3*mm) {
	translate([0, -2*thickness, 0])
		wedge([2*thickness, 2*thickness]);

	nut_trap_bot(thickness, nut_tolerance, nut_depth, bolt_tolerance);
}

/*
 * An M3 bolt hole
 */
module bolt_hole(h=7*mm, bolt_tolerance=0.3*mm, layer_thickness=0.25*mm) {
	/* Bolt hole */
	translate([0, 0, 4*mm + layer_thickness])
		polyhole(d=3*mm + bolt_tolerance, h=h + 2*epsilon);

	/* Cap hole */
	translate([0, 0, -epsilon])
		polyhole(d=5.5*mm + bolt_tolerance, h=4*mm + epsilon);
}

/*
 * The front, top, and sides of the housing
 */
module housing_fts(size, case_thickness) {
	/* Front panel */
	difference() {
		cube([size[0], size[2], case_thickness]);

		/* DPH3205 panel cutout */
		translate([size[0]/2, 39*mm/2 + case_thickness + 2*mm, 0]) {
			dph_panel_hole();

			/* DPH3205 bezel, for reference */
			translate([0, 0, -1*mm])
				color([0.5, 0.5, 0.5, 0.25])
				%cube([79*mm, 43*mm, 1*mm], center=true);
		}

		/* Binding post cutouts */
		translate([size[0]/2, size[2] - 25*mm, -epsilon]) {
			translate([3/8*inch, 0, 0])
				rotate([0, 0, 90])
				binding_post(h=case_thickness + 2*epsilon);

			translate([-3/8*inch, 0, 0])
				rotate([0, 0, 90])
				binding_post(h=case_thickness + 2*epsilon);
		}
	}

	/* Top */
	cube([size[0], case_thickness, size[1]]);

	/* Left */
	housing_side(case_thickness, size[2], size[1]);

	/* Right */
	translate([size[0], 0, 0])
		mirror([1, 0, 0])
		housing_side(case_thickness, size[2], size[1]);
}

/* The bottom and back of the housing */
module housing_bb(size, case_thickness) {
	in_size = [size[0] - 2*case_thickness, size[1] - case_thickness, size[2] - case_thickness];

	sink_offset = 10*mm;
	dph_offset = 14*mm;

	/* Bottom */
	difference() {
		union() {
			cube([in_size[0], in_size[1], case_thickness]);

			/* Boxes for DPH3205 mounting holes */
			translate([in_size[0]/2 - 93*mm/2 + dph_offset, in_size[1] - case_thickness - 71*mm, case_thickness])
				dph_mounting_boxes(h=4*mm);

			/* Boxes for mounting holes */
			for (x = [0, in_size[0] - 8*mm])
				for (y = [0, in_size[1] - 8*mm - case_thickness])
					translate([x, y, case_thickness])
						cube([8*mm, 8*mm, 4*mm]);
		}

		/* DPH3205 mounting holes */
		translate([in_size[0]/2 - 93*mm/2 + dph_offset, in_size[1] - case_thickness - 71*mm, 0])
			dph_mounting_holes(h=case_thickness + 4*mm);

		/* Hole for accessing the PD Buddy Sink */
		translate([sink_offset, in_size[1] - case_thickness, -epsilon])
			rotate([0, 0, -90])
			cube([8*mm, 26*mm, case_thickness + epsilon]);

		/* Holes for case bolts */
		for (x = [4*mm, in_size[0] - 4*mm])
			for (y = [4*mm, in_size[1] - 4*mm - case_thickness])
				translate([x, y, 0])
					bolt_hole();
	}

	/* Back */
	difference() {
		translate([0, in_size[1] - case_thickness, 0])
			cube([in_size[0], case_thickness, in_size[2]]);

		/* DPH3205 fan hole */
		translate([in_size[0]/2 + dph_offset, in_size[1] - case_thickness - epsilon, case_thickness + 4*mm + 42*mm - 15*mm])
			rotate([0, 0, 90])
			truncated_teardrop(radius=15*mm, length=case_thickness + 2*epsilon);

		/* PD Buddy Sink hole */
		translate([sink_offset + 8*mm, in_size[1] - case_thickness - epsilon, 8*mm])
			cube([10*mm, case_thickness + 2*epsilon, 5*mm]);
		translate([sink_offset + 8*mm - 2*mm, in_size[1] - case_thickness + 1*mm, 8*mm - 2*mm])
			cube([14*mm, case_thickness + 2*epsilon, 9*mm]);
	}

	/* PD Buddy Sink mount */
	translate([sink_offset, in_size[1] - case_thickness, 0])
		rotate([0, 0, -90])
		sink_mount();
}

case_thickness = 3*mm;
size = [150*mm, 90*mm, 80*mm];

housing_fts(size, case_thickness);

translate([0, 100*mm, 0])
	//#translate([case_thickness, -20*mm, case_thickness])
	//rotate([90, 0, 0])
	housing_bb(size, case_thickness);