Holodisk/holodisk_frame.scad

// dependency: https://github.com/revarbat/BOSL
use <BOSL/transforms.scad>
//use <BOSL/metric_screws.scad>
use <BOSL/masks.scad>

use <holodisk_spec.scad>
use <tape_spool.scad>
use <anim.scad>

module holodisk_frame() {
    size = get_holodisk_size();
    disk_size = get_holodisk_size();
    holodisk_size = get_holodisk_size();
    width=size.x;
    depth=size.y;
    height=size.z;
    
    wall=3;
    plate=3;
    top_rim=2;
    bolt_headtype="hex";
    front_body_depth=12;
    front_body_bolt_offset=8;
    back_bumpers_radius=5;
    back_bumpers_bolt_size=3;
    tape_height=5;
    tape_thickness=0.2;
    spool_tape_tolerance=1;
    spool_inner_height=tape_height+spool_tape_tolerance;
    spool_inner_radius=4;
    spool_outer_radius=18;
    spool_plate_height=2;
    spool_plate_holes=3;
    spool_plate_hole_angle=360/spool_plate_holes * 0.5;
    spool_plate_hole_inner_rim=1;
    spool_plate_hole_outer_rim=4;
    spool_slit_depth=0.8;
    spool1_depth=disk_size.y*0.77;
    spool2_depth=disk_size.y*0.40;
    spool3_depth=(spool1_depth+spool2_depth)/2;
    spool4_depth=disk_size.y*0.16;
    main_spools_x=disk_size.x*0.45;
    aux_spools_right_x=main_spools_x + spool_outer_radius + 1;
    aux_spools_left_x=main_spools_x - 13;
    middle_spool_in_r=2;
    middle_spool_out_r=7;
    aux_spool_plate_hole_inner_rim=2;
    aux_spool_plate_hole_outer_rim=2;
    spindle_diam=2;
    spindle_diam_tolerance=0.2;
    tape_z=plate+spool_plate_height;
    
    tr=top_rim;
    tc=tr*1.5;
    fbd=front_body_depth;
    bbr=back_bumpers_radius;
    
    walls_height=height-plate*2;
    
    module back_bumpers() {
        module bumper() { back_half() circle(r=bbr); }
        back(depth) {
            right(bbr) bumper();
            right(width-bbr) bumper();
        }
    }
    
    module bolt() { metric_bolt(size=back_bumpers_bolt_size, headtype=bolt_headtype, l=height, pitch=0); }
        module nut() { metric_nut(size=back_bumpers_bolt_size, pitch=0); }
        
    module back_bolts() {
        back(depth) {
            right(bbr) {
                up(height) bolt();
                nut();
            }
            right(width-bbr) {
                up(height) bolt();
                nut();
            }
        }
    }
    
    module front_bolts() { 
        bolt_offset=front_body_bolt_offset;
        back(front_body_depth/2) {
            right(bolt_offset) {
                up(height) bolt();
                nut();
            }
            right(width-bolt_offset) {
                up(height) bolt();
                nut();
            }
        }
    }

    module top_cover() {
      up(height-plate) linear_extrude(height=plate) {
        back_bumpers();
        polygon(points=[
                // frame
                [0, 0], [0, depth],
                [width, depth], [width, 0],
                // window
                [tr, tr+fbd], [tr, depth-tr-tc], [tr+tc, depth-tr],
                [width-tr-tc, depth-tr], [width-tr, depth-tr-tc], [width-tr, tr+fbd]
            ],
            paths=[
                [0,1,2,3], [4,5,6,7,8,9]
            ]);
        }
    }
    
    module walls() {
        difference() {
            up(plate) linear_extrude(height=walls_height) {
                //back_bumpers();
                shell2d(thickness=-wall) {
                    square([width, depth]);
                }
            }
            translate(get_holodisk_laserwindow_pos_center()) cube(get_holodisk_laserwindow_size(), center=true);
        }
    }
    
    module front_plates() {
        th = get_holodisk_front_plate_thickness();
        slide_pos = get_holodisk_slide_pos();
        offset=4.5;
        plate_len_side=slide_pos.y - offset/2;
        plate_len_left=plate_len_side/2;
        plate_len_right=plate_len_side + 5;
        // front
        fwd(th) left(th) up(offset) {
            cube([plate_len_left + th*2, th, height - offset*2]);
        }
        fwd(th) right(width-plate_len_right-th) up(offset) {
            cube([plate_len_right + th*2, th, height - offset*2]);
        }
        // left
        fwd(th) left(th) up(offset) {
            cube([th, plate_len_side, height - offset*2]);
        }
        // right
        fwd(th) right(width) up(offset) {
            cube([th, plate_len_side, height - offset*2]);
        }
    }
    
    module slides() {
        slide_size = get_holodisk_slide_size();
            slide_pos = get_holodisk_slide_pos();
            slide_plate_size = [0.1, slide_size.y, slide_size.z]; 
            sliding_size = get_holodisk_slide_sliding_size();
            sliding_pos = get_holodisk_slide_sliding_pos();
        
        module slide() {
            hull() {
                translate(sliding_pos) cube(sliding_size);
                translate(slide_pos) cube(slide_plate_size);
            }
        }
        
        module slider() {
            slider_size = get_holodisk_slide_slider_size();
            slider_pos = get_holodisk_slide_slider_pos();
            slider_plate_size = [0.1, slider_size.y, slider_size.z]; 
            slider_top_size = [slider_size.x, slider_size.y, sliding_size.z]; 
            hull() {
                up((slider_size.z-sliding_size.z)/2) translate(slider_pos) cube(slider_top_size);
                translate(slider_pos) cube(slider_plate_size);
            }
        }
        
        module slider_anim() {
            back(anim(1,2)*get_holodisk_slide_slider_travel()) // anim insert
        fwd(anim(5,6)*get_holodisk_slide_slider_travel()) // anim remove
            slider();
        }
            
        right(get_holodisk_size().x) {
           slide();
           slider_anim();
        }
        scale([-1,1,1]) {
            slide();
            slider_anim();
        }
        
        right(get_holodisk_laserwindow_pos_center().x) zrot(-90) {
           scale([1, 0.7, 1]) {
              slider();
           }
        }
    }
    
    module sliding_cover() {
        thickness=1;
        overlap=2;
        cover_size=[
            get_holodisk_size().x+thickness*2,
            get_holodisk_laser_cutout_size().y+overlap*2,
            thickness
        ];
        cover_posc=[
            get_holodisk_laser_cutout_pos_center().x,
            get_holodisk_laser_cutout_pos_center().y,
            cover_size.z/2
        ];
        cover_side_size=[thickness, cover_size.y,   get_holodisk_slide_slider_pos().z];
        cover_side_left_posd=[-cover_size.x/2+thickness/2, 0, cover_side_size.z/2];
        cover_side_right_posd=[cover_size.x/2-thickness/2, 0, cover_side_size.z/2];
        translate(cover_posc) {
            cube(cover_size, center=true);
            translate(cover_side_left_posd) cube(cover_side_size, center=true);
            translate(cover_side_right_posd) cube(cover_side_size, center=true);
        }
    }
    
    module sliding_cover_anim() {
        back(anim(1,2)*get_holodisk_slide_slider_travel()) // anim insert
        fwd(anim(5,6)*get_holodisk_slide_slider_travel()) // anim remove
        sliding_cover();
    }
    
    module laserwindow_door() {
        door_size = [
            get_holodisk_laserwindow_size().x,
            1,
            get_holodisk_laserwindow_size().z
        ];
        door_pos = [
            get_holodisk_laserwindow_pos_center().x,
            get_holodisk_laserwindow_pos_center().y + door_size.y/2,
            get_holodisk_laserwindow_pos_center().z
        ];
        
        translate(door_pos) scale(0.98) down(door_size.z/2) xrot(anim(1,2)*-90) xrot(anim(6,7)*90) up(door_size.z/2) cube(door_size, center=true);
    }
    
    module bottom_cover() {
        difference() {
            linear_extrude(height=plate) {
                back_bumpers();
                square([width, depth]);
            }
            // laser cutout
            down(0.1) translate(get_holodisk_laser_cutout_pos()) cube(get_holodisk_laser_cutout_size());
            // sliding cover
            sliding_cover();
            back(get_holodisk_slide_slider_travel()*0.5) sliding_cover();
            back(get_holodisk_slide_slider_travel()) sliding_cover();
            // spool spindles
            translate(get_holodisk_spool1_socket_pos_center()) spindle(h=height, d=get_holodisk_spools_spindle_diam());
            translate(get_holodisk_spool2_socket_pos_center()) spindle(h=height, d=get_holodisk_spools_spindle_diam());
        }
    }
    
    {
        overlap=1;
        rails_size = [
            get_holodisk_laserwindow_size().x * 2 + overlap*2,
            1,
            walls_height
        ];
        rail_size = [rails_size.x, rails_size.y, 2];
        rails_pos = [get_holodisk_laserwindow_pos().x - rails_size.x/2,
            -rails_size.y, plate];
        rail1_pos = [rails_pos.x, rails_pos.y, rails_pos.z];
        rail2_pos = [rails_pos.x, rails_pos.y, rails_pos.z + rails_size.z - rail_size.z];
        
        module laserwindow_slider_rails() {
            translate(rail1_pos) cube(rail_size);
            translate(rail2_pos) cube(rail_size);
        }
    
        module laserwindow_slider_cover() {
            cover_size=[
                get_holodisk_laserwindow_size().x,
                get_holodisk_slide_slider_size().x,
                get_holodisk_slide_slider_size().z
            ];
            cover_plate=[cover_size.x, rail_size.y, cover_size.z];
            cover_top=[cover_size.x - overlap, cover_size.y, cover_size.z - overlap];
            /*cover_pos=[rails_pos.x+overlap, rails_pos.y + rails_size.y, rails_pos.z];*/
            cover_pos=[get_holodisk_laserwindow_pos().x, rails_pos.y + rails_size.y, rails_pos.z];
            left(anim(0,1)*get_holodisk_laserwindow_size().x)
            right(anim(len(get_anim_keys())-2,len(get_anim_keys())-1)*get_holodisk_laserwindow_size().x)
            translate(cover_pos)
            hull() {
                fwd(cover_plate.y) cube(cover_plate);
                right(overlap/2) fwd(cover_top.y) up((cover_plate.z-cover_top.z)/2) cube(cover_top);
            }
        }
        
        color("red") laserwindow_slider_rails();
        color("red") laserwindow_slider_cover();
    }
    
    color("SaddleBrown") top_cover();
    color("grey") walls();
    color("gold") laserwindow_door();
    color("Silver") slides();
    color("Silver") sliding_cover_anim();
    color("SaddleBrown") bottom_cover();
    color("SaddleBrown") front_plates();
    //color("silver") back_bolts();
    //color("silver") front_bolts();
}

// test
holodisk_frame();