panel_mounts.scad

// general attachment pieces for panels
use <utils.scad>;
use <screws.scad>;

// constants
e = 0.01; // small extra for removing artifacts during differencing
2e= 0.02; // twice epsilon for extra length when translating by -e

// HELPER MODULES //

// standard attachment for a rectangular module affixed on top of a board
// @param thickness how thick base board is
// @param screws array of screw parameters (type, location x, location y, tolerance)
// @param block array of attachment block parameters (length, width, thickness, [offset from base board])
// @param location central point of the cutout
// @param rotation how much to rotate
// @param show whether to show cube (not intended for printing)
module panel_attachment (thickness, screws, block, location = [0,0,0], rotation = [0,0,0], show = false) {
  // parameters
  z_plus = 0.1; // how much thicker to make cutouts in z

  difference() {
    show_block(block, location + [0, 0, thickness], rotation, show)
    children(0);

    translate(location)
      rotate(rotation) {
        // screw holes
        for(x=[-1, 1])
          for(y=[-1, 1])
            translate([x*screws[1], y*screws[2], 0])
              machine_screw(screws[0], thickness+block[0]+block[1], tolerance = screws[3], z_plus = z_plus);
      }
  }
}

// just a show block (not intended for printing, just for showing location)
// @param block array of cube parameters (length, width, thickness, offset from base board)
module show_block (block, location, rotation, show = false) {
  union() {
    children(0);
    if (show) {
      // cube outline (not printed)
      if (str(block[3]) != "undef") {
        translate(location) rotate(rotation)
          translate([0, 0, block[3]])
            #xy_center_cube([block[0], block[1], block[2]]);
      } else {
        translate(location) rotate(rotation)
            #xy_center_cube([block[0], block[1], block[2]]);
      }
    }
  }
}

// standard snap-in cutout for a panel
// @param thickness how thick base board is
// @param block dimensions of snap in cutout (length, width, thickness)
// @param face dimensions of the face block  (length, width, thickness)
// @param clips dimensions of the gaps for clips (location x, location y, length, width, thickness)
// @param location central point of the cutout
// @param rotation how much to rotate
// @param show whether to show cube (not intended for printing)
// @param tolerance how much tolerance to add to the snap in cutout
module panel_snap_in (thickness, cutout, face, clips, location = [0,0,0], rotation=[0,0,0], show = false, tolerance = 0.15) {
  z_plus = 0.1; // how much thicker to make cutouts in z
  show_block (face, location - [0, 0, face[2]], rotation, show)
  show_block (cutout + [2*tolerance, 2*tolerance, 0], location, rotation, show)
  difference() {
    children(0);

    translate(location) rotate(rotation) {
      translate([0, 0, -z_plus])
        xy_center_cube([cutout[0], cutout[1], cutout[2]+2*z_plus]);
        for(x=[-1, 1])
          for(y=[-1, 1])
            translate([x*clips[0], y*clips[1], thickness - clips[4]])
              xy_center_cube([clips[2], clips[3], clips[4] + 2 * z_plus]);
    };

  }
}

// standard screw in for a panel
// @param thickness how thick base board is
// @param cutout dimensions of snap in cutout (length, width, thickness)
// @param face dimensions of the face block  (length, width, thickness)
// @param screws array of screw parameters (type, location x, location y, tolerance)
// @param location central point of the cutout
// @param rotation how much to rotate
// @param show whether to show cube (not intended for printing)
// @param tolerance how much tolerance to add to the snap in cutout
module panel_screw_in (thickness, cutout, face, screws, location = [0,0,0], rotation=[0,0,0], show = false, tolerance = 0.15) {
  z_plus = 0.1; // how much thicker to make cutouts in z
  difference() {
    show_block (face, location - [0, 0, face[2]], rotation, show)
    show_block (cutout + [2*tolerance, 2*tolerance, 0], location, rotation, show)
    children(0);

    translate(location) rotate(rotation) {
      translate([0, 0, -z_plus])
        xy_center_cube([cutout[0], cutout[1], cutout[2]+2*z_plus]);

        // screw holes
        for(x=[-1, 1])
          for(y=[-1, 1])
            translate([x*screws[1], y*screws[2], -face[2]])
              machine_screw(screws[0], thickness+face[2], countersink = false, tolerance = screws[3], z_plus = z_plus);
    };
  }
}

// standard panel cutout (use screw_in or snap_in for fastening cutouts)
// use x_round and/or y_round to add round panel cutouts to the square
// @param thickness how thick base board is (NOT used)
// @param cutout dimensions of snap in cutout (length, width, thickness)
// @param location central point of the cutout
// @param rotation how much to rotate
// @param x_round whether to add rounding in x
// @param y_round whether to add rounding in y
// @param show whether to show cube (not intended for printing)
// @param tolerance how much tolerance to add to the snap in cutout
module panel_cut_out (thickness, cutout, location = [0,0,0], rotation = [0,0,0], x_round = false, y_round = false, show = false, tolerance = 0.15) {
  echo("panel cutout: ", cutout, " at location: ", location);
  difference() {
    show_block (cutout + [2*tolerance, 2*tolerance, 0], location, rotation, show)
    children(0);
    translate(location) rotate(rotation) {
      translate([0, 0, -e])
        xy_center_cube([cutout[0], cutout[1], cutout[2] + 2e]);
      if (x_round) {
        for (x = [-1, 1])
          translate([x * cutout[0]/2, 0, -e])
            cylinder(h = cutout[2] + 2e, d = cutout[1], $fn = 120);
      }
      if (y_round) {
        for (y = [-1, 1])
          translate([0, y * cutout[1]/2, -e])
            cylinder(h = cutout[2] + 2e, d = cutout[0], $fn = 120);
      }
    };
  }
}

// ATTACHMENTS //

// standard particle photon holder board cutout
// NOTE: the power part does not behave well with rotations
// @param with_RJ45 whether to include a cutout for the RJ45 ethernet plug (also RJ50 compatible)
module photon_board(thickness, location = [0,0,0], rotation = [0,0,0], with_RJ45 = true, show = false) {
  screws = ["M3", 28, 16.5, 0.2];
  board = [64, 42, 1.6, 10];
  power = [3, 7, board[2]];
  rj45 = [15.5, 16.5, 16];
  // fixme: locations only support normal 90 rotation at the moment (do the math properly)
  power_location = rotation[2] == 90 ? [0, board[0]/2 + power[0]/2, thickness + board[3]] : [board[0]/2 + power[0]/2, 0, thickness + board[3]];
  rj45_location = rotation[2] == 90 ? [board[1]/2 - rj45[1]/2 + 0.8, -board[0]/2 + rj45[0]/2 + 8.1, 0] : [-board[0]/2 + rj45[0]/2 + 8.1, -board[1]/2 + rj45[1]/2 - 0.8, 0];

  // arrangment
  if (with_RJ45) {
    panel_attachment(thickness, screws, board, location, rotation, show)
    show_block(power, location + power_location, rotation, show)
    panel_cut_out(thickness = thickness, cutout = rj45, location = location + rj45_location, rotation = rotation, show = show)
    children(0);
  } else {
    panel_attachment(thickness, screws, board, location, rotation, show)
    show_block(power, location + power_location, rotation, show)
    children(0);
  }

}

// particle board
translate([-80, 80, 0])
photon_board(thickness = 5, show = true) xy_center_cube([80, 60, 5]);


// 85-240V AC to 5V 1A DC converter, enclosed (from DigiKey)
// https://www.digikey.com/products/en?keywords=102-2656-ND
module AC_DC_converter(thickness, location = [0,0,0], rotation = [0,0,0], show = false){
  screws = ["M3", 30.8, 11.5, 0.2];
  board = [76, 31.5, 23.96, 0];
  panel_attachment(thickness, screws, board, location, rotation, show)
  children(0);
}

// AC DC converter
translate([80, 80, 0])
AC_DC_converter(thickness = 5, show = true) xy_center_cube([100, 60, 5]);


// auber 25A solid state relay
// http://www.auberins.com/index.php?main_page=product_info&products_id=9
module relay(thickness, location = [0,0,0], rotation=[0,0,0], show = false) {
  screws = ["M4", 23.8, 0, 0.2];
  relay = [58, 44, 32, 0];
  panel_attachment(thickness, screws, relay, location, rotation, show)
  children(0);
}

// relay
translate([80, -100, 0]) color("green")
relay(thickness = 5, show = true) xy_center_cube([100, 80, 5]);


// auber solid 25A state relay with externally mounted heatsink
// relay: http://www.auberins.com/index.php?main_page=product_info&products_id=9
// heat sink: http://www.auberins.com/index.php?main_page=product_info&cPath=2_48&products_id=244
module relay_sink(thickness, location = [0,0,0], rotation=[0,0,0], show = false) {
  z_plus = 0.1; // how much thicker to make cutouts in z
  relay = [58, 44, 32, 0];
  cutout = [70, 55];
  screws = ["M4", 45, 39.75, 0.2];
  heat_sink = [100, 90, 30, -thickness];
  show_block (relay, location, rotation, show)
  panel_attachment(thickness, screws, heat_sink, location- [0, 0, heat_sink[2]], rotation, show)
  difference() {
    children(0);
    translate(location) rotate(rotation)
      translate([0, 0, -z_plus]) xy_center_cube([cutout[0], cutout[1], thickness+2*z_plus]);
  }
}

// relay sink
translate([-80, -100, 0]) color("green")
relay_sink(thickness = 5, show = true) xy_center_cube([120, 100, 5]);

// schurter AC power module with fuse and scwitch (rated for 10A)
// https://www.digikey.com/products/en?keywords=%09486-1965-ND
module AC_power (thickness, location = [0,0,0], rotation=[0,0,0], show = false, tolerance = 0.15) {
  cutout = [46.9, 27.9, 30.35];
  face = [50, 30.5, 2.5];
  clips = [42.5/2, cutout[1]/2 + 1.3, 4.5, 3.2, 3.5];
  panel_snap_in(thickness, cutout, face, clips, location, rotation, show, tolerance)
  children(0);
}

// power module
color("blue") AC_power(thickness = 5, show = true) xy_center_cube([120, 80, 5]);

module AC_outlet (thickness, location = [0,0,0], rotation=[0,0,0], show = false, tolerance = 0.15) {
  cutout = [25.1, 21.65, 24.75];
  face = [26.87, 26.95, 3.56];
  clips = [cutout[0]/2 + 2.9/2, 0, 3, 9.8, 3.5];
  panel_snap_in(thickness, cutout, face, clips, location, rotation, show, tolerance)
  children(0);
}

// NULSOM DB9 RS232 serial port
// cutoff such that connector can be vertically flipped (i.e. 5 pins up or 4 pins up)
// https://www.amazon.com/Ultra-Compact-RS232-Converter-Male/dp/B00OPU2QJ4
module DB9_serial_port (thickness, location = [0,0,0], rotation=[0,0,0], show = false, tolerance = 0.15) {
  cutout = [19.45, 11.0, 18.35];
  face = [30.85, 12.55, 5.43];
  screws = ["M3", 12.45, 0, 0.3];
  panel_screw_in(thickness, cutout, face, screws, location, rotation, show, tolerance)
  children(0);
}

// Adafruit MicroUSB Port
// https://www.adafruit.com/product/3258
// Note: could consider making the outside of these screws countersunk
// @param port_only whether to include the cable port only (otherwise the whole panel mount adapter withs crews)
module MicroUSB_port (thickness, location = [0,0,0], rotation = [0,0,0], port_only = false, show = false, tolerance = 0.15) {
  cutout = [12.3, 10.3, 22.0];
  face = [25.0, 10.0, 5.43];
  screws = ["4-40", 9, 0, 0.3];
  if (!port_only) {
    panel_screw_in(thickness, cutout, face, screws, location, rotation, show, tolerance)
    children(0);
  } else {
    // for port only, make tolerance a little bigger (2mm increase) and add half circle extra space for thicker wires
    cutout = cutout + [2, 2, 0];
    panel_cut_out(thickness = thickness, cutout = cutout, location = location, rotation = rotation, y_round = true, show = show, tolerance = tolerance)
    children(0);
  }
}

// RJ11 6p4c telephone cable port
// https://www.amazon.com/gp/product/B07KYTMXJN
module RJ11_port (thickness, location = [0,0,0], rotation = [0,0,0], show = false, tolerance = 0.15) {
  cutout = [22.80, 21.10, 27.00];
  face = [38.40, 21.10, 4.70];
  screws = ["M3", 14.50, 0, 0.3];
  panel_screw_in(thickness, cutout, face, screws, location, rotation, show, tolerance)
  children(0);
}

// Adafruit RJ45/Ethernet port
// --> usually using the PCB with integrated ethernet instead
// https://www.adafruit.com/product/909
module RJ45_port (thickness, location = [0,0,0], rotation = [0,0,0], show = false, tolerance = 0.15) {
  cutout = [20, 20, 28.0]; // could use some refinement NEED TO BE LARGER
  face = [33.0, 20.0, 4]; // could use some refinement NEED TO BE LARGER
  screws = ["4-40", 12.5, 0, 0.3];
  panel_screw_in(thickness, cutout, face, screws, location, rotation, show, tolerance)
  children(0);
}

// Power Barrel Connector Jack 2.00mm ID (0.079"), 5.50mm OD (0.217") Panel Mount
// https://www.digikey.com/products/en?keywords=CP-065A-ND
module power_jack(thickness, location = [0,0,0], rotation = [0,0,0], show = false) {

  z_plus = 0.1; // how much thicker to make cutouts in z
  plug_diameter = 8.1;
  plug_face = [11, 11, 15];

  difference() {
    show_block(plug_face, location + [0, 0, thickness], rotation, show = show)
    children(0);
    translate(location + [0,0,-z_plus])
      rotate(rotation)
        cylinder(h=thickness+2*z_plus, d=plug_diameter, $fn = 120);
  }
}