etc/meanwell_supply_cover.scad

   1 // Power Supply Cover
   2 // Copyright (c) 2014 "gregington"
   3 // CC BY-SA 3.0, http://www.thingiverse.com/thing:216951
   4
   5 // Customized by Clinton Ebadi <clinton@unknownlamer.org> for the
   6 // SE-600 power supply. Copyright (c) 2016.
   7
   8 // TODO:
   9
  10 //  - powerSocket, powerSwitch, screwHoles, ... might be cleaner if
  11 //    placement were done separately. Should be possible to add
  12 //    modules for placing parts (lying flat, centered on the origin)
  13 //    on each surface of the psu cover, fine tuning positions using
  14 //    translate().
  15 //
  16 //  - add powerpole mount option
  17
  18 // new todo: - recheck dimensions -- screw holes are fixed offset from
  19 // cover_depth... cover_depth needs to be rechecked/recalculated as
  20 // wall + clearance needed for power socket + screw y offset
  21
  22 // or: optimal case depth is buffer + screw hole distance from edge of
  23 // case + whatever space is needed inside the case + back wall
  24 // thickness
  25
  26
  27 // case depth = back wall thickness + cavity size + mounting hole offset + extra behind mounting hole
  28
  29 // cavity size is usually just enough for the plug or terminals + some extra
  30
  31 WALL = 2;
  32
  33 PSU_CLEARANCE = 1;
  34 PSU_WIDTH = 127 + PSU_CLEARANCE;
  35 PSU_HEIGHT = 63.5 + PSU_CLEARANCE;
  36 PSU_DEPTH = 200;
  37
  38 COVER_WIDTH = PSU_WIDTH + (2 * WALL);
  39 COVER_HEIGHT = PSU_HEIGHT + (2 * WALL);
  40
  41 COVER_DEPTH = 11 + 6 + 2*(25.4+2) + WALL; // ac
  42 //COVER_DEPTH = 11 + 6 + 30 + WALL; // dc
  43
  44 //COVER_SUPPORT_WIDTH = 20; // ??
  45
  46 VENT_HEIGHT = PSU_HEIGHT - PSU_CLEARANCE - WALL - 1;
  47 VENT_WIDTH = 2;
  48 VENT_DISTANCE = 5; // was 4
  49
  50 CABLE_SLOT_WIDTH = 18;
  51 CABLE_SLOT_HEIGHT = 50;
  52 CABLE_SLOT_Y_OFFSET = 40;
  53
  54 //CABLE_SLOT_VENT_DISTANCE = 2; // ???
  55
  56 POWER_SOCKET_OFFSET = WALL*2 + 43/2;
  57 POWER_SWITCH_OFFSET = 20;
  58
  59 SCREW_HOLE_HEIGHT = 12;
  60 SCREW_HOLE_WIDTH = 3;
  61 SCREW_HOLE_Z_OFFSET = 30; // offset from top of PSU
  62 SCREW_HOLE_GAP = 20; // distance between screw holes
  63 SCREW_HOLE_Y_OFFSET = COVER_DEPTH - 6; // offset from back of case
  64
  65
  66 module cover() {
  67   difference() {
  68        minkowski () {
  69             cube([COVER_WIDTH, COVER_DEPTH, COVER_HEIGHT]);
  70 //          sphere (d=1);
  71        }
  72             translate([WALL, WALL, WALL]) {
  73 #                cube([PSU_WIDTH, PSU_DEPTH, PSU_HEIGHT]);
  74             }
  75   }
  76 }
  77
  78 module vents(offset = 0, limit = COVER_WIDTH - WALL) {
  79   for (x = [ WALL + VENT_DISTANCE + offset : VENT_DISTANCE : limit ]) {
  80     translate([x, WALL, (COVER_HEIGHT - VENT_HEIGHT) / 2]) {
  81       rotate([0, -90, 90]) {
  82            slot(VENT_WIDTH, VENT_HEIGHT, 2 * WALL);
  83       }
  84     }
  85   }
  86
  87 }
  88
  89 module slot(width, height, depth, center = false) {
  90   translate([width / 2, 0, 0]) {
  91     union() {
  92       cube([height - width, width, depth]);
  93       translate([0, width / 2, 0]) {
  94         cylinder(h = depth, r = width / 2);
  95       }
  96       translate([height - width, width / 2, 0]) {
  97         cylinder(h = depth, r = width / 2);
  98       }
  99     }
 100   }
 101 }
 102
 103 module cslot(width, height, depth) {
 104      translate ([-height/2, -width/2, -depth/2])
 105      slot (width, height, depth);
 106 }
 107
 108
 109 // defaults for https://www.digikey.com/product-detail/en/1-1609112-2/CCM1916-ND/2292077
 110 //module powerSocket(width = 27, height = 38, screw_distance = 35, side=0) {
 111 module powerSocket(width = 1.06*25.4, height = 1.56*25.4, screw_distance = 1.42*25.4, side=0) {
 112   translate([WALL*(side ? 2 : 1) + 2 + (side ? PSU_WIDTH : 0), POWER_SOCKET_OFFSET, (COVER_HEIGHT/2+height)/2]) {
 113     rotate([0, 90, 0]) {
 114       translate([0,screw_distance/2,-5]) { rotate ([0, 0, 90]) cslot (3, 5, 22); }
 115       translate([0,-screw_distance/2,-5]) { rotate ([0, 0, 90]) cslot (3, 5, 22); }
 116       translate([0,0,-5.5 - 1.5])
 117         minkowski() {
 118           #cube([height-8,width-8,11], center=true);
 119           cylinder(r=4.5,h=0.1);
 120       }
 121     }
 122   }
 123 }
 124
 125 module powerSwitch() {
 126   translate([COVER_WIDTH / 2, POWER_SWITCH_OFFSET, COVER_HEIGHT + 2]) {
 127     rotate([0, 0, -90]) {
 128           cube([14.8,20.8,2], center=true);
 129           translate([0,0,-7-1]) cube([13,19.8,14], center=true);
 130     }
 131   }
 132 }
 133
 134 module cableSlot() {
 135   translate([(PSU_WIDTH - CABLE_SLOT_HEIGHT) / 2, WALL, (COVER_HEIGHT - VENT_HEIGHT) / 2]) {
 136     rotate([90, 0, 0]) {
 137       slot(CABLE_SLOT_WIDTH, CABLE_SLOT_HEIGHT, WALL * 2);
 138     }
 139   }
 140 }
 141
 142 module cableSlotOutline() {
 143   border = 4;
 144   translate([(PSU_WIDTH - CABLE_SLOT_HEIGHT - border) / 2, WALL, (COVER_HEIGHT - VENT_HEIGHT - border) / 2]) {
 145     rotate([90, 0, 0]) {
 146       slot(CABLE_SLOT_WIDTH + border, CABLE_SLOT_HEIGHT + border, WALL * 2);
 147     }
 148   }
 149 }
 150
 151 module screwHoles() {
 152      translate ([-2.5, SCREW_HOLE_Y_OFFSET + WALL - SCREW_HOLE_HEIGHT, -SCREW_HOLE_WIDTH/2 + WALL + + PSU_CLEARANCE/2 + SCREW_HOLE_Z_OFFSET]) {
 153     rotate([90, 0, 90]) {
 154          #slot(SCREW_HOLE_WIDTH, SCREW_HOLE_HEIGHT, COVER_WIDTH + 5);
 155          translate ([0, SCREW_HOLE_GAP, 0])
 156               slot(SCREW_HOLE_WIDTH, SCREW_HOLE_HEIGHT, COVER_WIDTH + 5);
 157     }
 158   }
 159 }
 160
 161 module ac_cover () {
 162      translate([0, COVER_HEIGHT, 0]) rotate([90, 0, 0]) {
 163           difference() {
 164                cover();
 165                vents(offset = PSU_WIDTH/2 );
 166                powerSocket(side=1);
 167                screwHoles();
 168           }
 169      }
 170 }
 171
 172 module dc_cover () {
 173      translate([0, COVER_HEIGHT, 0]) rotate([90, 0, 0]) {
 174           difference() {
 175                cover();
 176                difference () {
 177                     vents(limit = PSU_WIDTH);
 178                     cableSlotOutline();
 179                }
 180                cableSlot();
 181                screwHoles();
 182           }
 183      }
 184 }
 185
 186 $fs = 0.5;
 187
 188 intersection () {
 189 //     translate ([115, -10, -1]) #cube ([50, 100, 100]);
 190      ac_cover ();
 191
 192 }
 193 //translate ([200,0,0]) dc_cover ();
 194
 195 // power socket mockups
 196
 197 /* difference () { */
 198 /*      cube ([5,45,50]); */
 199 /*      #translate ([0, 0, -10]) powerSocket (); */
 200 /* } */
 201
 202 /* translate ([100, 0, 0]) */
 203 /* difference () { */
 204 /*      cube ([5, 40,50]); */
 205 /*      translate ([0, -30, -20]) #screwHoles(); */
 206 /* } */