/*
min y = 0
max y = 100
min x = 1205
max x = 1254

Makerfair X carriage plate adapter for the Wilson RepRap.
Copyright (c) 2015 Clinton Ebadi <clinton@unknownlamer.org>

    This program 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.

    This program 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 this program.  If not, see <http://www.gnu.org/licenses/>.

Measurements reverse engineered from
https://github.com/RickSisco/MakerFarm-Prusa-i3v-12-Inch

Intended for use with the itty bitty dual extruder series.

Source needs a good cleanup. Evil loops that don't take advantage of
the geometry of the object abound.

major todo:

 - square hole placement is a total mess

*/

use <MCAD/nuts_and_bolts.scad>

$fn = 64;

carriage_height = 64;
carriage_width = 52;

plate_width = 75; // wilson carriage is only 50mm wide!
plate_depth = 6; // wilson default depth = 8, makerfarm = 6

hole_tolerance = 0.25; // widen holes a bit, may still need to drill out

plate_cut_height = 6.5;
plate_cut_width = 6;
plate_cut_distance = 13;
plate_cut_center = 25.1;
plate_cut_y_offset = 27;
plate_cut_bolt = 3 + hole_tolerance;
plate_cut_x_bolt_offset = 10.5 + plate_cut_bolt / 2;

plate_extra_height = 4; // make plate a bit taller so it is structurally sound

plate_height = plate_cut_height + plate_cut_y_offset + plate_extra_height; 

lower_cut_y_offset = 5.33; // 5.325 in CAD
lower_bolt_x_offset = 1.5 + plate_cut_bolt / 2;
lower_bolt_y_offset = 3.275 + plate_cut_bolt / 2;

carriage_bolt = 4 + hole_tolerance;
carriage_hole_spacing = 23;
carriage_clearance = 20; // holes are 20mm from bottom of plate
carriage_y_offset =  plate_cut_y_offset + plate_cut_height + carriage_clearance;
carriage_nut_depth = 3.2 + 3.2/2 + 0.1; // m4 nut depth + half of an m4 nut + tolerance

corner_radius = 3; // round off the corners to make it look nicer

shelf_mount ();
translate ([(plate_width - carriage_width) / 2, plate_height - plate_extra_height/2, 0]) carriage_mount ();

// mount to wilson x-carriage
module carriage_mount () {
     difference () {
	  linear_extrude (height = plate_depth, convexity = 8) {
	       // outline of plate + bolt holes
	       difference () {
		    translate ([corner_radius, corner_radius, 0]) {
			 minkowski () {
			      square ([carriage_width - corner_radius*2, carriage_height - corner_radius]);
			      circle (r = corner_radius);
			 }
		    }

		    #translate ([(carriage_width - carriage_hole_spacing) / 2, (carriage_height - carriage_hole_spacing) /2, 0])
		    for (x = [0, carriage_hole_spacing], y = [0, carriage_hole_spacing]) {
			 translate ([x, y, 0]) circle (d = carriage_bolt);
		    }
	       }
	  }
	  // after extruding, cut out spaces for M4 hex nuts.
	  translate ([(carriage_width - carriage_hole_spacing) / 2, (carriage_height - carriage_hole_spacing) /2, plate_depth - carriage_nut_depth]) {
	       for (x = [0, carriage_hole_spacing], y = [0, carriage_hole_spacing]) {
		    translate ([x, y, 0]) linear_extrude (height = carriage_nut_depth + 0.01) nutHole (size = carriage_bolt, proj = 1);
	       }
	  }
     }
}

// mount for makerfarm extruder shelf
module shelf_mount () {
     linear_extrude (height = plate_depth, convexity = 8) {     
	  difference () {
	       translate ([corner_radius, corner_radius, 0]) {
		    minkowski () {
			 square ([plate_width - corner_radius*2, plate_height - corner_radius*2]);
			 circle (r = corner_radius);
		    }
	       }

	       // upper shelf mount
	       translate ([0, plate_cut_y_offset, 0]) {
		    for (x = [-0.01, plate_cut_width + plate_cut_distance, plate_cut_width*2 + plate_cut_distance + plate_cut_center, plate_cut_width*3 + plate_cut_distance*2 + plate_cut_center + 0.01])
			 #translate ([x - hole_tolerance/2, 0, 0]) square ([plate_cut_width + hole_tolerance, plate_cut_height]);

		    // looks like the bolt is at the midpoint between the cut outs
		    for (x = [plate_cut_x_bolt_offset, plate_width - plate_cut_x_bolt_offset])
			 translate ([x, plate_cut_height / 2, 0]) circle (d = plate_cut_bolt + hole_tolerance);
	       }

	       // lower shelf mount
	       translate ([0, lower_cut_y_offset, 0]) {
		    for (x = [plate_cut_width/2 - 0.01, plate_width - plate_cut_width/2 + 0.01]) {
			 // lower cut out is closer to 6mm than 6.5mm in cad drawings
			 translate ([x, plate_cut_height/2, 0]) square ([plate_cut_width, plate_cut_height - 0.5], center=true);
		    }
		    // I think the intention is for the screw holes to be centered over the cut out
		    for (x = [lower_bolt_x_offset, plate_width - lower_bolt_x_offset])
			 translate ([x, plate_cut_height + lower_bolt_y_offset, 0]) circle (d = plate_cut_bolt + hole_tolerance);
	       }
	  }
     }
}