arcade-panel: bevel lid, better positioning, dual hinges

Cleaned up attachment code and used new code to attach multiple
binges.

Fixed alignment of lid hinge (rotating the mount made it off by a few
mm).

Bevel lid for looks and possibly a more secure mounting.

diff --git a/ble arcade controller/arcade-box.scad b/ble arcade controller/arcade-box.scad
index 0fa783e..1aa02fa 100644 (file)
--- a/ble arcade controller/arcade-box.scad
+++ b/ble arcade controller/arcade-box.scad
@@ -20,6 +20,7 @@
 // - hinge is not aligned -- either male arm length or connector placement is wrong
 
 use <obiscad/bcube.scad>
+use <obiscad/bevel.scad>
 use <obiscad/attach.scad>
 use <joints.scad>
 
@@ -37,6 +38,7 @@ module preview () {
 
 panel_width = 250;
 panel_height = 130;
+panel_bevel = 2; // fixme: calculate based on box_base_thickness?
 
 box_depth = 80;
 box_wall = 2;
@@ -47,19 +49,24 @@ $button_d = 30; // I think this should be special
 joystick_width = 85;
 joystick_height = 40;
 
-// fixme: these are a bit confused
-hinge_joint_width = 8;
-hinge_joint_thickness = 5;
-hinge_box_base_thicknesseight = 10;
-hinge_joint_height = 10;
+hinge_arm_width = 6;
+hinge_arm_thickness = 6;
 hinge_arm_length = 50;
 
+// size of block to cut female connector from
+hinge_base_size = [hinge_arm_width * 2, hinge_arm_thickness * 2, hinge_arm_thickness * 2];
+
+hinge_x_offset = 15; // distance from side of case
+
 
 // gunk that should be elsewhere...
 // bcube parameters, clean up
 cr = box_wall*2;
 cres = 0;
 
+// switch to hide panel in previews
+_hide_panel = false;
+
 // PANEL COMPONENTS
 
 module button (bezel = $button_d+4) {
@@ -81,8 +88,8 @@ module joystick () {
 
 // CASE
 
-module case_base (h=box_base_thickness) {
-     bcube([panel_width, panel_height, h], cr, cres);
+module case_base (width=panel_width, height=panel_height, d=box_base_thickness) {
+     bcube([width, height, d], cr, cres);
 }
 
 module case_walls () {
@@ -90,13 +97,15 @@ module case_walls () {
          union () {
               difference() {
                    bcube([panel_width, panel_height, box_depth-box_base_thickness], cr, cres);
-                   bcube([panel_width-box_wall*2, panel_height-box_wall*2, box_depth+1], cr, cres);
+                   bcube([panel_width-box_wall*2, panel_height-box_wall*2, box_depth+1], cr, cres); // FIXME: does this accidentally cut some of the bottom out?
               }
-              attach (case_connector_wall (x=10), hinge_connector_back ()) hinge_female_base ();
+              attach (case_connector_wall ([panel_width/2-hinge_x_offset, -box_wall+0.01, box_depth/2]), hinge_connector_back (h=hinge_base_size[2]+(hinge_arm_thickness+panel_bevel)/2)) hinge_female_base (support=true);
+              attach (case_connector_wall ([-panel_width/2+hinge_x_offset, -box_wall+0.01, box_depth/2]), hinge_connector_back (h=hinge_base_size[2]+(hinge_arm_thickness+panel_bevel)/2)) hinge_female_base (support=true);
          }
-         attach (case_connector_wall (x=10), hinge_connector_back ()) hinge_female_cut ();
+         attach (case_connector_wall ([panel_width/2-hinge_x_offset, -box_wall+0.01, box_depth/2]), hinge_connector_back (h=hinge_base_size[2]+(hinge_arm_thickness+panel_bevel)/2)) hinge_female_cut ();
+                 attach (case_connector_wall ([-panel_width/2+hinge_x_offset, -box_wall+0.01, box_depth/2]), hinge_connector_back (h=hinge_base_size[2]+(hinge_arm_thickness+panel_bevel)/2)) hinge_female_cut ();
      }
-     %connector (case_connector_wall (x=10));
+     %connector (case_connector_wall ([panel_width/2-hinge_x_offset, -box_wall+0.01, box_depth/2]));
 }
 
 module case () {
@@ -109,78 +118,91 @@ module case () {
 //   specify which wall (rear, front, left, right). vector addition may help...
 //   offset from center of wall, as vector (and use vector subtraction!)
 //   optional: inside/outside
-function case_connector_wall (x=0, y=0, z=0) = [ [panel_width/2-x, panel_height/2-y, (box_depth-box_base_thickness)/2-z], [0,-1, 0], 0 ];
+CASE_WALL_BACK = [0, panel_height/2, -box_base_thickness/2];
+
+function case_connector_wall (offset=[0,0,0], wall=CASE_WALL_BACK) = [ wall + offset, [0, -1, 0], 0 ];
 
 // HINGE
 
 // hinge todo:
-//   calculate z offset so that hinge will align when closed
-//   calculate offset into panel surface for length of peg
-//   attach to case, calculating offset from wall as fixed value + width
-
-// add connector for pin to socket so that can easily be test fit in
-// software instead of guessing
+//  allow override of global base dimensions
 
-//   should panel connector be on its side? Limits motion to 90⁰ Or
-//   maybe just walls only + fillet with no base...
+// maybe: add connector for pin to socket so that can easily be test
+// fit in software for a nicer preview
 
-function hinge_connector_back (th=hinge_joint_thickness*2, h=hinge_box_base_thicknesseight) = [ [0, th/2, h/2], [0,1, 0], 0 ];
+function hinge_connector_back (th=hinge_arm_thickness*2, h=hinge_base_size[2]) = [ [0, th/2, h/2], [0,1, 0], 0 ];
+function hinge_connector_bottom (th=hinge_arm_thickness*2, h=hinge_base_size[2]) = [ [0, 0, -h/2], [0, 0, 1], 0 ];
 
 // todo:
-//   gusset support underneath
-//   split into base and negative so that a hole can be punched into case wall
-
-module hinge_female_base () {
-     w  = hinge_joint_width * 2;
-     th = hinge_joint_thickness * 2;
-
-     %connector (hinge_connector_back ());
-     cube ([w, th, hinge_box_base_thicknesseight], center=true);
+//   gusset support underneath (with argument to toggle)
+
+module hinge_female_base (support=false) {
+//     %connector (hinge_connector_back ());
+//     %connector (hinge_connector_bottom ());
+     color ([0.5,0.3,0.1, 0.3]) cube (hinge_base_size, center=true);
+
+     if (support) {
+         corner = [ [ 0, hinge_base_size[1]/2, -hinge_base_size[2]/2], [ 0, -1, -1 ], 0];
+         base_a = [ [0, hinge_base_size[1]/2, -hinge_base_size[2]/2], [1, 0, 0], 0];
+         connector (corner);
+         connector (base_a);
+         // fixme: calculate actual radius 
+         color ([0.5,0.7,0.1, 0.3]) bconcave_corner_attach(base_a, corner , l=hinge_base_size[1], cr=hinge_base_size[0],cres=0, ext_corner=false, th=0);
+     }
 }
 
 module hinge_female_cut () {
-     w  = hinge_joint_width * 2;
-     th = hinge_joint_thickness * 2;
-
-     // cruft from earlier hacking, remove...
-     jt = hinge_joint_thickness;
-     jw = hinge_joint_width;
-
-     joint_male_negative(male_joint_width=jw, male_joint_thickness=jt, forward_rom=90, backward_rom=90, male_joint_height=hinge_joint_height);
+     joint_male_negative (male_joint_width=hinge_arm_width,
+                         male_joint_thickness=hinge_arm_thickness,
+                         forward_rom=90,
+                         backward_rom=90,
+                         male_joint_height=hinge_arm_length);
 }
 
-module hinge_female () {
+module hinge_female (support=false) {
      difference () {
-         hinge_female_base ();
+         hinge_female_base (support);
          hinge_female_cut ();
      }
 }
 
 module hinge_male () {
      for (i=[0,1])  mirror ([0, i, 0]) translate ([0, -hinge_arm_length/4, 0])
-       joint_male(male_joint_width=hinge_joint_width, male_joint_thickness=hinge_joint_thickness, male_joint_height=hinge_arm_length/2, side=true);
-
+        joint_male (male_joint_width=hinge_arm_width,
+                    male_joint_thickness=hinge_arm_thickness,
+                    male_joint_height=hinge_arm_length/2,
+                    side=true);
 }
 
 
-// hinge to panel...
-// mount hinge on panel arm_length back from edge
-
-// fixme: wall thickness is not taken into account
-
 // PANEL
 
+// fixme: when attachment axis is [0, 0, -1] something makes the math
+// go funky and the connector is facing upward, adding very slight y
+// misalignment "fixes" it...
+PANEL_BOTTOM = [ [ 0, 0, -box_base_thickness/2+0.01 ], [ 0, 0.000000000001, -1 ] ];
+PANEL_TOP    = [ [ 0, 0, box_base_thickness/2-0.01 ], [ 0, 0, 1 ] ];
 
-// cleanup after general case_connector_wall() is done
-panel_c = [ [panel_width/2-10, panel_height/2-hinge_arm_length, -box_base_thickness/2+0.01], [0,0, 1], 180 ];
+function panel_connector (offset=[0,0,0], wall=PANEL_BOTTOM) = [ wall[0]+offset, wall[1], 0 ];
 
 module panel () {
      difference () {
-         case_base ();
-         linear_extrude (box_base_thickness*2,center=true) panel_layout ();
+         union () {
+              // bevel
+              translate ([0, 0, panel_bevel/2]) {
+                   case_base (d=box_base_thickness-panel_bevel);
+              }
+              case_base (width=panel_width-box_wall*2-0.1, height=panel_height-box_wall*2-0.1);
+         }
+         if (!_hide_panel) {
+              linear_extrude (box_base_thickness*2,center=true) panel_layout ();
+         }
      }
-     %connector (panel_c);
-     attach (panel_c, hinge_connector_back ()) hinge_female ();
+
+     attach (panel_connector (offset=[panel_width/2-hinge_x_offset, panel_height/2-hinge_arm_length, 0]),
+            hinge_connector_bottom ()) hinge_female ();
+     attach (panel_connector (offset=[-panel_width/2+hinge_x_offset, panel_height/2-hinge_arm_length, 0]),
+            hinge_connector_bottom ()) hinge_female ();
 }
 
 module panel_attach (position, angle=0) {