Use BOSL2 library for dovetails, inscribe tolerance on tolerance test pieces. and other stuff

1 files changed, 136 insertions, 112 deletions

diff --git a/cubbies.scad b/cubbies.scad
index fdd4eb8..a05ae97 100644
--- a/cubbies.scad
+++ b/cubbies.scad
@@ -1,88 +1,123 @@
 include <BOSL2/std.scad>;       // https://github.com/revarbat/BOSL2
 include <BOSL2/walls.scad>;
+include <BOSL2/fnliterals.scad>;
+include <BOSL2/joiners.scad>;
 
-$fn=20;
+$fn=100;
 
-part="divider"; // [both:Bottom + Divider,bottom::Bottom Only,divider:Divider Only,male tab line:Line of male tabs,female tab line: Line of female tabs,view_fit_test:Generate a model to view tab fit (for debugging)]
+/* $fs = 0.01; */
+/* $fa = 1; */
+
+
+part="side test fit"; // [both:Bottom + Side,bottom::Bottom Only,side:Side Only,view_fit:Debugging view to confirm tab fit,bottom_tabs:Tabs only from bottom,side_tabs:Holes only from side]
 
 /* [Cubby dimensions] */
-cubby_width=50;
-cubby_depth=180;
-cubby_divider_height=90;
+cubby_width=150;
+cubby_depth=120;
+cubby_height=90;
 
-// thickness of both bottom + dividers
+// thickness of bottom and side
 thickness=5;
 
-// thickness of struts
+// thickness of struts (used in both bottom and side)
 strut_thickness=5;
 
+// If set (to non zero), this is used in the max_bridge paramater for the
+// sparse_struct BOSL 2 function (which generates the wireframe rectangles). By
+// default, it is calculated as max_bridge=(cubby_height + cubby_width)/5.
+max_bridge=0;
+
 /* [Tab Dimensions] */
 tab_width=10;
-tab_padding=5;
+tab_padding=5;                  // minimum material between tabs
 tab_tolerance=0.5;
 
+/* [Used only in tab fit tests] */
+// Smallest tolerance
+//tolerance_start=0.5;
+// Largest tolerance
+//tolerance_end=1.0;
+// Steps to increment from smallest to largest tolerance
+//tolerance_step=0.1;
+/* [Screw Tabs] */
+screw_tabs=true;
+
 /* [Hidden] */
 tab_depth=thickness;
 tab_height=thickness;
 
-
-if ( part == "bottom" ) {
-     rot(90) yrot(90) cubby_bottom(cubby_width, cubby_depth);
-} else if ( part == "divider" ) {
-     yrot(180+90) cubby_divider(cubby_depth, cubby_divider_height);
-} else if ( part == "male tab line" ) {
-     print_tab_line(cubby_width, cubby_depth, cubby_divider_height, male=true);
-} else if ( part == "female tab line" ) {
-     print_tab_line(cubby_width, cubby_depth, cubby_divider_height, male=false);
-} else if ( part == "male tab" ) {
-     print_single_tab(male=true);
-} else if ( part == "female tab") {
-     print_single_tab(male=false);
-} else if ( part == "view fit test") {
-     view_tab_fit(cubby_width, cubby_depth, cubby_divider_height);
-} else if ( part == "both") {
-     cubby(cubby_width, cubby_depth, cubby_divider_height);
+/* text inscribed (when printing tolerances)  */
+text_extrude=2;
+text_size=thickness * 0.8;
+
+
+if ( part == "both" ) {
+     both();
+} else if ( part =="bottom") {
+     cubby_bottom(cubby_width, cubby_depth);
+} else if ( part == "side" ) {
+     cubby_side(cubby_depth, cubby_height, screw_tabs);
+} else if ( part == "view_fit") {
+     view_tab_fit(cubby_width, cubby_depth, cubby_height);
+} else if ( part == "bottom_tabs" ) {
+     bottom_test_fit(cubby_width, cubby_depth);
+} else if ( part == "side_tabs" ) {
+     side_test_fit(cubby_depth, cubby_height);
 }
 
-module cubby (w, d, h) {
-     position_flat() children();
+function double (x) = x * 2;
+function half (x) = x / 2;
 
-     module position_flat () {
-          rot(90) yrot(90) cubby_bottom(w, d);
-          gap=5;
-          yrot(180+90) {
-               down(((w + h) / 2) + (tab_height * 2) + gap) cubby_divider(d, h);
-          }
-     }
+module both () {
+    gap=5;
+    cubby_bottom(cubby_width, cubby_depth);
+    left(((cubby_width + cubby_height) / 2) + (tab_height * 2) + gap)
+        cubby_side(cubby_depth, cubby_height, screw_tabs);
 }
 
-module cubby_divider (depth, height, screw_tabs=true) {
-     function bracket_height() = thickness * 2;
+module cubby_bottom (width, depth) {
+    rot(90) yrot(90) color("blue") bottom_wall() yrot(90) down(tab_height / 2) {
+          move_dist=width / 2 + (tab_depth / 2);
+          fwd(move_dist)
+               alternating_tabs(false, "male", depth, tab_width,
+                                 tab_depth, tab_height, tab_padding, tab_tolerance);
+          back(move_dist)
+               alternating_tabs(true, "male", depth, tab_width,
+                                 tab_depth, tab_height, tab_padding, tab_tolerance);
+    }
+    children();
+    module bottom_wall () {
+        strut_wall(width, depth) children();
+    }
+}
+
+/* this calculation needs to be referenced by the view_tab_fit function */
+function cubby_side_bracket_height() = double(tab_height) + tab_tolerance;
+module cubby_side (depth, height, screw_tabs=true) {
      screw_tab_width=15;
      screw_tab_height=20;
      screw_tab_thickness=thickness;
 
-     divider_wall() {
-          if ( screw_tabs ) {
-               position(TOP+FRONT+LEFT) screw_tab();
-               up(screw_tab_height) position(BOTTOM+FRONT+LEFT) screw_tab();
-          }
-          attach(BOTTOM, TOP)  zrot(90) tab_bracket();
-          attach(TOP, BOTTOM)  zrot(90) tab_bracket();
+     yrot(180+-90) color("red") side_wall() {
+         if ( screw_tabs ) {
+           position(TOP+FRONT+LEFT) screw_tab();
+           up(screw_tab_height) position(BOTTOM+FRONT+LEFT) screw_tab();
+         }
+         attach(BOTTOM, TOP)  zrot(90) tab_bracket();
+         attach(TOP, BOTTOM)  zrot(90) tab_bracket();
      }
      children();
 
-     module divider_wall () {
-          strut_wall(depth, height - bracket_height()) children();
+     module side_wall () {
+         strut_wall(depth, height - cubby_side_bracket_height() * 2) children();
      }
 
      module tab_bracket () {
           difference() {
-               cuboid([depth,thickness,bracket_height()]);
-               add_tabs(depth, male=false, between=false);
-               add_tabs(depth, male=false, between=true);
+               cuboid([depth,thickness,cubby_side_bracket_height()]);
+               alternating_tabs(true, "female", depth, tab_width, tab_depth, tab_height, tab_padding, tab_tolerance);
+               alternating_tabs(false, "female", depth, tab_width, tab_depth, tab_height, tab_padding, tab_tolerance);
           }
-
           children();
      }
 
@@ -91,8 +126,8 @@ module cubby_divider (depth, height, screw_tabs=true) {
                cuboid([screw_tab_width, screw_tab_thickness,screw_tab_height],
                       anchor=LEFT+TOP);
                right(screw_tab_width * (2 / 3)) zrot(90) yrot(90) {
-                    right(screw_tab_height * (1 / 3)) #cyl(l=15, r=2, anchor=RIGHT);
-                    right(screw_tab_height * (2 / 3)) #cyl(l=15, r=2, anchor=LEFT);
+                    right(screw_tab_height * (1 / 3)) cyl(l=15, r=2, anchor=RIGHT);
+                    right(screw_tab_height * (2 / 3)) cyl(l=15, r=2, anchor=LEFT);
                }
 
           }
@@ -100,79 +135,68 @@ module cubby_divider (depth, height, screw_tabs=true) {
      }
 }
 
-module cubby_bottom (width, depth) {
-     color("blue") {
-          bottom_wall();
-          yrot(90) {
-               move_dist=width / 2 + (tab_depth / 2);
-               fwd(move_dist)
-                    add_tabs(depth, male=true, between=false);
-               back(move_dist)
-                    add_tabs(depth, male=true, between=true);
-          }
-     }
-     children();
-
-     module bottom_wall () {
-          strut_wall(width, depth) children();
-     }
-}
-
 module strut_wall(w, h) {
+     bridge=max_bridge ? max_bridge : (h+w)/5;
      sparse_strut(
           l=w,
           h=h,
           thick=thickness,
           maxang=45,
           strut=5,
-          max_bridge=(h+w)/5
+          max_bridge=bridge
     ) children();
 }
 
+module bottom_test_fit (w, d) {
+     keep=(w / 2) - thickness;
+     //right_half(x=keep) cubby_bottom(cubby_width, cubby_depth);
 
-function tab_spacing (tab_width) = tab_width * 3.5;
-
-module single_tab (
-     tab_width=10,
-     tab_depth=5,
-     tab_height=5,
-     male=true,
-     tolerance=1
-) {
-     size=male
-          ? [tab_width, tab_depth, tab_height]
-          : [tab_width + tolerance, tab_depth + tolerance, tab_height + tolerance];
-     if (male) {
-          #cuboid(size) children();
-     } else {
-          cuboid(size) children();
+     text=str("t=", tab_tolerance);
+     text_pos=[(-w / 2) + (thickness * 0.9),
+               -d / 2 + thickness,
+               (thickness / 2) - text_extrude];
+
+     difference() {
+       left_half(x=-keep) cubby_bottom(cubby_width, cubby_depth);
+       #translate(text_pos) zrot(90) linear_extrude(text_extrude) color("green") text(size=text_size, text);
      }
 }
 
-/* module single_hole ( size_of_yo_hole = 2000mm )  { */
-/*      if (male) { */
-/*           #cylinder(size_of_yo_hole) children(); */
-/*      } else { */
-/*           cylinder(size_of_yo_hole) children(); */
-/*      } */
-
-/* } */
-
-module tab_line (
-     distance=100,
-     tab_width=10,
-     tab_depth=5,
-     tab_height=5,
-     tab_padding=5,
-     male=true,
-     tolerance=1,
-     edge_padding=0,
-     between=false,
-) {
-     start = between ? ((tab_padding * 2) + tab_width) : tab_padding;
-     tab_spacing = (tab_width * 2) + (tab_padding * 2);
-     shift = (distance - (tab_padding * 2)) / -2;
-     for ( i = [shift+start:tab_spacing:(shift * -1) - tab_padding] ) {
-          right(i) #single_tab(tab_width, tab_depth, tab_height, male, tolerance);
-     }
+module side_test_fit (d, h) {
+    text=str("t=", tab_tolerance);
+    text_pos=[-h/2 + (thickness * 0.9),
+              -d / 2 + thickness,
+              (thickness / 2) - text_extrude];
+
+    difference() {
+      left_half(x=(h / -2 + (thickness * 3)))
+        cubby_side(d, h, screw_tabs=false);
+      #translate(text_pos) zrot(90) linear_extrude(text_extrude) color("green") text(size=text_size, text);
+    }
+}
+
+module view_tab_fit (w, d, h) {
+    // position for testing tab fit
+    module position_fit_test (left=true) {
+        cubby_bottom(w, d);
+        dist=(w / 2) + (thickness / -2) + tab_depth - 2;
+        down=half(h) - half(thickness) - tab_height - half(tab_tolerance);
+        yflip() yrot(90) down(dist * (left ? 1 : -1)) left(down) cubby_side(d, h, screw_tabs);
+    }
+
+    position_fit_test(left=true);
+    yrot(180) up(h) position_fit_test(left=false);
+}
+
+module alternating_tabs ( first, gender, length, tab_width, tab_depth, tab_height, tab_padding, tolerance ) {
+     dist=length - (tab_padding * 2);
+     total_tabs=dist / (tab_width + tab_padding + tolerance);
+     half_tabs=total_tabs / 2;
+     tab_qty = total_tabs % 2 == 0 ? half_tabs : first ? ceil(half_tabs) : floor(half_tabs);
+     start = first ? tab_padding : (tab_padding * 2) + tab_width;
+     spacing = (tab_width + tab_padding) * 2;
+     xcopies(spacing, tab_qty, dist, sp=((dist / -2) + start))
+          #dovetail(gender, angle=0, slide=add_tol(tab_depth), width=add_tol(tab_width), height=add_tol(tab_height));
+
+     function add_tol (x) = gender == "male" ? x : x + tolerance;
 }