Add parametric Ring solar siding adapter model.

Track OpenSCAD sources and project notes; ignore generated STL exports.
2026-06-11 21:03:37 -04:00
commit 98e2abd0e0
4 changed files with 325 additions and 0 deletions
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+// Ring Solar Charger — Vinyl Siding Adapter Plate
+// BACKUP: flat upper rear + slow lower taper, no bead coping groove yet.
+// Units: millimeters. Vanilla OpenSCAD only.
+
+/* [Plate] */
+plate_width = 93.1;
+plate_height = 171.45;
+min_wall_thickness = 3.0;
+edge_round = 0;
+
+/* [Siding Profile] */
+siding_projection = 27.0;
+face_inset_depth = 8.0;
+flat_upper_ratio = 0.55;
+course_pitch = 165.1;
+profile_segments = 8;
+profile_mode = "curved";
+rear_clearance = 0.2;
+
+/* [Mounting Holes] */
+mount_hole_offset_top = 50.0;
+mount_hole_offset_bottom = 44.7;
+mount_hole_dia = 4.5;
+mount_hole_x = 0;
+
+/* [Export] */
+part_mode = "full";
+profile_strip_width = 20;
+
+/* [Hidden] */
+$fn = 64;
+epsilon = 0.01;
+
+function projection_z() = siding_projection - rear_clearance;
+
+function face_inset_z() = projection_z() - face_inset_depth;
+
+function face_y_flat_end() = plate_height * (1 - flat_upper_ratio);
+
+function lower_curve_z(y) =
+    let(
+        y1 = face_y_flat_end(),
+        t = y / max(y1, epsilon),
+        ease = pow(sin(t * 90), 1.4),
+        z_bottom = projection_z(),
+        z_top = face_inset_z()
+    )
+    z_top + (z_bottom - z_top) * (1 - ease);
+
+function stepped_rear_z(y) =
+    y >= face_y_flat_end() ? face_inset_z() : projection_z();
+
+function rear_z_at(y) =
+    y >= face_y_flat_end() ? face_inset_z()
+    : profile_mode == "stepped" ? stepped_rear_z(y)
+    : lower_curve_z(y);
+
+function rear_profile_points() =
+    let(step = plate_height / max(profile_segments * 12, 24))
+    [for (y = [0 : step : plate_height])
+        [y, rear_z_at(y)]];
+
+function max_rear_z() =
+    let(pts = rear_profile_points())
+    max([for (p = pts) p[1]]);
+
+function front_z() = max_rear_z() + min_wall_thickness;
+
+function rear_y_min() =
+    min([for (p = rear_profile_points()) p[1]]);
+
+function minkowski_active() =
+    edge_round > 0 && min_wall_thickness >= 2 * edge_round + 1;
+
+function hole_y_min() =
+    rear_y_min() - (minkowski_active() ? edge_round : 0) - epsilon;
+
+function hole_y_max() =
+    front_z() + (minkowski_active() ? edge_round : 0) + epsilon;
+
+function cross_section_polygon() =
+    let(
+        rear_pts = rear_profile_points(),
+        fz = front_z()
+    )
+    [
+        for (p = rear_pts) p,
+        [plate_height, fz],
+        [0, fz]
+    ];
+
+module cross_section_2d() {
+    polygon(cross_section_polygon());
+}
+
+module adapter_body(width) {
+    linear_extrude(width, center = true)
+        cross_section_2d();
+}
+
+module mount_holes() {
+    y_min = hole_y_min();
+    y_max = hole_y_max();
+    hole_depth = y_max - y_min;
+    center_y = (y_min + y_max) / 2;
+    for (y_pos = [plate_height - mount_hole_offset_top, mount_hole_offset_bottom]) {
+        translate([y_pos, center_y, mount_hole_x])
+            rotate([90, 0, 0])
+                cylinder(h = hole_depth, d = mount_hole_dia, center = true);
+    }
+}
+
+module rounded_body(width) {
+    if (minkowski_active()) {
+        minkowski() {
+            adapter_body(max(width - 2 * edge_round, 1));
+            sphere(r = edge_round);
+        }
+    } else {
+        adapter_body(width);
+    }
+}
+
+module adapter_plate() {
+    width = part_mode == "profile_strip" ? profile_strip_width : plate_width;
+    if (part_mode == "full") {
+        difference() {
+            rounded_body(width);
+            mount_holes();
+        }
+    } else {
+        rounded_body(width);
+    }
+}
+
+adapter_plate();