Add parametric Ring solar siding adapter model.

Track OpenSCAD sources and project notes; ignore generated STL exports.

ring-solar-siding-adapter.scad

@@ -0,0 +1,185 @@
+// Ring Solar Charger — Vinyl Siding Adapter Plate
+// Mounts the integrated Ring Solar Charger on horizontal beaded vinyl lap siding.
+// Units: millimeters. Vanilla OpenSCAD only.
+//
+// Rear profile (y=0 bottom, y=plate_height top):
+//   TOP    — bead coping cavity scooped into rear face (concave semicircle)
+//   MID    — flat rear shelf continues downward
+//   BOTTOM — slow taper outward toward siding projection
+//
+// Backup (flat + taper only): ring-solar-siding-adapter.backup.scad
+
+/* [Plate] */
+plate_width = 93.1;
+plate_height = 171.45;
+min_wall_thickness = 5.0;
+edge_round = 0;
+
+/* [Siding Profile] */
+siding_projection = 27.0;
+face_inset_depth = 8.0;
+bead_coping_radius = 10.00;      // Semicircle radius for bead groove (measured on siding)
+bead_coping_offset_top = 11.00;  // Distance from plate top to groove center (tune on wall)
+flat_upper_ratio = 0.55;         // Fraction of plate height that stays flat at the top
+bottom_taper_depth_ratio = 1.6;  // Rear depth at plate bottom = min_wall_thickness * this (outward from flat shelf)
+course_pitch = 165.1;
+profile_segments = 8;
+profile_mode = "curved"; // [curved, stepped]
+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"; // [full, profile_strip]
+profile_strip_width = 20;
+
+/* [Hidden] */
+$fn = 64;
+epsilon = 0.01;
+
+// ---------------------------------------------------------------------------
+// Siding rear-profile geometry
+// OpenSCAD 2D polygon uses [plate_Y, plate_Z]; linear_extrude() goes along +Z (width).
+// OpenSCAD 3D: X = plate height (y), Y = depth (z), Z = plate width.
+// Lower depth Y = toward wall (back). Higher depth Y = toward Ring (front).
+// ---------------------------------------------------------------------------
+
+function projection_z() = siding_projection - rear_clearance;
+
+function face_inset_z() = projection_z() - face_inset_depth;
+
+function bead_coping_y_center() = plate_height - bead_coping_offset_top;
+
+// Bottom of flat rear shelf (flat_upper_ratio measured from plate top downward).
+function face_y_flat_end() = plate_height * (1 - flat_upper_ratio);
+
+// Rear depth where the bottom taper ends (outward from flat shelf, in wall-thickness units).
+function bottom_rear_z() =
+    face_inset_z() + min_wall_thickness * bottom_taper_depth_ratio;
+
+// Slow taper from bottom_rear_z at the plate bottom up to the flat shelf.
+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 = bottom_rear_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() : bottom_rear_z();
+
+// Concave bead coping on the rear face near the plate top.
+// Flat chord at face_inset_z; arc scoops into the plate (toward the front).
+function bead_coping_rear_z(y) =
+    let(
+        r = bead_coping_radius,
+        shelf = face_inset_z(),
+        dy = y - bead_coping_y_center(),
+        disc = r * r - dy * dy
+    )
+    disc >= 0 ? shelf + sqrt(disc) : shelf;
+
+// Flat top shelf + bead cavity + lower taper.
+function rear_z_at(y) =
+    y >= face_y_flat_end() ? bead_coping_rear_z(y)
+    : profile_mode == "stepped" ? stepped_rear_z(y)
+    : lower_curve_z(y);
+
+function rear_profile_points() =
+    let(
+        step = plate_height / max(profile_segments * 12, 24),
+        yc = bead_coping_y_center(),
+        r = bead_coping_radius,
+        arc_step = r / 16
+    )
+    concat(
+        [for (y = [0 : step : max(yc - r - epsilon, 0)]) [y, rear_z_at(y)]],
+        [for (y = [yc - r : arc_step : yc + r]) [y, rear_z_at(y)]],
+        [for (y = [min(yc + r + step, plate_height) : 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]
+    ];
+
+// ---------------------------------------------------------------------------
+// Modules
+// ---------------------------------------------------------------------------
+
+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();