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