fix ventilation for sidewalls

Author: jazwa

README.md

@@ -2,7 +2,7 @@
 
 ![display](media/renders/rackDisplayRounded.png)
 
-### A parametric 3d-printable mini rack system
+### A modular 3d-printable mini rack system
 - ***Mount Anything:*** Perfect for organizing SBCs, mini PCs, small switches, power hubs, etc.
 - ***Fully customizable:*** Fully written in OpenSCAD. Everything, from the dimensions of the rack, to the roundness of the corners, can be modified with a simple code change.
 - ***Printable from home:*** Designed to be printed with conventional FDM printers. Requires minimal supports when printing, and final assembly needs only a few easy-to-source parts. 
@@ -11,12 +11,12 @@
 
 ## Assembly
 
-Pre-generated STLs for roughly 200mm^3 (mini), 180mm^3 (micro), and 100mm^3 (nano) rack frames can be found in [stl](stl).
+Pre-generated STLs for roughly 200mm^3 (mini), 180mm^3 (micro), and 100mm^3 (nano) rack frames can be found in the [stl](stl) dir.
 These STLs are generated from the files in [rack/print](rack/print), and [rack-mount/print](rack-mount/print) - further information about printing these parts 
 (supports, orientation) can be found in these files.
 
 ### Assembly Instructions
-Please see [the assembly README here](./assembly-guide)
+Please see [the assembly guide](./assembly-guide).
 
 ### Required Tools:
 - 3d FDM Printer - build size requirements depend on configured rack profile
@@ -48,15 +48,15 @@ Please see [the assembly README here](./assembly-guide)
 | [Left Side Wall](./rack/print/sideWallLeft_P.scad)           | 1        |
 | [Right Side Wall](./rack/print/sideWallRight_P.scad)         | 1        |
 | [XY-Plate](./rack/print/xyPlate_P.scad)                      | 2        |
-| [Feet](./rack/print/feet_P.scad) (optional)                  | 2        |
+| [Feet](./rack/print/rackFeet_P.scad) (optional)                  | 2        |
 
 
 #### Notes: 
 - Before printing the actual parts. It's recommended to print this evaluation part: [eval_P](./rack/print/eval_P.scad) to test tolerances. If you find the fits too tight/loose, you can adjust them [here](./config/slack.scad).
 - Please also adjust [this file](./config/slicer.scad) to match your slicer settings.
 - Omitted actual plastic for printing. Any conventional 3d printing plastic should do (PLA, PETG, ABS),
 but beware of PLA's thermal limits. Higher infill is recommended for all parts.
-- For joining two racks, you will need to print 4 [stackConnectorDuals](./rack/print/stackConnectorDual_P.scad), as well as 8 M3 hex nuts, and 8 M3x12 FHCS.
+- For joining two racks, you will need to print 4 [rackJoiners](./rack/print/rackJoiner_P.scad), as well as 8 M3 hex nuts, and 8 M3x12 FHCS.
 - Main front rails use M4 hex nuts and screws.
 - Side rails are mounted using M3 hex nuts and screws.
 
@@ -74,6 +74,7 @@ Generate all project files for the `micro` profile:
 `python3 rbuild.py -b all -c micro`
 
 This will build all the parts defined in [rack/print](./rack/print), and put the STLs in [stl/micro](./stl/micro). 
+You can also provide a `-dz {n}` parameter to adjust the height of the generated rack.
 
 For generating a specific part: 
 

assembly-guide/gifs/attachSideConnectorModulesToYBars.gif

@@ -1,9 +1,15 @@
-
 // Manually set this variable to toggle rack profile
 profileName = "micro";
 
-
 _profileConfigs = [
+    // You can introduce a custom profile like:
+    /*
+    ["custom", [
+      ["maxUnitWidth", 180],
+      ["maxUnitDepth", 120],
+      ["numRailScrews", 10]
+    ]],
+    */
     ["default", [
       ["maxUnitWidth", 180],
       ["maxUnitDepth", 180],
@@ -27,7 +33,7 @@ _profileConfigs = [
     ["mini", [
       ["maxUnitWidth", 205],
       ["maxUnitDepth", 205],
-      ["numRailScrews", 20]
+      ["numRailScrews", 16]
     ]]
   ];
 

assembly-guide/gifs/attachXBarWithYBar.gif

@@ -26,6 +26,6 @@ module slideHexNutToFeet(at=0) {
     slideNut();
 
   if (!plasticMask) {
-    stackConnectorFeet();
+    rackFeet();
   }
 }

assembly-guide/gifs/attachXYPlates.gif

@@ -1,4 +1,4 @@
 use <../stackEnds.scad>
 
 
-stackConnectorFeet();
+rackFeet();

assembly-guide/gifs/attachXYTrays.gif

@@ -2,4 +2,4 @@ include <../stackEnds.scad>
 
 // Oriented for 3d printing. No supports required, but it's reccommended to print this with a brim.
 // Adding a brim will require some post-processing in the form of trimming the bottom.
-stackConnectorDual();
+rackJoiner();

assembly-guide/gifs/connectXYTrayWithMainRails.gif

@@ -131,41 +131,76 @@ module sideWallBase() {
   }
 }
 
-module sideWallVerticalRibs(numRibs, ribZ, ribYDiff, ribExtrusion=1) {
+module applySideWallDefaultVentilation(numVents) {
 
-  ribRampLength = 5;
-  ribWidth = 2;
+  r = 2; // vent roundness
+  ventLength = sideWallY - 2*sideWallDefaultVentilationToZEdge;
+  ventZDiff = (sideWallZ - 2*sideWallDefaultVentilationToYEdge)/(numVents-1);
 
-  intersection() {
-    for (i = [0:numRibs-1]) {
-
-      translate(v = [sideWallThickness, i*ribYDiff, (sideWallZ-ribZ)/2])
-      translate(v = [ribExtrusion-ribWidth, 0, 0])
-      verticalRib(ribExtend=4, ribWidth=ribWidth);
+  apply_n() {
+    for (i = [0:numVents-1]) {
+      translate(v = [0, sideWallDefaultVentilationToZEdge, i * ventZDiff + sideWallDefaultVentilationToYEdge])
+        vent();
     }
+    children(0);
+  }
 
-    halfspace(vpos=[1,0,0], p=[0,0,0]);
+  module vent() {
+    translate(v=[-inf/2,r,-sideWallDefaultVentilationWidth/2])
+    minkowski() {
+      rotate(a=[0,90,0])
+        cylinder(r=r,h=inf);
+      cube(size = [inf, max(eps, ventLength-2*r), max(eps,sideWallDefaultVentilationWidth-2*r)]);
+    }
   }
+}
 
+module applySideWallBracing(numRibs) {
 
-  module verticalRib(ribExtend, ribWidth) {
+  apply_p() {
+    // TODO add horizontal bracing
+    sideWallVerticalBracing(numRibs = numRibs);
+    children(0);
+  }
 
-    roundness = 0.5;
+  module sideWallVerticalBracing(numRibs, ribZ, ribExtrusion=1) {
 
-    minkowski() {
-      hull() {
-        translate(v=[0,0,roundness])
-        cube(size = [eps, ribWidth, eps]);
+    ribRampLength = 5;
+    ribWidth = 2;
+    ribZ = sideWallZ;
+    ribYDiff = sideWallY - 2*sideWallDefaultVerticalBracingToZEdge;
 
-        translate(v = [0, 0, ribRampLength])
-        cube(size = [ribExtend, ribWidth, ribZ-2*(ribRampLength+roundness)]);
+    translate(v=[0,sideWallDefaultVerticalBracingToZEdge,0])
+      intersection() {
+        for (i = [0:numRibs-1]) {
 
-        translate(v = [0, 0, ribZ-roundness])
-        cube(size = [eps, ribWidth, eps]);
+          translate(v = [sideWallThickness, i*ribYDiff, (sideWallZ-ribZ)/2])
+            translate(v = [ribExtrusion-ribWidth, 0, 0])
+              verticalRib(ribExtend=4, ribWidth=ribWidth);
+        }
+
+        halfspace(vpos=[1,0,0], p=[0,0,0]);
       }
 
-      sphere(r=roundness);
-    }
+    module verticalRib(ribExtend, ribWidth) {
+
+      roundness = 0.5;
+      translate(v=[0,-ribWidth/2,0])
+        minkowski() {
+          hull() {
+            translate(v=[0,0,roundness])
+              cube(size = [eps, ribWidth, eps]);
+
+            translate(v = [0, 0, ribRampLength])
+              cube(size = [ribExtend, ribWidth, ribZ-2*(ribRampLength+roundness)]);
+
+            translate(v = [0, 0, ribZ-roundness])
+              cube(size = [eps, ribWidth, eps]);
+          }
 
+          sphere(r=roundness);
+        }
+    }
   }
-}
+}
+

assembly-guide/gifs/insertFeet.gif

@@ -4,37 +4,9 @@ include <./sideWallBase.scad>
 
 module sideWallLeft() {
 
-  applySideWallVerticalRibs()
-  applyEpicVentilation()
-  sideWallBase();
-
-  module applyEpicVentilation() {
-    apply_n() {
-      for (i = [1:8]) {
-        translate(v = [0, 41, i * 12 + 10])
-        vent();
-      }
-      children(0);
-    }
-
-    module vent() {
-      minkowski() {
-        rotate(a=[0,90,0])
-        cylinder(r=2,h=1);
-
-        cube(size = [10, 100, 1]);
-      }
-    }
-  }
+  numVentsCustom = ceil((sideWallZ - 2*sideWallDefaultVentilationToYEdge)/10);
 
-  module applySideWallVerticalRibs() {
-    echo("sideWallZ", sideWallZ);
-    apply_p() {
-      translate(v = [0, 30, 0])
-      sideWallVerticalRibs(numRibs = 2, ribZ = sideWallZ, ribYDiff = 120, ribExtrusion = 1.5);
-
-      children(0);
-    }
-  }
+  applySideWallBracing(numRibs=2)
+  applySideWallDefaultVentilation(numVents=numVentsCustom)
+  sideWallBase();
 }
-

assembly-guide/gifs/propUpBottomXYTraywithSideWalls.gif

@@ -4,40 +4,11 @@ include <./sideWallBase.scad>
 
 module sideWallRight() {
 
-  applyEpicVentilation()
+  numVentsCustom = ceil((sideWallZ - 2*sideWallDefaultVentilationToYEdge)/10);
+
   mirror(v=[1,0,0])
-  applySideWallVerticalRibs()
+  applySideWallBracing(numRibs=2)
+  applySideWallDefaultVentilation(numVents=numVentsCustom)
   sideWallBase();
-
-  module applyEpicVentilation() {
-
-    apply_n() {
-      translate(v=[-10,0,0])
-      for (i = [1:8]) {
-        translate(v = [0, 41, i * 12 + 10])
-        vent();
-      }
-      children(0);
-    }
-
-    module vent() {
-      minkowski() {
-        rotate(a=[0,90,0])
-        cylinder(r=2,h=1);
-
-        cube(size = [10, 100, 1]);
-      }
-    }
-
-  }
-
-  module applySideWallVerticalRibs() {
-    apply_p() {
-      translate(v = [0, 30, 0])
-      sideWallVerticalRibs(numRibs = 2, ribZ = sideWallZ, ribYDiff = 120, ribExtrusion = 1.5);
-
-      children(0);
-    }
-  }
 }
 

assembly-guide/gifs/screwFeet.gif

@@ -32,3 +32,8 @@ sideWallX = (yBarWidth-(railTotalWidth+railSlotToInnerYEdge)) - sideWallXGapClea
 
 hingePoleDx = sideWallSlotToOuterYEdge + sideWallConnW/2.0;
 hingePoleDy = sideWallY - (sideWallSlotToOuterXEdge + (hingePoleR+radiusXYSlack));
+
+sideWallDefaultVerticalBracingToZEdge = 30;
+sideWallDefaultVentilationToZEdge = 40;
+sideWallDefaultVentilationToYEdge = 25;
+sideWallDefaultVentilationWidth = 6;

assembly-guide/gifs/screwXBarAndYBar.gif

@@ -7,7 +7,7 @@ stackConnectorDx = rackTotalWidth - 2*(connectorXEdgeToYBarXEdge + connectorRect
 stackConnectorDy = rackTotalDepth - 2*(connectorYEdgeToYBarYEdge + connectorRectDepth/2);
 stackConnectorDualSpacing = 0.5;
 
-module stackConnectorDual() {
+module rackJoiner() {
   translate(v=[0,0,stackConnectorDualSpacing/2])
   stackConnectorPlug();
 
@@ -19,7 +19,7 @@ module stackConnectorDual() {
   cube(size=[connectorRectWidth+connectorRectPlugSlack, connectorRectDepth+connectorRectPlugSlack, stackConnectorDualSpacing]);
 }
 
-module stackConnectorFeet() {
+module rackFeet() {
 
   bandThickness = 2;
   height = 18;