Left wall (#4)

* Add screw insert to hold the teensy

* Allow wider wall spacings for more internal room

* Fix the clunky thumb connections

* Enable the teensy holder for all styles

1 files changed, 178 insertions, 101 deletions

diff --git a/src/dactyl_keyboard/dactyl.clj b/src/dactyl_keyboard/dactyl.clj
index 358ee24..2cdd862 100644
--- a/src/dactyl_keyboard/dactyl.clj
+++ b/src/dactyl_keyboard/dactyl.clj
@@ -22,12 +22,12 @@
 (def centercol 3)                       ; controls left-right tilt / tenting (higher number is more tenting)
 (def orthographic-x (> nrows 5))        ; for larger number of rows don't curve them in as much
 ; (def orthographic-x true)             ; controls curvature of rows
-(def maltron-style false)                ; use fixed angles for columns
+(def maltron-style false)               ; use fixed angles for columns
 (def maltron-angles [(deg2rad 10) (deg2rad 10) 0 0 0 (deg2rad -15) (deg2rad -15)])  ; starting point: http://patentimages.storage.googleapis.com/EP0219944A2/imgf0002.png 
 
 (defn column-offset [column] (cond
   (= column 2) [0 2.82 -4.5]
-  (>= column 4) [0 -12 5.64]           ; original [0 -5.8 5.64]
+  (>= column 4) [0 -12 5.64]            ; original [0 -5.8 5.64]
   :else [0 0 0]))
 
 (def thumb-offsets [6 -3 7])
@@ -35,8 +35,11 @@
 (def keyboard-z-offset  9)              ; controls height; original=24
 
 (def extra-width 2.5)                   ; extra space between the base of keys; original= 2
-(def extra-height 1.0)                  ; origin= 1/2
+(def extra-height 1.0)                  ; original= 0.5
 
+(def wall-z-offset -15)                 ; length of the first downward-sloping part of the wall (negative)
+(def wall-xy-offset 5)                  ; offset in the x and/or y direction for the first downward-sloping part of the wall (negative)
+(def wall-thickness 2)                  ; wall thickness parameter; originally 5
 
 ;;;;;;;;;;;;;;;;;;;;;;;
 ;; General variables ;;
@@ -214,7 +217,7 @@
          (map + [0 0 keyboard-z-offset]))))
 
 ; (pr (rotate-around-y π [10 0 1]))
-(pr (key-position 1 cornerrow [(/ mount-width 2) (- (/ mount-height 2)) 0]))
+; (pr (key-position 1 cornerrow [(/ mount-width 2) (- (/ mount-height 2)) 0]))
 
 ;;;;;;;;;;;;;;;;;;;;
 ;; Web Connectors ;;
@@ -452,26 +455,37 @@
 (defn bottom-hull [& p]
   (hull p (bottom 0.001 p)))
 
-(def wall-offset -15)
-(def wall-thickness 2)     ; originally 5
+(def left-wall-x-offset 10)
+(def left-wall-z-offset  3)
+
+(defn left-key-position [row direction]
+  (map - (key-position 0 row [(* mount-width -0.5) (* direction mount-height 0.5) 0]) [left-wall-x-offset 0 left-wall-z-offset]) )
+
+(defn left-key-place [row direction shape]
+  (translate (left-key-position row direction) shape))
+
+
+(defn wall-locate1 [dx dy] [(* dx wall-thickness) (* dy wall-thickness) -1])
+(defn wall-locate2 [dx dy] [(* dx wall-xy-offset) (* dy wall-xy-offset) wall-z-offset])
+(defn wall-locate3 [dx dy] [(* dx (+ wall-xy-offset wall-thickness)) (* dy (+ wall-xy-offset wall-thickness)) wall-z-offset])
 
 (defn wall-brace [place1 dx1 dy1 post1 place2 dx2 dy2 post2]
   (union
     (hull
       (place1 post1)
-      (place1 (translate [0 0 wall-offset] post1))
-      (place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) -4] post1))
-      (place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) wall-offset] post1))
+      (place1 (translate (wall-locate1 dx1 dy1) post1))
+      (place1 (translate (wall-locate2 dx1 dy1) post1))
+      (place1 (translate (wall-locate3 dx1 dy1) post1))
       (place2 post2)
-      (place2 (translate [0 0 wall-offset] post2))
-      (place2 (translate [(* dx2 wall-thickness) (* dy2 wall-thickness) -4] post2))
-      (place2 (translate [(* dx2 wall-thickness) (* dy2 wall-thickness) wall-offset] post2)))
+      (place2 (translate (wall-locate1 dx2 dy2) post2))
+      (place2 (translate (wall-locate2 dx2 dy2) post2))
+      (place2 (translate (wall-locate3 dx2 dy2) post2)))
     (bottom-hull
-      (place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) wall-offset] post1))
-      (place1 (translate [0         0         wall-offset] post1))
-      (place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) wall-offset] post1))
-      (place2 (translate [0         0         wall-offset] post2))
-      (place2 (translate [(* dx2 wall-thickness) (* dy2 wall-thickness) wall-offset] post2)))))
+      (place1 (translate (wall-locate2 dx1 dy1) post1))
+      (place1 (translate (wall-locate3 dx1 dy1) post1))
+      (place2 (translate (wall-locate2 dx2 dy2) post2))
+      (place2 (translate (wall-locate3 dx2 dy2) post2)))
+      ))
 
 (defn key-wall-brace [x1 y1 dx1 dy1 post1 x2 y2 dx2 dy2 post2] 
   (wall-brace (partial key-place x1 y1) dx1 dy1 post1 
@@ -482,17 +496,25 @@
    ; back wall
    (for [x (range 0 ncols)] (key-wall-brace x 0 0 1 web-post-tl x       0 0 1 web-post-tr))
    (for [x (range 1 ncols)] (key-wall-brace x 0 0 1 web-post-tl (dec x) 0 0 1 web-post-tr))
-   (key-wall-brace 0 0 0 1 web-post-tl 0 0 -1 0 web-post-tl)
    (key-wall-brace lastcol 0 0 1 web-post-tr lastcol 0 1 0 web-post-tr)
    ; right wall
    (for [y (range 0 lastrow)] (key-wall-brace lastcol y 1 0 web-post-tr lastcol y       1 0 web-post-br))
    (for [y (range 1 lastrow)] (key-wall-brace lastcol (dec y) 1 0 web-post-br lastcol y 1 0 web-post-tr))
    (key-wall-brace lastcol cornerrow 0 -1 web-post-br lastcol cornerrow 1 0 web-post-br)
    ; left wall
-   (for [y (range 0 lastrow)] (key-wall-brace 0 y -1 0 web-post-tl 0 y       -1 0 web-post-bl))
-   (for [y (range 1 lastrow)] (key-wall-brace 0 (dec y) -1 0 web-post-bl 0 y -1 0 web-post-tl))
+   (for [y (range 0 lastrow)] (union (wall-brace (partial left-key-place y 1)       -1 0 web-post (partial left-key-place y -1) -1 0 web-post)
+                                     (hull (key-place 0 y web-post-tl)
+                                           (key-place 0 y web-post-bl)
+                                           (left-key-place y  1 web-post)
+                                           (left-key-place y -1 web-post))))
+   (for [y (range 1 lastrow)] (union (wall-brace (partial left-key-place (dec y) -1) -1 0 web-post (partial left-key-place y  1) -1 0 web-post)
+                                     (hull (key-place 0 y       web-post-tl)
+                                           (key-place 0 (dec y) web-post-bl)
+                                           (left-key-place y        1 web-post)
+                                           (left-key-place (dec y) -1 web-post))))
+   (wall-brace (partial key-place 0 0) 0 1 web-post-tl (partial left-key-place 0 1) 0 1 web-post)
+   (wall-brace (partial left-key-place 0 1) 0 1 web-post (partial left-key-place 0 1) -1 0 web-post)
    ; front wall
-   (key-wall-brace 0 0 0 1 web-post-tl 0 0 -1 0 web-post-tl)
    (key-wall-brace lastcol 0 0 1 web-post-tr lastcol 0 1 0 web-post-tr)
    (key-wall-brace 3 lastrow   0 -1 web-post-bl 3 lastrow 0.5 -1 web-post-br)
    (key-wall-brace 3 lastrow 0.5 -1 web-post-br 4 cornerrow 1 -1 web-post-bl)
@@ -502,7 +524,7 @@
    (wall-brace thumb-mr-place  0 -1 web-post-br thumb-tr-place  0 -1 thumb-post-br)
    (wall-brace thumb-mr-place  0 -1 web-post-br thumb-mr-place  0 -1 web-post-bl)
    (wall-brace thumb-br-place  0 -1 web-post-br thumb-br-place  0 -1 web-post-bl)
-   (wall-brace thumb-ml-place  0  1 web-post-tr thumb-ml-place  0  1 web-post-tl)
+   (wall-brace thumb-ml-place -0.3  1 web-post-tr thumb-ml-place  0  1 web-post-tl)
    (wall-brace thumb-bl-place  0  1 web-post-tr thumb-bl-place  0  1 web-post-tl)
    (wall-brace thumb-br-place -1  0 web-post-tl thumb-br-place -1  0 web-post-bl)
    (wall-brace thumb-bl-place -1  0 web-post-tl thumb-bl-place -1  0 web-post-bl)
@@ -514,112 +536,147 @@
    (wall-brace thumb-ml-place  0  1 web-post-tl thumb-bl-place  0  1 web-post-tr)
    (wall-brace thumb-bl-place -1  0 web-post-bl thumb-br-place -1  0 web-post-tl)
    (wall-brace thumb-tr-place  0 -1 thumb-post-br (partial key-place 3 lastrow)  0 -1 web-post-bl)
-   ; clunky bit on the top left thumb connection
-   (wall-brace thumb-ml-place  0  1 web-post-tr thumb-tl-place -2.5  0 thumb-post-tl)
-   (wall-brace thumb-tl-place -1  0 thumb-post-tl (partial key-place 0 cornerrow) -1  0 web-post-bl)
-   ;; another incomplete try to fix this
-   ;  (bottom-hull (thumb-tl-place thumb-post-tl)
-   ;               (thumb-tl-place (translate [-7 0 0] thumb-post-tl))
-   ;               (thumb-ml-place web-post-tr)
-   ;               (thumb-ml-place (translate [0 5 -4] web-post-tr)))
+   ; clunky bit on the top left thumb connection  (normal connectors don't work well)
+   (bottom-hull
+     (left-key-place cornerrow -1 (translate (wall-locate2 -1 0) web-post))
+     (left-key-place cornerrow -1 (translate (wall-locate3 -1 0) web-post))
+     (thumb-ml-place (translate (wall-locate2 -0.3 1) web-post-tr))
+     (thumb-ml-place (translate (wall-locate3 -0.3 1) web-post-tr)))
+   (hull
+     (left-key-place cornerrow -1 (translate (wall-locate2 -1 0) web-post))
+     (left-key-place cornerrow -1 (translate (wall-locate3 -1 0) web-post))
+     (thumb-ml-place (translate (wall-locate2 -0.3 1) web-post-tr))
+     (thumb-ml-place (translate (wall-locate3 -0.3 1) web-post-tr))
+     (thumb-tl-place thumb-post-tl))
+   (hull
+     (left-key-place cornerrow -1 web-post)
+     (left-key-place cornerrow -1 (translate (wall-locate1 -1 0) web-post))
+     (left-key-place cornerrow -1 (translate (wall-locate2 -1 0) web-post))
+     (left-key-place cornerrow -1 (translate (wall-locate3 -1 0) web-post))
+     (thumb-tl-place thumb-post-tl))
+   (hull
+     (left-key-place cornerrow -1 web-post)
+     (left-key-place cornerrow -1 (translate (wall-locate1 -1 0) web-post))
+     (key-place 0 cornerrow web-post-bl)
+     (key-place 0 cornerrow (translate (wall-locate1 -1 0) web-post-bl))
+     (thumb-tl-place thumb-post-tl))
+   (hull
+     (thumb-ml-place web-post-tr)
+     (thumb-ml-place (translate (wall-locate1 -0.3 1) web-post-tr))
+     (thumb-ml-place (translate (wall-locate2 -0.3 1) web-post-tr))
+     (thumb-ml-place (translate (wall-locate3 -0.3 1) web-post-tr))
+     (thumb-tl-place thumb-post-tl))
   ))
 
-(defn on-wall-place [column depth shape]
-  (translate [0 0 (- depth)]
-    (key-place column 0
-      (->> shape
-           (rotate (+ (* β (- centercol column)) (/ π 12)) [0 -1 0])      
-           (rotate (* α centerrow) [-1 0 0])      
-           (translate [0 (/ mount-height 2) wall-offset])
-           ))))
 
-(def rj9-vertical-offset (- (last (key-position 0 0 [0 (/ mount-height 2) 0])) 35))
+(def rj9-start  (map + [0 -3  0] (key-position 1 0 (map + (wall-locate3 0 1) [0 (/ mount-height  2) 0]))))
+(def rj9-position  [(first rj9-start) (second rj9-start) 11])
 (def rj9-cube   (cube 14.78 13 22.38))
-(def rj9-space  (on-wall-place 1 rj9-vertical-offset rj9-cube))
-(def rj9-holder (on-wall-place 1 rj9-vertical-offset 
+(def rj9-space  (translate rj9-position rj9-cube))
+(def rj9-holder (translate rj9-position
                   (difference rj9-cube
                               (union (translate [0 2 0] (cube 10.78  9 18.38))
                                      (translate [0 0 5] (cube 10.78 13  5))))))
 
-(def teensy-vertical-offset (+ rj9-vertical-offset 10))
 (def teensy-width 20)  
 (def teensy-height 12)
 (def teensy-length 33)
 (def teensy2-length 53)
 (def teensy-pcb-thickness 1.6) 
+(def teensy-holder-width  (+ 7 teensy-pcb-thickness))
+(def teensy-holder-height (+ 6 teensy-width))
 (def teensy-offset-height 5)
-(def teensy-holder-length 68)
-(def teensy-holder-offset (- 0 (/ teensy-holder-length 2)))
-(def teensy-holder-top-length 14)
-(def teensy-holder-top-offset (- 1 (/ teensy-holder-top-length 2)))
-
+(def teensy-holder-length 72)
+(def teensy-holder-offset (/ teensy-holder-length -2))
+(def teensy-holder-top-length 18)
+(def teensy-top-xy (key-position 0 0 (map + (wall-locate3  0 1) [(/ mount-width -2) (/ mount-height  2) 0])))
+(def teensy-bot-xy (map + (key-position 0 2 (map + (wall-locate3 -1 0) [(/ mount-width -2)  (/ mount-height  2) 0]))
+                          [(* 1 teensy-holder-width) 0 0]))
+(def teensy-holder-top-offset (/ teensy-holder-top-length -2))
+(def teensy-holder-angle (Math/atan2 (- (first teensy-top-xy) (first teensy-bot-xy)) (- (second teensy-top-xy) (second teensy-bot-xy))))
+ 
 (def teensy-holder 
-    (on-wall-place 0 teensy-vertical-offset
-      (translate [-5 0 0] 
+    (->> 
         (union 
           (->> (cube 3 teensy-holder-length (+ 6 teensy-width))
-               (translate [-1.5 teensy-holder-offset 0]))
+               (translate [1.5 teensy-holder-offset 0]))
           (->> (cube teensy-pcb-thickness teensy-holder-length 3)
-               (translate [(/ teensy-pcb-thickness 2) teensy-holder-offset (- -1.5 (/ teensy-width 2))]))
+               (translate [(+ (/ teensy-pcb-thickness 2) 3) teensy-holder-offset (- -1.5 (/ teensy-width 2))]))
           (->> (cube 4 teensy-holder-length 4)
-               (translate [(+ 2 teensy-pcb-thickness) teensy-holder-offset (-  -1 (/ teensy-width 2))]))
+               (translate [(+ teensy-pcb-thickness 5) teensy-holder-offset (-  -1 (/ teensy-width 2))]))
           (->> (cube teensy-pcb-thickness teensy-holder-top-length 3)
-               (translate [(/ teensy-pcb-thickness 2) teensy-holder-top-offset (+ 1.5 (/ teensy-width 2))]))
+               (translate [(+ (/ teensy-pcb-thickness 2) 3) teensy-holder-top-offset (+ 1.5 (/ teensy-width 2))]))
           (->> (cube 4 teensy-holder-top-length 4)
-               (translate [(+ 2 teensy-pcb-thickness) teensy-holder-top-offset (+ 1 (/ teensy-width 2))]))
-           ))))
+               (translate [(+ teensy-pcb-thickness 5) teensy-holder-top-offset (+ 1 (/ teensy-width 2))]))
+          (->> (cube teensy-holder-width 2 teensy-holder-height)
+               (translate [(+ (/ teensy-holder-width 2)) -1 0])))
+        (translate [(- teensy-holder-width) 0 0])
+        (rotate teensy-holder-angle [0 0 -1])
+        (translate [(first teensy-top-xy) 
+                    (- (second teensy-top-xy) 1) 
+                    (/ (+ 6 teensy-width) 2)])
+           ))
 
 (def usb-cutout
-  (let [hole-height 7.5
-        side-radius (/ hole-height 2)
-        hole-width 12
-        side-cylinder (->> (cylinder side-radius teensy-length)
-                           (with-fn 20)
-                           (translate [(/ (- hole-width hole-height) 2) 0 0]))]
-    (->> (hull side-cylinder
-               (mirror [-1 0 0] side-cylinder))
-         (rotate (/ π 2) [1 0 0])
-         (rotate (/ π 2) [0 1 0])
-         (on-wall-place 0 teensy-vertical-offset))))
-
-(def usb-cutout
-  (on-wall-place 0 teensy-vertical-offset (->> (cube 9 30 12)
-                                               (translate [-1 10 0]))))
+  (->> (cube 8 30 12)
+       (translate [-4 -5 0])
+       (rotate teensy-holder-angle [0 0 -1])
+       (translate [(+ (first teensy-top-xy) 3)
+                   (+ (second teensy-top-xy) 0) 
+                   (/ teensy-holder-height 2)])
+       )) 
+
+(def teensy-holder-hole
+  (->> (cube teensy-holder-width 30 teensy-holder-height)
+       (translate [(/ teensy-holder-width -2) -15 (/ teensy-holder-height 2)])
+       (rotate teensy-holder-angle [0 0 -1])
+       (translate [(first teensy-top-xy) 
+                   (- (second teensy-top-xy) 1) 
+                   0])))
+
+
+(defn screw-insert-shape [bottom-radius top-radius height] 
+   (union (cylinder [bottom-radius top-radius] height)
+          (translate [0 0 (/ height 2)] (sphere top-radius))))
 
 (defn screw-insert [column row bottom-radius top-radius height] 
-  (let [position (key-position column row [0 0 0])
-        column-offset (/ mount-width 2)
-        row-offset    (/ mount-height 2)
-        shift-right   (= column lastcol)
+  (let [shift-right   (= column lastcol)
         shift-left    (= column 0)
         shift-up      (and (not (or shift-right shift-left)) (= row 0))
         shift-down    (and (not (or shift-right shift-left)) (= row lastrow))
-        is-vertical   (or shift-left shift-right)
-        col-angle     (+ (* β (- centercol column)) (/ π 12))
-        row-angle     (* α (- row centerrow))]
-    (->> (union (cylinder [bottom-radius top-radius] height)
-                (translate [0 0 (/ height 2)] (sphere top-radius)))
+        position      (if shift-up     (key-position column row (map + (wall-locate2  0  1) [0 (/ mount-height 2) 0]))
+                       (if shift-down  (key-position column row (map - (wall-locate2  0 -1) [0 (/ mount-height 2) 0]))
+                        (if shift-left (map + (left-key-position row 0) (wall-locate3 -1 0)) 
+                                       (key-position column row (map + (wall-locate2  1  0) [(/ mount-width 2) 0 0])))))
+        ]
+    (->> (screw-insert-shape bottom-radius top-radius height)
          (translate [(first position) (second position) (/ height 2)])
-         (translate [(* (if shift-right 1 (if shift-left -1 0)) column-offset)
-                     (* (if shift-up    1 (if shift-down -1 0)) row-offset)
-                     0])
-         (translate [(* wall-offset (Math/sin col-angle))
-                     (* wall-offset (Math/sin row-angle))
-                     0]))))
-
-(defn screw-insert-shapes [bottom-radius top-radius height]
-  (union (screw-insert 0 0         bottom-radius top-radius height)
-         (screw-insert 0 cornerrow bottom-radius top-radius height)
+    )))
+
+(defn screw-insert-all-shapes [bottom-radius top-radius height]
+  (union ; (screw-insert 0 0         bottom-radius top-radius height)
+         (screw-insert 0 1         bottom-radius top-radius height)
          (screw-insert 3 lastrow   bottom-radius top-radius height)
          (screw-insert 3 0         bottom-radius top-radius height)
-        ;  (screw-insert lastcol (dec cornerrow) radius height)
+         (screw-insert lastcol 1   bottom-radius top-radius height)
          ))
 (def screw-insert-height 3.8)
 (def screw-insert-bottom-radius (/ 5.31 2))
 (def screw-insert-top-radius (/ 5.1 2))
-(def screw-insert-holes  (screw-insert-shapes screw-insert-bottom-radius screw-insert-top-radius screw-insert-height))
-(def screw-insert-outers (screw-insert-shapes (+ screw-insert-bottom-radius 1.6) (+ screw-insert-top-radius 1.6) (+ screw-insert-height 1.6)))
+(def screw-insert-holes  (screw-insert-all-shapes screw-insert-bottom-radius screw-insert-top-radius screw-insert-height))
+(def screw-insert-outers (screw-insert-all-shapes (+ screw-insert-bottom-radius 1.6) (+ screw-insert-top-radius 1.6) (+ screw-insert-height 1.6)))
+
+(defn teensy-screw-insert-place [shape] 
+ (let [position (vec (map - teensy-bot-xy (map (partial * 0.3) (map - teensy-top-xy teensy-bot-xy))))] 
+   (->> shape 
+        (rotate (/ π 2) [0 -1 0])
+        (translate [(- 3 teensy-holder-width (/ screw-insert-height 2)) (- (+ teensy2-length 4)) 0])
+        (rotate teensy-holder-angle [0 0 -1])
+        (translate [(first teensy-top-xy) (second teensy-top-xy) 15])
+        )))
 
+(def teensy-screw-insert-hole  (teensy-screw-insert-place (cylinder [screw-insert-bottom-radius screw-insert-top-radius] (+ screw-insert-height 0.4))))
+(def teensy-screw-insert-outer (teensy-screw-insert-place (translate [0 0 1] (cylinder [(+ screw-insert-bottom-radius 1.6) (+ screw-insert-top-radius 1.6)] (+ screw-insert-height 2)))))
 
 (spit "things/right.scad"
       (write-scad (difference 
@@ -628,26 +685,46 @@
                     connectors
                     thumb
                     thumb-connectors
-                    (difference (union case-walls 
-                                       screw-insert-outers 
-                                       (if (= nrows 4) teensy-holder)) 
+                    (difference (union (difference 
+                                         (union case-walls 
+                                                screw-insert-outers 
+                                                teensy-screw-insert-outer)
+                                         teensy-holder-hole)
+                                       teensy-holder)
                                 rj9-space 
                                 usb-cutout 
+                                teensy-screw-insert-hole
                                 screw-insert-holes)
                     rj9-holder
                     ; thumbcaps
                     ; caps
                     )
                    (translate [0 0 -20] (cube 350 350 40)) 
-                  ;  (translate [0 0 -50] (cube 5 5 20)) 
+                  ;  (translate [0 0 -150] (cube 5 5 20)) 
                   )))
                    
+(spit "things/right-test.scad"
+      (write-scad 
+                   (union
+                    key-holes
+                    connectors
+                    thumb
+                    thumb-connectors
+                    case-walls 
+                    teensy-holder
+                    ; teensy-holder-hole
+                                screw-insert-outers 
+                                teensy-screw-insert-hole
+                                teensy-screw-insert-outer
+                                usb-cutout 
+                                rj9-space 
+                  )))
 
-(spit "things/test.scad"
-      (write-scad (intersection (translate [29 -5 0] (cube 30 30 30))
-                   (difference (union case-walls screw-insert-outers) 
-                               screw-insert-holes)
-                   )))
+; (spit "things/test.scad"
+;       (write-scad (intersection (translate [29 -5 0] (cube 30 30 30))
+;                    (difference (union case-walls screw-insert-outers) 
+;                                screw-insert-holes)
+;                    )))
 
 ; (spit "things/test.scad"
 ;       (write-scad screw-insert-holes))