Rename hardware related variables and clean up their usage

Author: opatut

README.md

@@ -294,13 +294,13 @@ rider and would like to use a top rider mount. The opposite is not available.
 ### Dimensions
 
 * General
-  * `ScrewHole_diameter_M3`: A hole for an M3 bolt has this diameter. Usually,
-    the bolt is not meant to grab this hole, but slide into and out of it. For
-    (almost) each bolt, there is a corresponding threaded metal part (nut or
-    insert), so increase this value if your bolts are hard to get where they
-    need to go. Print `Calibration/ScrewHoles` to find a good value for your
-    printer.
-  * `HexNutHole_diameter`: The outer circle around a hex nut's hexagon has this
+  * `m3_screw_diameter_loose`: A hole for an M3 bolt has this diameter. The
+    bolt is not meant to grab this hole, but slide into and out of it ("loose"
+    fit). For (almost) each bolt, there is a corresponding threaded metal part
+    (nut or insert), so increase this value if your bolts are hard to get where
+    they need to go. Print `Calibration/ScrewHoles` to find a good value for
+    your printer.
+  * `m3_hex_nut_diameter`: The outer circle around a hex nut's hexagon has this
     diameter. This is **not** the same as the "wrench size" from [DIN
     934](https://www.fasteners.eu/standards/DIN/934/) (dimension `S`), but its
     nominal value is `2 / sqrt(3) * S`. For M3, this equals `6.35mm` nominally.

lib/utils.scad

@@ -39,16 +39,15 @@ module roundedCube(dimen, radii, center=false) {
 }
 
 module HeatsetInsertHole(bottom=false) {
-  translate([0, 0, bottom ? 0 : -HeatsetInsert_height]) {
-
+  translate([0, 0, bottom ? 0 : -m3_insert_hole_depth]) {
     rotate_extrude()
     polygon([
       [0, 0],
-      [0, HeatsetInsert_height],
-      [HeatsetInsert_diameter/2, HeatsetInsert_height],
-      [HeatsetInsert_diameter/2, HeatsetInsert_height-HeatsetInsert_full_depth],
-      [HeatsetInsert_diameter/2+HeatsetInsert_extra_radius, HeatsetInsert_height-HeatsetInsert_full_depth-HeatsetInsert_extra_radius],
-      [HeatsetInsert_diameter/2+HeatsetInsert_extra_radius, 0],
+      [0, m3_insert_hole_depth],
+      [m3_insert_hole_diameter/2, m3_insert_hole_depth],
+      [m3_insert_hole_diameter/2, m3_insert_cavity_depth+(m3_insert_cavity_diameter-m3_insert_hole_diameter)/2],
+      [m3_insert_cavity_diameter/2, m3_insert_cavity_depth],
+      [m3_insert_cavity_diameter/2, 0],
     ]);
   }
 }
@@ -97,7 +96,7 @@ module MountRail(clearance=MountRail_clearance) {
 
 module ScrewHole(
   depth, // total depth, including head
-  diameter=ScrewHole_diameter_M3,
+  diameter,
   head_depth=0,
   head_diameter=0,
   elongation=0,
@@ -126,9 +125,9 @@ module ScrewHole(
 module ScrewHoleM3(depth, head_depth=0, elongation=0) {
   ScrewHole(
     depth,
-    diameter=ScrewHole_diameter_M3,
+    diameter=m3_screw_diameter_loose,
     head_depth=head_depth,
-    head_diameter=ScrewHole_diameter_M3*2,
+    head_diameter=m3_screw_head_diameter,
     elongation=elongation
   );
 }

src/DisplayCase/DisplayCableStrainRelief.scad

@@ -31,7 +31,7 @@ module DisplayCableStrainRelief() {
         for(i=[-1,1])
         translate([0, i*4.4, 10])
         rotate([0, 90, 0])
-        cylinder(r=3.2, h=3);
+        cylinder(d=m3_screw_head_diameter, h=3);
       }
 
       // for the cable
@@ -46,11 +46,11 @@ module DisplayCableStrainRelief() {
       translate([3, 4.4, 10])
       rotate([0, 90, 0])
       rotate([0, 0, 360/6/2])
-      cylinder(r=3.2, h=200, $fn=6);
+      cylinder(d=m3_hex_nut_diameter, h=200, $fn=6);
 
       translate([3, -4.4, 10])
       rotate([0, 90, 0])
-      cylinder(r=3.2, h=200);
+      cylinder(d=m3_screw_head_diameter, h=200);
 
       for(i=[-1,1])
       translate([0, i*4.4, 10])

src/DisplayCase/DisplayCaseBottom.scad

@@ -44,7 +44,7 @@ module DisplayCaseBottom() {
         scale([14/12, 1, 1]) // scale to a side ratio of 14:12
         cylinder(d=12, h=100);
 
-        left = DisplayCase_outer_width-DisplayCase_outer_large_radius-(DisplayCase_outer_radius+2+HeatsetInsert_diameter/2+1);
+        left = DisplayCase_outer_width-DisplayCase_outer_large_radius-(DisplayCase_outer_radius+2+m3_insert_hole_diameter/2+1);
         right =  DisplayCase_outer_width/2+DisplayCaseTop_pcb_width/2-default_clearance-DisplayCaseBottom_standoff_size-(DisplayCase_outer_width-DisplayCase_outer_large_radius);
         translate([-left, 0, 4])
         cube([left+right, 5+21/2, 30]);

src/MainCase/MainCase.scad

@@ -20,7 +20,7 @@ module DebugPCB() {
   translate([wall_thickness, wall_thickness, wall_thickness])
 
   // move up by the height of the screw inserts
-  translate([0, 0, HeatsetInsert_height])
+  translate([0, 0, m3_insert_hole_depth])
 
   // move by the offset
   translate([PCB_offset.x, PCB_offset.y, 0])
@@ -32,12 +32,12 @@ module DebugPCB() {
 
 module HeatsetInsertStandoff(extend=0) {
   HeatsetInsertStandoff_profile_points = [
-    [0, HeatsetInsert_height*0/3],
-    [0, HeatsetInsert_height*3/3],
-    [HeatsetInsert_diameter, HeatsetInsert_height*3/3],
-    [HeatsetInsert_diameter, HeatsetInsert_height*2/3],
-    [HeatsetInsert_diameter + HeatsetInsert_height/3, HeatsetInsert_height*1/3],
-    [HeatsetInsert_diameter + HeatsetInsert_height/3, HeatsetInsert_height*0/3],
+    [0, m3_insert_hole_depth*0/3],
+    [0, m3_insert_hole_depth*3/3],
+    [m3_insert_hole_diameter, m3_insert_hole_depth*3/3],
+    [m3_insert_hole_diameter, m3_insert_hole_depth*2/3],
+    [m3_insert_hole_diameter  + m3_insert_hole_depth/3, m3_insert_hole_depth*1/3],
+    [m3_insert_hole_diameter  + m3_insert_hole_depth/3, m3_insert_hole_depth*0/3],
   ];
 
   render()
@@ -116,7 +116,7 @@ module GpsAntennaLid() {
     }
 
     translate([0, GpsAntennaHousing_top_height / 2 - GpsAntennaHousing_screw_offset,  GpsAntennaHousing_depth - GpsAntennaLid_thickness])
-    cylinder(d=ScrewHole_diameter_M3, h=10, $fn=32);
+    cylinder(d=m3_screw_diameter_loose, h=10, $fn=32);
   }
 }
 
@@ -235,11 +235,11 @@ module MainCase(without_inserts=false, top_rider=MainCase_top_rider, back_rider=
           rotate([90,0,0])
           linear_extrude(OBS_width)
           polygon(polyRound([
-            [wall_thickness, wall_thickness+HeatsetInsert_height, 0],
-            [OBS_height-wall_thickness, wall_thickness+HeatsetInsert_height, 0],
-            [OBS_height-wall_thickness, OBS_depth-2*HeatsetInsert_height, 0],
+            [wall_thickness, wall_thickness+m3_insert_hole_depth, 0],
+            [OBS_height-wall_thickness, wall_thickness+m3_insert_hole_depth, 0],
+            [OBS_height-wall_thickness, OBS_depth-2*m3_insert_hole_depth, 0],
             [OBS_height/2, OBS_depth-20+OBS_height/2, 0],
-            [wall_thickness, OBS_depth-2*HeatsetInsert_height, 0],
+            [wall_thickness, OBS_depth-2*m3_insert_hole_depth, 0],
           ], fn=$pfn));
 
           translate([0, 78, 0])
@@ -273,7 +273,7 @@ module MainCase(without_inserts=false, top_rider=MainCase_top_rider, back_rider=
 
             // a little standoff for the PCB
             translate([wall_thickness, PCB_offset.y + wall_thickness, wall_thickness])
-            linear_extrude(HeatsetInsert_height)
+            linear_extrude(m3_insert_hole_depth)
             polygon(polyRound([
               [0, 0, 0],
               [3, 0, 0],
@@ -362,7 +362,7 @@ module MainCase(without_inserts=false, top_rider=MainCase_top_rider, back_rider=
     }
 
     // Hole for USB Charger Port
-    translate([UsbPort_offset, 0, HeatsetInsert_height + wall_thickness - UsbPort_vertical_offset])
+    translate([UsbPort_offset, 0, m3_insert_hole_depth + wall_thickness - UsbPort_vertical_offset])
     hull()for(i=[-1, 1])for(j=[-1, 1]) {
       translate([i/2*6.5, 0, j/2*0.7])
       rotate([-90, 0, 0])
@@ -394,14 +394,14 @@ module MainCase(without_inserts=false, top_rider=MainCase_top_rider, back_rider=
   }
 }
 
-module HexNutHole(depth=0) {
+module HexNutHole(nut_depth=3, screw_depth=0) {
   mirror([0, 0, 1])
   union() {
-    cylinder(d=HexNutHole_diameter, h=HexNutHole_depth, $fn=6);
+    cylinder(d=m3_hex_nut_diameter, h=nut_depth, $fn=6);
 
-    if (depth > HexNutHole_depth) {
-      translate([0, 0, HexNutHole_depth])
-      cylinder(d=ScrewHole_diameter_M3, h=depth - HexNutHole_depth, $fn=32);
+    if (screw_depth > nut_depth) {
+      translate([0, 0, nut_depth])
+      cylinder(d=m3_screw_diameter_loose, h=screw_depth - nut_depth, $fn=32);
     }
   }
 }
@@ -467,7 +467,7 @@ module MountAttachmentHolePattern(with_cable_hole=true) {
           j * MountAttachment_holes_dy / 2,
           0,
         ])
-        HexNutHole(20);
+        HexNutHole(nut_depth=4, screw_depth=20);
       }
     }
   }

src/MainCase/MainCaseLid.scad

@@ -121,7 +121,7 @@ module MainCaseLid() {
     // Holes for M3 screws
     for (hole = MainCaseLid_hole_positions) {
       translate([hole.x, hole.y, -1])
-      cylinder(d=ScrewHole_diameter_M3, h=10, $fn=32);
+      cylinder(d=m3_screw_diameter_loose, h=10, $fn=32);
     }
   }
 }

src/Mounting/LockingPin.scad

@@ -1,14 +1,5 @@
 include <../../variables.scad>
 
-LockingPin_diameter = 5.2;
-LockingPin_hole_diameter = 3.0;
-LockingPin_small_hole_diameter = 2.0;
-LockingPin_height = 15;
-LockingPin_handle_length = 15.2;
-LockingPin_handle_height = 3.5;
-LockingPin_foot_height = 2.0;
-LockingPin_fillet_radius = 2.0;
-
 // $fa = 1;
 // $fs = 0.1;
 $fn = 64;
@@ -69,7 +60,7 @@ module LockingPin() {
 
       // hole in main shaft, for holding screw
       translate([0, 0, -1])
-      cylinder(d=LockingPin_hole_diameter, h=LockingPin_height+2);
+      cylinder(d=m3_screw_diameter_tight, h=LockingPin_height+2);
     }
   }
 }

src/Mounting/StandardMountAdapter.scad

@@ -9,7 +9,7 @@ module LockingPinHole(depth=16) {
   union() {
     // the pin
     translate([0, 0, -depth-4])
-    cylinder(h=depth, d=3.2);
+    cylinder(h=depth, d=m3_screw_diameter_loose);
 
     // the chamber
     translate([-6, -5.5/2, -4])

variables.scad

@@ -53,19 +53,23 @@ MainCase_top_rider_cable = !(MainCase_back_rider && MainCase_back_rider_cable);
 // Dimensions for parts
 // ------------------------
 
-HeatsetInsert_diameter = 4;
-HeatsetInsert_height = 5.75;
-HeatsetInsert_full_depth = 4.5; // how far the normal hole reaches before it expands to the cavity
-HeatsetInsert_extra_radius = 0.5;
+// General thickness of all walls of the main case and where applicable
+wall_thickness = 2;
 
-// Holes for M3 screws, including clearance
-ScrewHole_diameter_M3 = 3.2;
+// Dimensions of M3 hardware
+m3_screw_diameter_tight = 3.0; // screw should grab the plastic well
+m3_screw_diameter_loose = 3.25; // screw should slide in nicely
+m3_screw_head_depth = 3; // minimum depth for sinking the screw head
+m3_screw_head_diameter = 6; // can have a little clearance
+m3_hex_nut_diameter = 6.45; // outer circle, *not* wrench size (S), but `S*2/sqrt(3)`, plus clearance
+m3_insert_hole_diameter = 4;
+m3_insert_hole_depth = 5.75;
+m3_insert_cavity_depth = 5.75 - 4.5;  // size of cavity on the bottom for displaced plastic
+m3_insert_cavity_diameter = m3_insert_hole_diameter + 1;
 
 SensorHole_diameter = 22.3; // 0.3 clearance
 SensorHole_ledge = 1.0;
 
-wall_thickness = 2;
-
 UsbCover_height = 9.7;
 UsbCover_foot_height = 1.5;
 UsbCover_width = 15.5;
@@ -222,9 +226,6 @@ MountAttachment_holes_x_offset = -0.5;
 MountAttachment_holes_dx = 15;
 MountAttachment_holes_dy = 33;
 
-HexNutHole_diameter = 6.5;
-HexNutHole_depth = 4;
-
 HandlebarRailRail_height = 7;
 HandlebarRailRail_length = 32.4;
 
@@ -303,3 +304,11 @@ BikeRackMountSide_height = 28 + BikeRackMount_bottom_spacing;
 
 TopTubeMount_diameter = 72;
 TopTubeMount_height = 20;
+
+LockingPin_diameter = 5.2;
+LockingPin_small_hole_diameter = 2.0;
+LockingPin_height = 15;
+LockingPin_handle_length = 15.2;
+LockingPin_handle_height = 3.5;
+LockingPin_foot_height = 2.0;
+LockingPin_fillet_radius = 2.0;