Felipe M.
2767709809
Drops all the custom slot/latch-shelf/face-stop/base-notch parameters and modules in favour of the imported rj45Receiver() component. The receiver sits flat behind the front face with its slot opening at cap z=0 (after a 180° flip around Y) and its body extending into the cavity / wall box. Validation now uses rj45_width × rj45_height as the in-plane footprint. Also bumps screw_countersink_diameter from 5.5 mm to 6.6 mm.
272 lines
11 KiB
OpenSCAD
272 lines
11 KiB
OpenSCAD
// ============================================
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// Blind Cap (Tapa Ciega)
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// ============================================
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// A blank cover plate for a flush-mounted electrical wall box.
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// Square plate with rounded corners, hollow back, and two
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// internal screw bosses on the vertical centerline.
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use <../components/rj45_keystone.scad>;
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// ============================================
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// CUSTOMIZABLE PARAMETERS
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// ============================================
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// Outer width and height of the cap (square)
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outer_size = 80; // [50:1:120]
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// Radius of the rounded outer corners
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corner_radius = 5; // [1:0.5:15]
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// Total depth of the cap (front face to back rim)
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total_depth = 3; // [5:0.5:20]
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// Thickness of the front face
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front_thickness = 2; // [1:0.1:5]
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// Thickness of the side walls (the rim around the cavity)
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wall_thickness = 1; // [1:0.1:5]
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// Center-to-center distance between the two screw holes
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screw_hole_spacing = 60; // [30:1:100]
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// Through-hole diameter for the mounting screw shank
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screw_hole_diameter = 3; // [2:0.1:6]
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// Countersink diameter on the front face for the screw head
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screw_countersink_diameter = 6.6; // [4:0.1:12]
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// Countersink depth on the front face
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screw_countersink_depth = 1.2; // [0:0.1:3]
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// Diameter of the internal screw bosses
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boss_diameter = 9; // [5:0.5:15]
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// Front-face edge rounding (slight chamfer on the visible front edge)
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front_edge_round = 1.5; // [0:0.1:3]
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// Back-rim edge rounding (slight chamfer on the rear outer edge)
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back_edge_round = 0; // [0:0.1:3]
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// ============================================
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// KEYSTONE JACK CRADLE
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// ============================================
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// The cradle behind the front-face cutout is the marcuswu RJ45
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// keystone receiver, imported from ../components/rj45_keystone.scad.
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// Its slot, latch shelf, fulcrum/clip bars, and insertion ramp are
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// all defined by that module — we just position it behind the front
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// face and cut a hole in the front face for the keystone face to
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// show through.
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//
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// The receiver's Y axis (insertion direction) is rotated to align
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// with the cap's Z axis (depth). The keystone slides in face-first
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// from the cavity side and clips into the receiver's built-in
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// latch-catch.
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// Add the keystone receiver behind the front-face cutout
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keystone_enabled = true; // [false, true]
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// Front-face cutout — sized to the visible portion of the keystone face.
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keystone_face_width = 14.5; // [10:0.1:25]
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keystone_face_length = 16.0; // [10:0.1:25]
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// Offset of the front-face cutout along the receiver's long axis (Y in
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// cradle local). The receiver's slot is taller than the visible face,
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// so the cutout typically needs to sit a few mm off-centre to align
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// with where the face actually shows.
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keystone_face_offset_y = 1.2; // [-6:0.1:6]
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// Print-tolerance clearance added on each side of the front-face cutout
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keystone_clearance = 0.2; // [0:0.05:1]
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// Rotation of the keystone (receiver + front cutout) about the cap's
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// Z axis, in 90° steps. 0° puts the receiver's long axis along Y;
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// 90° puts it along X.
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keystone_rotation = 90; // [0, 90, 180, 270]
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// Translate the whole keystone (receiver + cutout) away from the cap's
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// centre.
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keystone_position_x = 15; // [-40:0.5:40]
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keystone_position_y = 0; // [-40:0.5:40]
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// ============================================
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// RENDERING QUALITY
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// ============================================
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$fn = 64;
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// ============================================
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// PARAMETER VALIDATION
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// ============================================
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assert(outer_size > 2 * corner_radius, "Outer size must be larger than twice the corner radius");
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assert(total_depth > front_thickness, "Total depth must be greater than front thickness");
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assert(boss_diameter > screw_hole_diameter, "Boss diameter must exceed screw hole diameter");
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assert(screw_countersink_diameter >= screw_hole_diameter, "Countersink must be at least as wide as the screw hole");
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assert(screw_hole_spacing + boss_diameter < outer_size - 2 * wall_thickness, "Screw bosses must fit inside the cavity");
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assert(front_edge_round < front_thickness, "Front edge round must be smaller than front thickness");
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assert(back_edge_round < total_depth - front_thickness, "Back edge round must be smaller than the cavity depth");
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assert(front_edge_round + back_edge_round < total_depth, "Combined edge rounds must not exceed total depth");
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// Keystone-specific validation. The receiver sits flat behind the
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// front face, so its X × Y footprint is rj45_width × rj45_height
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// (with rj45_depth becoming the cap-Z protrusion). At 90°/270° the
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// X and Y swap in the cap frame, which changes which screw boss the
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// receiver might hit.
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KS_OUTER_X = rj45_width();
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KS_OUTER_Y = rj45_height();
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KS_ROT_SWAP = (keystone_rotation == 90 || keystone_rotation == 270);
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KS_EFF_X = KS_ROT_SWAP ? KS_OUTER_Y : KS_OUTER_X;
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KS_EFF_Y = KS_ROT_SWAP ? KS_OUTER_X : KS_OUTER_Y;
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KS_X_MIN = keystone_position_x - KS_EFF_X / 2;
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KS_X_MAX = keystone_position_x + KS_EFF_X / 2;
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KS_Y_MIN = keystone_position_y - KS_EFF_Y / 2;
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KS_Y_MAX = keystone_position_y + KS_EFF_Y / 2;
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// Helper: do AABBs [a1,a2] and [b1,b2] overlap on one axis?
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function _ks_overlap(a1, a2, b1, b2) = !(a2 < b1 || a1 > b2);
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// Each screw boss's AABB in cap coords (square inscribing the circle).
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KS_BOSS_R = boss_diameter / 2;
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KS_TOP_Y = screw_hole_spacing / 2;
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KS_BOT_Y = -screw_hole_spacing / 2;
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KS_HITS_TOP = _ks_overlap(KS_X_MIN, KS_X_MAX, -KS_BOSS_R, KS_BOSS_R)
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&& _ks_overlap(KS_Y_MIN, KS_Y_MAX, KS_TOP_Y - KS_BOSS_R, KS_TOP_Y + KS_BOSS_R);
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KS_HITS_BOT = _ks_overlap(KS_X_MIN, KS_X_MAX, -KS_BOSS_R, KS_BOSS_R)
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&& _ks_overlap(KS_Y_MIN, KS_Y_MAX, KS_BOT_Y - KS_BOSS_R, KS_BOT_Y + KS_BOSS_R);
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assert(keystone_rotation == 0 || keystone_rotation == 90
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|| keystone_rotation == 180 || keystone_rotation == 270,
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"keystone_rotation must be 0, 90, 180, or 270");
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assert(!keystone_enabled
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|| (KS_X_MIN >= -(outer_size / 2 - wall_thickness)
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&& KS_X_MAX <= (outer_size / 2 - wall_thickness)),
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"Keystone receiver (with rotation+offset) extends beyond the cap's inner cavity along X");
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assert(!keystone_enabled
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|| (KS_Y_MIN >= -(outer_size / 2 - wall_thickness)
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&& KS_Y_MAX <= (outer_size / 2 - wall_thickness)),
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"Keystone receiver (with rotation+offset) extends beyond the cap's inner cavity along Y");
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assert(!keystone_enabled || !KS_HITS_TOP,
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"Keystone receiver (with rotation+offset) would collide with the top screw boss");
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assert(!keystone_enabled || !KS_HITS_BOT,
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"Keystone receiver (with rotation+offset) would collide with the bottom screw boss");
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// ============================================
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// MAIN ASSEMBLY
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// ============================================
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difference() {
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union() {
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// Outer shell with the back cavity already removed
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difference() {
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outer_shell();
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// Hollow out the back cavity
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translate([0, 0, front_thickness])
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rounded_prism(
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size = outer_size - 2 * wall_thickness,
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radius = max(corner_radius - wall_thickness, 0.5),
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height = total_depth - front_thickness + 1
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);
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}
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// Internal screw bosses (rise from the inside of the front face)
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for (y = [-screw_hole_spacing / 2, screw_hole_spacing / 2])
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translate([0, y, front_thickness])
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cylinder(h = total_depth - front_thickness, d = boss_diameter);
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// Keystone receiver — imported from components/rj45_keystone.scad.
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// Sits flat behind the front face: receiver Z=0 (its slot
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// opening) is at cap z=0, so the keystone is inserted face-
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// first through the front-face cutout into the receiver. The
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// body extends in cap +Z into the cavity / wall box. Centred
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// in cap X/Y at (keystone_position_x, keystone_position_y) and
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// rotated about cap Z by keystone_rotation.
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if (keystone_enabled)
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translate([keystone_position_x, keystone_position_y, 0])
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rotate([0, 0, keystone_rotation])
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translate([rj45_width() / 2, (-rj45_height() / 2)+2, rj45_depth()])
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rotate([0, 180, 0])
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rj45Receiver();
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}
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// Through-holes for the mounting screws
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for (y = [-screw_hole_spacing / 2, screw_hole_spacing / 2])
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translate([0, y, -1])
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cylinder(h = total_depth + 2, d = screw_hole_diameter);
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// Countersinks on the front face for the screw heads
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if (screw_countersink_depth > 0)
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for (y = [-screw_hole_spacing / 2, screw_hole_spacing / 2])
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translate([0, y, -0.01])
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cylinder(
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h = screw_countersink_depth + 0.01,
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d1 = screw_countersink_diameter,
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d2 = screw_hole_diameter
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);
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// Keystone front-face cutout — sized to the visible portion of the
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// keystone face only. Punches through the cap's front face so the
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// keystone face inside the receiver is visible from outside. The
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// face flange behind the cutout seats against the back of the
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// front-face material. Rotated and translated together with the
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// receiver so they stay aligned.
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if (keystone_enabled) {
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cw = keystone_face_width + 2 * keystone_clearance;
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cl = keystone_face_length + 2 * keystone_clearance;
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translate([keystone_position_x, keystone_position_y, 0])
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rotate([0, 0, keystone_rotation])
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translate([-cw / 2, -cl / 2 + keystone_face_offset_y, -1])
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cube([cw, cl, front_thickness + 2]);
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}
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}
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// ============================================
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// COMPONENT MODULES
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// ============================================
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// Outer shell with softly tapered front and back outer edges.
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// Front face sits at z = 0 (build plate), back rim at z = total_depth.
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module outer_shell() {
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if (front_edge_round > 0 || back_edge_round > 0) {
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hull() {
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// Front face (inset) — only when front edge is rounded
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if (front_edge_round > 0)
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translate([0, 0, 0])
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rounded_prism(
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size = outer_size - 2 * front_edge_round,
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radius = max(corner_radius - front_edge_round, 0.1),
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height = 0.01
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);
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// Full-size middle section
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translate([0, 0, front_edge_round])
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rounded_prism(
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size = outer_size,
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radius = corner_radius,
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height = total_depth - front_edge_round - back_edge_round
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);
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// Back rim (inset) — only when back edge is rounded
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if (back_edge_round > 0)
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translate([0, 0, total_depth - 0.01])
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rounded_prism(
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size = outer_size - 2 * back_edge_round,
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radius = max(corner_radius - back_edge_round, 0.1),
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height = 0.01
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);
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}
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} else {
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rounded_prism(outer_size, corner_radius, total_depth);
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}
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}
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// Square prism with rounded corners, centered on the X/Y origin.
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module rounded_prism(size, radius, height) {
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hull()
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for (x = [-size / 2 + radius, size / 2 - radius])
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for (y = [-size / 2 + radius, size / 2 - radius])
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translate([x, y, 0])
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cylinder(h = height, r = radius);
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}
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