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Improvements (#3)

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* Start at Kludgy maltron style spacing

* Thumb and pinky tweaks

* Fix keyboard-z-offset problem

* Tweaks for a shorter-height version

* Add wall-thickness parameter

* Change hex-spacers to screw-inserts

* Adjust height

* Fix usb-cutout size and alignment

* Adjust teensy-holder

* Clean out junk
This commit is contained in:
Tom Short
2017-03-13 19:02:03 -04:00
committed by GitHub
parent 4e0d902884
commit a9cbe36abd
20 changed files with 121 additions and 1834266 deletions
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202
src/dactyl_keyboard/dactyl.clj
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@@ -6,6 +6,9 @@
[unicode-math.core :refer :all]))
(defn deg2rad [degrees]
(* (/ degrees 180) pi))
;;;;;;;;;;;;;;;;;;;;;;
;; Shape parameters ;;
;;;;;;;;;;;;;;;;;;;;;;
@@ -14,20 +17,26 @@
(def ncols 5)
(def α (/ π 12)) ; curvature of the columns
(def β (/ π (if (= nrows 4) 26 36))) ; curvature of the rows
(def β (/ π 36)) ; curvature of the rows
(def centerrow (- nrows 3)) ; controls front-back tilt
(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 orthographic-x true) ; controls curvature of rows
(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 -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])
(def keyboard-z-offset 24) ; controls height
(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
;;;;;;;;;;;;;;;;;;;;;;;
;; General variables ;;
@@ -123,13 +132,14 @@
(def rows (range 0 nrows))
(def cap-top-height (+ plate-thickness sa-profile-key-height))
(def row-radius (+ (/ (/ (+ mount-height 1/2) 2)
(def row-radius (+ (/ (/ (+ mount-height extra-height) 2)
(Math/sin (/ α 2)))
cap-top-height))
(def column-radius (+ (/ (/ (+ mount-width 2.0) 2)
(def column-radius (+ (/ (/ (+ mount-width extra-width) 2)
(Math/sin (/ β 2)))
cap-top-height))
(def column-x-delta (+ -1 (- (* column-radius (Math/sin β)))))
(def column-base-angle (* β (- centercol 2)))
(defn key-place [column row shape]
(let [row-placed-shape (->> shape
@@ -144,10 +154,10 @@
(translate (column-offset column)))
column-z-delta (* column-radius (- 1 (Math/cos column-angle)))
placed-shape-ortho (->> row-placed-shape
(rotate column-angle [0 1 0])
(rotate (if maltron-style (+ column-base-angle (nth maltron-angles column)) column-angle) [0 1 0])
(translate [(- (* (- column centercol) column-x-delta)) 0 column-z-delta])
(translate (column-offset column)))]
(->> (if orthographic-x placed-shape-ortho placed-shape)
(->> (if (or maltron-style orthographic-x) placed-shape-ortho placed-shape)
(rotate (/ π 12) [0 1 0])
(translate [0 0 keyboard-z-offset]))))
@@ -196,15 +206,15 @@
(map + (column-offset column)))
column-z-delta (* column-radius (- 1 (Math/cos column-angle)))
placed-position-ortho (->> row-position
(rotate-around-y column-angle)
(rotate-around-y (if maltron-style (+ column-base-angle (nth maltron-angles column)) column-angle))
(map + [(- (* (- column centercol) column-x-delta)) 0 column-z-delta])
(map + (column-offset column)))]
(->> (if orthographic-x placed-position-ortho placed-position)
(->> (if (or maltron-style orthographic-x) placed-position-ortho placed-position)
(rotate-around-y (/ π 12))
(map + [0 0 24]))))
(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 ;;
@@ -266,24 +276,27 @@
thumb-offsets))
; (pr thumborigin)
(defn deg2rad [degrees]
(* (/ degrees 180) pi))
(defn thumb-tr-place [shape]
(->> shape
; (rotate (deg2rad 10) [1 0 0])
; (rotate (deg2rad -23) [0 1 0])
; (rotate (deg2rad -3) [0 0 1])
(rotate (deg2rad 10) [1 0 0])
(rotate (deg2rad -23) [0 1 0])
(rotate (deg2rad -3) [0 0 1])
(rotate (deg2rad 10) [0 0 1])
(translate thumborigin)
(translate [-10 -16 0])
(translate [-12 -16 3])
))
(defn thumb-tl-place [shape]
(->> shape
; (rotate (deg2rad 10) [1 0 0])
; (rotate (deg2rad -23) [0 1 0])
; (rotate (deg2rad -3) [0 0 1])
(rotate (deg2rad 10) [1 0 0])
(rotate (deg2rad -23) [0 1 0])
(rotate (deg2rad -3) [0 0 1])
(rotate (deg2rad 10) [0 0 1])
(translate thumborigin)
(translate [-30 -15 -2])))
(translate [-32 -15 -2])))
(defn thumb-mr-place [shape]
(->> shape
(rotate (deg2rad -6) [1 0 0])
@@ -434,30 +447,31 @@
(defn bottom [height p]
(->> (project p)
(extrude-linear {:height height :twist 0 :convexity 0})
(translate [0 0 (/ height 2)])))
(translate [0 0 (- (/ height 2) 10)])))
(defn bottom-hull [& p]
(hull p (bottom 10.001 p)))
(hull p (bottom 0.001 p)))
(def wall-offset -15)
(def wall-thickness 2) ; originally 5
(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 5) (* dy1 5) -4] post1))
(place1 (translate [(* dx1 5) (* dy1 5) wall-offset] post1))
(place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) -4] post1))
(place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) wall-offset] post1))
(place2 post2)
(place2 (translate [0 0 wall-offset] post2))
(place2 (translate [(* dx2 5) (* dy2 5) -4] post2))
(place2 (translate [(* dx2 5) (* dy2 5) wall-offset] post2)))
(place2 (translate [(* dx2 wall-thickness) (* dy2 wall-thickness) -4] post2))
(place2 (translate [(* dx2 wall-thickness) (* dy2 wall-thickness) wall-offset] post2)))
(bottom-hull
(place1 (translate [(* dx1 5) (* dy1 5) wall-offset] post1))
(place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) wall-offset] post1))
(place1 (translate [0 0 wall-offset] post1))
(place1 (translate [(* dx1 5) (* dy1 5) wall-offset] post1))
(place1 (translate [(* dx1 wall-thickness) (* dy1 wall-thickness) wall-offset] post1))
(place2 (translate [0 0 wall-offset] post2))
(place2 (translate [(* dx2 5) (* dy2 5) wall-offset] post2)))))
(place2 (translate [(* dx2 wall-thickness) (* dy2 wall-thickness) wall-offset] 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
@@ -519,7 +533,7 @@
(translate [0 (/ mount-height 2) wall-offset])
))))
(def rj9-vertical-offset (- (last (key-position 0 0 [0 (/ mount-height 2) 0])) 40))
(def rj9-vertical-offset (- (last (key-position 0 0 [0 (/ mount-height 2) 0])) 35))
(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
@@ -527,34 +541,38 @@
(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-offset-height 5)
(def teensy-vertical-offset )
(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
(on-wall-place 0 rj9-vertical-offset
(on-wall-place 0 teensy-vertical-offset
(translate [-5 0 0]
(union
(->> (cube 3 (* 1.2 teensy2-length) (+ 6 teensy-width))
(translate [-1.5 -30 0]))
(->> (cube teensy-pcb-thickness (* 1.2 teensy2-length) 3)
(translate [(/ teensy-pcb-thickness 2) -30 (- -1.5 (/ teensy-width 2))]))
(->> (cube 4 (* 1.2 teensy2-length) 4)
(translate [(+ 2 teensy-pcb-thickness) -30 (- -1 (/ teensy-width 2))]))
(->> (cube teensy-pcb-thickness (* 0.2 teensy2-length) 3)
(translate [(/ teensy-pcb-thickness 2) (+ (* 0.5 teensy2-length) -30) (+ 1.5 (/ teensy-width 2))]))
(->> (cube 4 (* 0.2 teensy2-length) 4)
(translate [(+ 2 teensy-pcb-thickness) (+ (* 0.5 teensy2-length) -30) (+ 1 (/ teensy-width 2))]))
(->> (cube 3 teensy-holder-length (+ 6 teensy-width))
(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))]))
(->> (cube 4 teensy-holder-length 4)
(translate [(+ 2 teensy-pcb-thickness) 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))]))
(->> (cube 4 teensy-holder-top-length 4)
(translate [(+ 2 teensy-pcb-thickness) teensy-holder-top-offset (+ 1 (/ teensy-width 2))]))
))))
(def usb-cutout
(let [hole-height 6.2
(let [hole-height 7.5
side-radius (/ hole-height 2)
hole-width 10.75
hole-width 12
side-cylinder (->> (cylinder side-radius teensy-length)
(with-fn 20)
(translate [(/ (- hole-width hole-height) 2) 0 0]))]
@@ -562,10 +580,13 @@
(mirror [-1 0 0] side-cylinder))
(rotate (/ π 2) [1 0 0])
(rotate (/ π 2) [0 1 0])
(on-wall-place 0 rj9-vertical-offset))))
(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]))))
(defn hex-spacer [column row radius height]
(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)
@@ -576,55 +597,74 @@
is-vertical (or shift-left shift-right)
col-angle (+ (* β (- centercol column)) (/ π 12))
row-angle (* α (- row centerrow))]
(->> (cylinder radius height)
(rotate (if is-vertical (/ π 6) 0) [0 0 1])
(->> (union (cylinder [bottom-radius top-radius] height)
(translate [0 0 (/ height 2)] (sphere top-radius)))
(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])
(with-fn 6))))
0]))))
(defn hex-spacer-shapes [radius height]
(union (hex-spacer 0 0 radius height)
(hex-spacer 0 cornerrow radius height)
(hex-spacer 3 lastrow radius height)
(hex-spacer 3 0 radius height)
(hex-spacer lastcol (dec cornerrow) radius height)
(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)
(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)
))
(def hex-spacer-height 10)
(def hex-spacer-radius (/ 5.42 2))
(def hex-spacer-holes (hex-spacer-shapes hex-spacer-radius hex-spacer-height))
(def hex-spacer-outers (hex-spacer-shapes (+ hex-spacer-radius 1.6) (+ hex-spacer-height 1.6)))
(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)))
;; teensy info
; base width - 18
; height - 1.45
;
(spit "things/right.scad"
(write-scad (union
key-holes
connectors
thumb
thumb-connectors
(difference (union case-walls hex-spacer-outers)
rj9-space
usb-cutout
hex-spacer-holes)
rj9-holder
(if (= nrows 4) teensy-holder)
; thumbcaps
; caps
)))
(write-scad (difference
(union
key-holes
connectors
thumb
thumb-connectors
(difference (union case-walls
screw-insert-outers
(if (= nrows 4) teensy-holder))
rj9-space
usb-cutout
screw-insert-holes)
rj9-holder
; thumbcaps
; caps
)
(translate [0 0 -20] (cube 350 350 40))
; (translate [0 0 -50] (cube 5 5 20))
)))
(spit "things/test.scad"
(write-scad (intersection (translate [29 -5 0] (cube 30 30 30))
(difference (union case-walls hex-spacer-outers)
hex-spacer-holes)
(difference (union case-walls screw-insert-outers)
screw-insert-holes)
)))
; (spit "things/test.scad"
; (write-scad screw-insert-holes))
; (spit "things/test-half.scad"
; (write-scad (difference
; (union
; key-holes
; connectors
; thumb
; thumb-connectors
; (difference (union case-walls screw-insert-outers)
; ; rj9-space
; usb-cutout
; screw-insert-holes)
; ; rj9-holder
; ; (if (= nrows 4) teensy-holder)
; )
; (translate [0 0 -5] (cube 350 350 40))
; )))