include <../core.scad>

function hinge_width(type) = type[1]; //! Width

function hinge_depth(type) = type[2]; //! Depth of each leaf

function hinge_thickness(type) = type[3]; //! Thickness of the leaves

function hinge_pin_dia(type) = type[4]; //! The pin diameter

function hinge_knuckle_dia(type) = type[5]; //! The knuckle diameter

function hinge_knuckles(type) = type[6]; //! How many knuckles

function hinge_screw(type) = type[7]; //! Screw type to mount it

function hinge_screws(type) = type[8]; //! How many screws

function hinge_clearance(type) = type[9]; //! Clearance between knuckles

function hinge_margin(type) = type[10]; //! How far to keep the screws from the knuckes

function hinge_radius(type) = washer_radius(screw_washer(hinge_screw(type))) + 1;

module hinge_screw_positions(type) { //! Place children at the screw positions

screws = hinge_screws(type);

w = hinge_width(type);

d = hinge_depth(type);

r = hinge_radius(type);

m = hinge_margin(type);

assert(screws > 1, "must be at least two screws");

w_pitch = (w - 2 * r) / (screws - 1);

d_pitch = d - 2 * r - m;

wr = washer_radius(screw_washer(hinge_screw(type)));

assert(w_pitch >= wr && norm([w_pitch, d_pitch]) >= 2 * wr && d_pitch >= 0, "not enough room for screws");

for(i = [0 : screws - 1])

translate([-w / 2 + r + i * w_pitch, r + m + (i % 2) * d_pitch])

children();

}

module hinge_male(type, female = false) { //! The half with the stationary pin

stl(str("hinge_", female ? "fe": "", "male_", type[0]));

r = hinge_radius(type);

w = hinge_width(type);

t = hinge_thickness(type);

kr = hinge_knuckle_dia(type) / 2;

pr = hinge_pin_dia(type) / 2;

assert(kr > pr, "knuckle diameter must be bigger than the pin diameter");

n = hinge_knuckles(type);

assert(n >= 3, "must be at least three knuckes");

mn = ceil(n / 2); // Male knuckles

fn = floor(n / 2); // Female knuckles

gap = hinge_clearance(type);

mw = (w - (n - 1) * gap) / 2 / mn; // Male knuckle width

fw = (w - (n - 1) * gap) / 2 / fn; // Female knuckle width

teardrop_r = kr / cos(22.5); // The corner on the teardrop

inset = sqrt(sqr(teardrop_r + gap) - sqr(kr - t)) - kr;

linear_extrude(height =t)

difference() {

hull() {

for(side = [-1, 1])

translate([side * (w / 2 - r), hinge_depth(type) - r])

circle4n(r);

translate([-w / 2, inset])

square([w, eps]);

}

hinge_screw_positions(type)

poly_circle(screw_clearance_radius(hinge_screw(type)));

}

pitch = mw + gap + fw + gap;

dir = female ? -1 : 1;

translate([0, -kr, kr])

rotate([90, 0, -90])

for(z = [0 : (female ? fn : mn) - 1])

translate_z(-dir * w / 2 + z * dir * pitch + (female ? -fw - mw - gap : 0))

linear_extrude(height = female ? fw : mw)

difference() {

hull() {

rotate(180)

teardrop(r = kr, h = 0);

translate([-kr - 1, -kr])

square(1);

}

teardrop_plus(r = pr + (female ? gap : 0), h = 0);

}

}

module hinge_female(type) hinge_male(type, true);

module hinge_both(type) { //! Both parts together for printing

hinge_male(type);

translate([0, -hinge_knuckle_dia(type)])

rotate(180)

hinge_female(type);

}

module hinge_assembly(type, angle = 0)

assembly(str("hinge_", type[0])) { //! Assembled hinge

kr = hinge_knuckle_dia(type) / 2;

hr = hinge_pin_dia(type) / 2;

w = hinge_width(type);

vitamin(str(": Hinge pin ", w, " x ", 2 * hr, "mm"));

color(pp1_colour) hinge_male(type);

translate([0, -kr, kr]) {

rotate([0, 90, 0])

explode(w + 10)

color("silver") cylinder(r = hr , h = w, center = true);

rotate([-angle, 0, 0])

translate([0, -kr, -kr])

rotate(180)

color(pp2_colour) hinge_female(type);

}

}

module hinge_fastened_assembly(type, thickness1, thickness2, angle, show_hinge = true) { //! Assembled hinge with its fasteners

if(show_hinge)

hinge_assembly(type, angle);

screw = hinge_screw(type);

washer_t = 2 * washer_thickness(screw_washer(screw));

nut = screw_nut(screw);

nut_t = nut_thickness(nut, true);

t = hinge_thickness(type);

kr = hinge_knuckle_dia(type) / 2;

module fasteners(thickness)

if(thickness)

hinge_screw_positions(type) {

translate_z(t)

screw_and_washer(screw, screw_longer_than(t + thickness + washer_t + nut_t));

translate_z(-thickness)

vflip()

nut_and_washer(nut, true);

}

fasteners(thickness1);

translate([0, -kr, kr])

rotate([-angle, 0, 0])

translate([0, -kr, - kr])

rotate(180)

fasteners(thickness2);

}