include <body.scad>
include <body_config.scad>
include <helpers.scad>
include <holes.scad>

// 80 35 15

// screw holes on back plate
// 42.5 47.5

// back plate height from profile 47, thickness 10
// full h 67
back_plate_s = [80, 10, 67];
bps = back_plate_s;
// dist bitw back plate and back screw holder 26
bp_bsh_dist = 26;

// openscad y is scanner z, and wise versa
back_screw_holder_s = [80, 15, 35];
bshs = back_screw_holder_s;

// for base part mounted on profiles
base_wall_thickness = 10;
bwt = base_wall_thickness;

side_wall_s = [bwt, 65, 55];
sws = side_wall_s;

limit_switch_pcb_s = [40, 17, 1.6];
ls_pcb_s = limit_switch_pcb_s;

carriage_s = [80, 50, 32];
// scanner coords
carriage_top_y_offset = 56;
carriage_z_pos = 240;

module profile_20x20x50()
{
    scale([1, 1, 10])
    translate([-0.06, -61, -10])
    import("Modular profile 20x20 - 973094/files/Profilo_20x20_L50.stl");
}

module calibration_template()
{
    zo = 5;
    cs = carriage_s;
    // TODO: create a global var for this
    lhs = laser_holder_size();
    
    top_s = [bshs[0] + bwt * 2, sws[1], wt * 2];
    cut_s = [main_frame_width_x, sws[1] * 2, wt + $tiny_padding * 2];
    
    // decrease if there are some reflections
    adjustment_z = -0;
    
    translate([0, carriage_z_pos + carriage_s[1] - 5, lhs[2] / 2])
    translate([0, top_s[1] / 2, cut_s[2] / 2 + bshs[2] + bwt + wt])
    // arranged: should switch from triangles to surface
    // by rotating by 180 around scanner z axis
    translate([0, 0, adjustment_z])
    union()
    {        
        // centered
        rotate([0, 180, 0])
        {
            color("green", 0.3)
            translate([-125, 0, zo])
            translate([85, -50, -5.8])
            rotate([-90, 0, 0])
            rotate([0, 90, 0])
            import("calibration_template.stl");
        }
        
        {
            color("blue", 0.3)
            translate([-125, 0, zo])
            translate([85, -54, -5.8])
            rotate([-90, 0, 0])
            rotate([0, 90, 0])
            import("calibration_template.stl");
        }
        
        color("blue")
        {
            x_offsets = [-30, 0, 30];
            y_offsets = [0, 4];
            
            for (xo = x_offsets, yo = y_offsets)
            {
                translate([xo, -cs[1] + 0.45 + yo, 0])
                cylinder($fn = dToFn(m3), d = m3, h = 100, center = true);
            }
        }
    }
}

module calibration_template_holder()
{
    cs = carriage_s;
    
    calibration_template_holder_s = [cs[0], cs[1], 8];
    cths = calibration_template_holder_s;
    
    yo = cs[1] / 2 + carriage_z_pos;
    //zo = -cs[2] / 2 - 20 + carriage_top_y_offset;// + cs[2];
    zo = - 20 + carriage_top_y_offset + cths[2] / 2;


    difference()
    {
        translate([0, yo, zo])
        {
            color("orange", 0.5)
            cube(cths, center = true);
            
            top_cube_s = [cths[0], 13, 10.5];
            tcs = top_cube_s;
            
            color("red", 0.5)
            translate([-tcs[0] / 2, -3, 4])
            cube(tcs);
        }
        
        //color("red")
        translate([0, 0, cths[2] / 2])
        carriage_screw_holes();
    }
}

module calibration_template_holder_to_print()
{
    difference()
    {
        calibration_template_holder();
        calibration_template();
    }
}


// hot inserts for m4 are not needed;
// d_padding - diameter delta. can be set to 0
// if cutting a thread with a screw is needed, and
// to 0.5 for just a screw hole
module m4_screw_hole(hole_side, d_padding = 0.5)
{
    screw_hole(
        m = m4 + 0.2,
        id = m4 + 0.5,
        il = 15,
        hd = m4_head_diameter + 1,
        hh = m4_head_height,
        hs = hole_side);
}

module base_side_screw_holes()
{
    // right x offset
    rxo = bshs[0] / 2 + bwt - m4_head_height;
    lxo = -rxo;
    // back y offset
    byo = sws[1] * 1 / 8;
    fyo = sws[1] * 7 / 8;
    zo = -20 / 2;
    
    translate([lxo, byo, zo])
    m4_screw_hole(hole_side_left);

    translate([lxo, fyo, zo])
    m4_screw_hole(hole_side_left);

    translate([rxo, byo, zo])
    m4_screw_hole(hole_side_right);

    translate([rxo, fyo, zo])
    m4_screw_hole(hole_side_right);
}

limit_switch_pcb_screw_hole_d = 3.5;
lspshd = limit_switch_pcb_screw_hole_d;
// dist betw holes 19 14
// dist betw hole side and short qpcb side = 1-1.1,
// and 1.3 for long pcb side
ls_pcb_h_delta_long = 1.3;
ls_pcb_h_delta_short = 1.1;
ls_pcb_h_delta_btw_holes = 19;

// 56
// w 80 d 50 h 32

module carriage_screw_holes(d_padding)
{
    cs = carriage_s;
    yo = cs[1] / 2 + carriage_z_pos;
    zo = -cs[2] / 2 - 20 + carriage_top_y_offset;
    
    // scanner coords
    distance_between_holes_x = 60;
    distance_between_holes_z = 30;
    dbhx = distance_between_holes_x;
    dbhz = distance_between_holes_z;
    
    translate([0, yo, zo])
    {
        for (xo = [-dbhx / 2, dbhx / 2], yo = [-dbhz / 2, dbhz / 2])
        {
            translate([xo, yo, cs[2] / 2])
            m4_screw_hole(hole_side_top, d_padding = d_padding);
        }
    }
}

module carriage()
{

// carriage_top_z_offset
    cs = carriage_s;
    yo = cs[1] / 2 + carriage_z_pos;
    zo = -cs[2] / 2 - 20 + carriage_top_y_offset;


    difference()
    {
        translate([0, yo, zo])
        {
            color("grey", 0.5)
            cube(carriage_s, center = true);
        }
        
        //color("red")
        carriage_screw_holes();
    }
}

// limit switch designed by makerbot.com
// instructions: www.bigtree-tech.com
// license: GPLv3
module limit_switch()
{
    translate([0, -ls_pcb_s[1] / 2, 0])
    union()
    {
        limit_switch_size = [13, 6.5, 6.5];
        lss = limit_switch_size;
        // pcb
        color("red", 0.7)
        translate([0, 0, -ls_pcb_s[2] / 2])
        cube(ls_pcb_s, center = true);
        
        // switch itself
        
        // 6.5
        lss_xo = lss[0] / 2 - ls_pcb_s[0] / 2 + 6.5;
        lss_yo = -lss[1] / 2 + ls_pcb_s[1] / 2;
        lss_zo = -lss[2] / 2 - ls_pcb_s[2] / 2;
        color("black", 0.7)
        translate([lss_xo, lss_yo, lss_zo])
        cube(lss, center = true);
    }
    
    d = lspshd;
    x_delta = ls_pcb_h_delta_short;
    y_delta = ls_pcb_h_delta_long;
    xd = d / 2 - ls_pcb_s[0] / 2 + x_delta;
    yd = -d / 2 - y_delta;
    
    // screw holes
    color("green", 0.4)
    union()
    {
        translate([xd, yd, 0])
        cylinder($fn = dToFn(d), d = d, h = 4, center = true);
        
        translate([xd + ls_pcb_h_delta_btw_holes, yd, 0])
        cylinder($fn = dToFn(d), d = d, h = 4, center = true);
    }
    
    // holes to cut
    color("blue", 0.4)
    {
        m3_id = m3_hole_insert_diameter;
        m3_h = m3_hole_insert_height;
        translate([xd, yd, m3_h / 2])
        cylinder($fn = dToFn(m3_id), d = m3_id, h = m3_h, center = true);
        
        translate([xd + ls_pcb_h_delta_btw_holes, yd, m3_h / 2])
        cylinder($fn = dToFn(m3_id), d = m3_id, h = m3_h, center = true);
    }
}

module base()
{
    // base
    color("orange", 0.4)
    {
        // left wall
        translate([-sws[0] / 2 - bshs[0] / 2, sws[1] / 2, sws[2] / 2 - 20])
        cube(sws, center = true);
        
        // right wall
        translate([sws[0] / 2 + bshs[0] / 2, sws[1] / 2, sws[2] / 2 - 20])
        cube(sws, center = true);
        
        // top wall
        top_s = [bshs[0] + bwt * 2, sws[1], bwt];
        translate([0, top_s[1] / 2, top_s[2] / 2 + bshs[2]])
        cube(top_s, center = true);
    }
}

module stand()
{
    // back plate/motor holder
    color("black", 0.5)
    translate([0, -bps[1] / 2, bps[2] / 2 - 20])
    cube(bps, center = true);

    // back screw holder
    color("black", 0.5)
    translate([0, bshs[1] / 2 + bp_bsh_dist, bshs[2] / 2])
    cube(bshs, center = true);

    // profiles base
    color("grey")
    {
        translate([-(bshs[0] - 20) / 2, 0, -20 / 2])
        rotate([-90, 0, 0])
        profile_20x20x50();

        translate([(bshs[0] - 20) / 2, 0, -20 / 2])
        rotate([-90, 0, 0])
        profile_20x20x50();
    }
}

module stand_top_m3_holes()
{
    m3_id = m3_hole_insert_diameter;
    m3_h = m3_hole_insert_height;
    
    rxo = bshs[0] / 2 + bwt / 2;
    lxo = -rxo;
    
    for (xo = [rxo, lxo], yo = [sws[1] * 1 / 6, sws[1] * 3 / 6, sws[1] * 5 / 6])
    {
        translate([xo, yo, -20 + sws[2] + bwt + $tiny_padding])
        cylinder($fn = dToFn(m3_id), d = m3_id, h = m3_h * 2, center = true);
    }
}

module stand_top_m3_screw_holes()
{
    m3_id = m3_hole_insert_diameter;
    m3_h = m3_hole_insert_height;
    
    rxo = bshs[0] / 2 + bwt / 2;
    lxo = -rxo;
    
    
    for (xo = [rxo, lxo], yo = [sws[1] * 1 / 6, sws[1] * 3 / 6, sws[1] * 5 / 6])
    {
        translate([xo, yo, -20 + sws[2] + bwt + $tiny_padding])
        //cylinder($fn = dToFn(m3_id), d = m3_id, h = m3_h * 2, center = true);
        scale([1, 1, 2])
        screw_hole(
            m = m3,
            id = m3_hole_insert_diameter,
            il = m3_hole_insert_height * 2,
            hd = m3_head_diameter,
            hh = m3_head_height,
            hs = hole_side_top);
    }
}

module base_to_print()
{
    difference()
    {
        base();
        translate([0, sws[1], -20 + sws[2]])
        limit_switch();
        base_side_screw_holes();
        stand_top_m3_holes();
    }
}

module scanner_side_hole_cutters()
{
    id = 4;
    
    side_offsets = [
        back_bottom_side_hole_offset + [0, 0, 0],
        back_top_side_hole_offset + [0, 0, 0],
        top_side_hole_offset + [0, -id, -id],
        front_bottom_side_hole_offset + [0, -id * 2, 0],
        front_top_side_hole_offset + [0, -id * 2, 0]
    ];
    
    // left x offset
    lxo = -main_frame_width_x / 2;
    rxo = -lxo;
    
    color("red")
    //translate([0, 0, 0])
    translate([0, wt, 0])
    
    for (so = side_offsets)
    {
        translate(so + [lxo, 0, 0])
        screw_hole(
            m = m2,
            id = 4,
            il = m2_hole_insert_height * 2,
            hd = m2_head_diameter,
            hh = m2_head_height,
            hs = hole_side_left);
            
        translate(so + [rxo, 0, 0])
        screw_hole(
            m = m2,
            id = 4,
            il = m2_hole_insert_height * 2,
            hd = m2_head_diameter,
            hh = m2_head_height,
            hs = hole_side_right);
    }
}

module scanner_holder()
{
    top_s = [bshs[0] + bwt * 2, sws[1], wt * 2];
    cut_s = [main_frame_width_x, sws[1] * 2, wt + $tiny_padding * 2];
    
    difference()
    {
        color("green", 0.3)
        translate([0, top_s[1] / 2, top_s[2] / 2 + bshs[2] + bwt])
        cube(top_s, center = true);
        
        
        color("red", 0.3)
        translate([0, top_s[1] / 2, cut_s[2] / 2 + bshs[2] + bwt + wt])
        cube(cut_s, center = true);
    }
}

module scanner_holder_to_print()
{
    difference()
    {
        scanner_holder();
        stand_top_m3_screw_holes();
    }
}

module visualize_stand()
{
    carriage();

    calibration_template();
    calibration_template_holder();
    *calibration_template_holder_to_print();

    stand();

    union()
    {
        base();
        translate([0, sws[1], -20 + sws[2]])
        limit_switch();
        base_side_screw_holes();
        stand_top_m3_holes();
    }



    translate([0, -back_wall_offset + wt, -20 + sws[2] + bwt + wt])
    translate([0, 0, laser_holder_size()[2] / 2 + wt])
    {
        scanner_side_hole_cutters();

        color("yellow", 0.2)
        body_to_print();
        color("green", 0.3)
        
        visualize_range();
        visualize_xz_range();

    }

    //stand_top_m3_holes();
    //stand_top_m3_screw_holes();

    color("grey", 0.6)
    base_to_print();

    //scanner_holder();
    scanner_holder_to_print();
}

visualize_stand();