From 721b1a77dd7d9870827226a1db7307e4eca2634d Mon Sep 17 00:00:00 2001
From: David Phillips <david@yeah.nah.nz>
Date: Mon, 4 Nov 2019 20:58:04 +1300
Subject: Initial rough working of light

This initial patch adds a draft of the light with a version of the 133mm
diameter pin-based heatsink available from China, cut down to 90mm. This is
just a placeholder for now.

No fan has been modelled either, just a simple placeholder cylinder.

No placeholder has been inserted for wiring, circuit board, sockets, controls
and so on.
---
 led-light.scad | 160 +++++++++++++++++++++++++++++++++++++++++++++++++++++++++
 1 file changed, 160 insertions(+)
 create mode 100644 led-light.scad

diff --git a/led-light.scad b/led-light.scad
new file mode 100644
index 0000000..e641401
--- /dev/null
+++ b/led-light.scad
@@ -0,0 +1,160 @@
+/*
+ * LED light - 2k lumen luminaire designed around Cree XLamp 17 W modules
+ */
+
+$fn = 50;
+
+module xlamp(bs, led) {
+    translate([-bs/2, -bs/2, 0])
+        cube([bs, bs, 1]);
+
+    translate([0, 0, 1]) {
+        color([1, 0.9, 0])
+            cylinder(d=led-1, h=0.4);
+
+        cylinder(d=led, h=0.3);
+    }
+}
+
+module xlamp_clamp() {
+    diam = 44;
+    height = 3.4;
+    difference() {
+        /* main body */
+        cylinder(d=diam, h=height);
+
+        union() {
+            hole_diam = 3;
+            hole_spac = 35;
+            /* mounting holes */
+            translate([-hole_spac / 2, 0, -1]) cylinder(d=hole_diam, h=height+2);
+            translate([ hole_spac / 2, 0, -1]) cylinder(d=hole_diam, h=height+2);
+
+            /* main bore for LED */
+            translate([0, 0, -1]) cylinder(d=16, h=height+2);
+
+            /* bore taper */
+            translate([0, 0, pcb_dz]) cylinder(d1=16, d2=21, h=height - pcb_dz + 0.01);
+
+            /* retaining well for LED board
+               FIXME rotation not correct*/
+            pcb_dz = 1;
+            pcb_dx = 18;
+            pcb_dy = 18;
+            rotate([0, 0, -26]) translate([-pcb_dx / 2, -pcb_dy / 2, -1]) cube([pcb_dx, pcb_dy, pcb_dz + 1]);
+        }
+    }
+}
+
+module diffuser(d, h, standoff_h, diff_col, bolt_col, standoff_col) {
+    bolt_diam = 5;
+    bolt_h = 2;
+    bolt_from_edge = 4;
+
+    module bolthead(con) {
+        translate([con, 0, 0])
+            scale([bolt_diam, bolt_diam, bolt_h])
+                sphere(d=1);
+    }
+
+    module standoff(d, h, con) {
+         translate([con, 0, 0])
+            cylinder(d=d, h=h);
+    }
+
+    /* diffuser hardware (standoffs, bolts) */
+    for (theta = [0 : 120 : 360]) {
+        rotate([0, 0, theta]) {
+            con = d / 2 - bolt_from_edge;
+            color(bolt_col)
+                translate([0, 0, standoff_h])
+                    bolthead(con=con);
+
+            color(standoff_col)
+                standoff(d=bolt_diam, h=standoff_h, con=con);
+        }
+    }
+
+    /* Diffuser plate. Needs to come last for correct alpha */
+    color(diff_col) {
+        translate([0, 0, standoff_h - h]) {
+            cylinder(d=d, h=h);
+        }
+    }
+}
+
+module outer_case(di, h, wt) {
+    difference() {
+        cylinder(d=di+2*wt, h=h);
+        translate([0, 0, -1])
+            cylinder(d=di, h=h+2);
+    }
+}
+
+module heatsink_style_pins(d, h, bt) {
+    con_factor = 7;
+    count_factor = 7;
+
+    module pin(d, h, con) {
+        translate([con, 0, 0])
+            cylinder(d=d, h=h);
+    }
+
+    module pins_ring(d, h, n) {
+        count = n * count_factor;
+        con = n * con_factor;
+        deg = 360/count;
+        for (theta = [0 : deg : 360]) {
+        rotate([0, 0, theta])
+            pin(d=d, h=h, con=con);
+        }
+    }
+
+    cylinder(d=d, h=bt);
+    translate([0, 0, bt]) {
+        pd = 2;
+        ph = h - bt;
+        rows = (d / 2 - pd) / con_factor;
+        for (i = [0 : rows]) {
+            pins_ring(pd, ph, i);
+        }
+    }
+}
+
+/* entire luminaire */
+{
+    color([0.2, 0.2, 0.2])
+        outer_case(di=100, h=130, wt=3);
+
+    /* fan */
+    fan_h = 20;
+    #cylinder(d=90, h=fan_h);
+
+    /* FIXME circuit board, controls */
+
+    /* heatsink and gear mounted to it */
+    heatsink_h = 50;
+    translate([0, 0, heatsink_h + fan_h]) {
+        mirror([0, 0, 1]) {
+            /* heatsink */
+            color([0.2, 0.2, 0.2])
+                heatsink_style_pins(d=90, h=heatsink_h, bt=10);
+        }
+
+        /* LED plus clamp */
+        {
+            rotate([0, 0, -26])
+                xlamp(bs=18, led=16);
+
+            color([0.9, 0.9, 0.9])
+                xlamp_clamp();
+        }
+
+        /* diffuser */
+        diffuser(d=90, h=3, standoff_h=50,
+            diff_col=[0.8, 0.8, 0.8, 0.7], /* temporarily set opacity down */
+            bolt_col=[0.6, 0.6, 0.6],
+            standoff_col=[0.6, 0.6, 0.3]);
+    }
+}
+
-- 
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