"""Lay the seven lids out on the inside of the cupboard door, with their clips, and work out the backboard and the bars that carry the clips. Writes diagrams/door-layout.svg (both versions side by side) and cad/layout.scad (positions for the OpenSCAD assembly). Run from the project folder: python3 diagrams/door_layout.py Door coordinates, mm: x from the hinge edge, y down from the top, seen from inside. """ import itertools, math, time L = {"L7": 215, "L3": 195, "L2": 192, "L6": 190, "L1": 173, "L4": 150, "L5": 150} DOOR = (495, 715) FRAME = 70 # Carcass opening C1 464 x C2 684, centred across; the base panel (18) sits at the # door's bottom edge, so the cupboard floor is 18 up from it and the opening top 13 down. X0, X1, Y0, Y1 = 15.5, 479.5, 13, 697 EDGE = 4 # keep everything this far inside the opening HINGES = [(0, 75, 45, 125), (0, 75, 590, 670)] # Titus plates, full width of the hinge stile # The shelf: 20 thick, C4 328 from the floor (top or underside unknown, so allow both), # only 55 behind the door there. A lid stands ~85 off the door at the handle, so only # its outer ring (RING mm in from the rim: rim, glass and clip, under 40) may cross it. SHELF = (715 - 18 - 348 - 5, 715 - 18 - 308 + 5) RING = 35 GAP = 8 # rim to rim HW_GAP = 3 # clip to anything # Clip heads, relative to the rim point they hold (must match cad/lid-clips.scad) HOOK_W, HOOK_UP, HOOK_DOWN = 30, 14, 6 # above the top of the rim / overlapping it CRADLE_W, CRADLE_UP, CRADLE_DOWN = 56, 7, 5 # lip over the rim / base below it # Bars (cad/lid-clips.scad): ends screwed into the stiles BAR_H, BAR_X = 24, (20, 475) # the bar heights in layout.scad were chosen with 24; bars are now 30 (cad/lid-clips.scad), still clear of the hinges STEM_MAX = 45 # furthest a clip head sits from its bar def heads(x, y, r): """Rectangles (x0, x1, y0, y1) of a lid's hook and cradle.""" top, bot = y - r, y + r return [(x - HOOK_W / 2, x + HOOK_W / 2, top - HOOK_UP, top + HOOK_DOWN), (x - CRADLE_W / 2, x + CRADLE_W / 2, bot - CRADLE_UP, bot + CRADLE_DOWN)] def rect_circle(rc, x, y, r): a, b, c, d = rc return math.hypot(x - min(max(x, a), b), y - min(max(y, c), d)) < r def rect_rect(p, q, g): return p[0] < q[1] + g and q[0] < p[1] + g and p[2] < q[3] + g and q[2] < p[3] + g def fits(x, y, r, placed): if y - (r - RING) < SHELF[1] and y + (r - RING) > SHELF[0]: return False if any(rect_circle(h, x, y, r + 3) for h in HINGES): return False hs = heads(x, y, r) for h in hs: if h[0] < X0 + EDGE or h[1] > X1 - EDGE or h[2] < Y0 + EDGE or h[3] > Y1 - EDGE: return False if any(rect_rect(h, k, 3) for k in HINGES): return False for _, px, py, pr in placed: if math.hypot(x - px, y - py) < r + pr + GAP: return False for q in heads(px, py, pr): if rect_circle(q, x, y, r + HW_GAP) or any(rect_rect(h, q, HW_GAP) for h in hs): return False if any(rect_circle(h, px, py, pr + HW_GAP) for h in hs): return False return True def pack(order, step=4): placed = [] for n in order: r = L[n] / 2 spot = None for y in range(int(Y0 + r), int(Y1 - r) + 1, step): for x in range(int(X1 - r), int(X0 + r) - 1, -step): if fits(x, y, r, placed): spot = (n, x, y, r) break if spot: break if not spot: return None placed.append(spot) return placed def bar_ok(yc): band = (yc - BAR_H / 2, yc + BAR_H / 2) if band[0] < Y0 + EDGE or band[1] > Y1 - EDGE: return False return not any(band[0] < h[3] + 3 and h[2] - 3 < band[1] for h in HINGES) def choose_bars(layout): """Fewest bar heights so every clip head is within STEM_MAX of one (greedy cover).""" targets = sorted([(y - r - HOOK_UP / 2, n, "hook") for n, x, y, r in layout] + [(y + r + CRADLE_DOWN / 2, n, "cradle") for n, x, y, r in layout]) bars, i = [], 0 while i < len(targets): t = targets[i][0] yc = next((c for c in range(int(t + STEM_MAX), int(t - STEM_MAX) - 1, -1) if bar_ok(c)), None) assert yc is not None, f"no bar can reach {targets[i]}" bars.append(yc) while i < len(targets) and abs(targets[i][0] - yc) <= STEM_MAX: i += 1 return bars def backboard(): """Board outline: the opening less EDGE, notched round the hinges.""" x0, x1, y0, y1 = 20, 475, 17, 693 (_, hx, a0, a1), (_, _, b0, b1) = HINGES hx += 5 return [(x0, a1 + 5), (hx, a1 + 5), (hx, y0), (x1, y0), (x1, y1), (hx, y1), (hx, b0 - 5), (x0, b0 - 5)] def search(names, budget=120): """First packing found over orderings of names, or None after budget seconds.""" t0 = time.time() for order in itertools.permutations(sorted(names, key=lambda n: -L[n])): found = pack(order) if found or time.time() - t0 > budget: return found layout = search(L) if not layout: print("all seven don't fit with their clips; trying six") for drop in sorted(L, key=lambda n: L[n]): layout = search([n for n in L if n != drop], 60) if layout: print("left off the door:", drop) break assert layout, "nothing fits" bars = choose_bars(layout) board = backboard() for n, x, y, r in layout: print(f"{n}: Ø{2*r:.0f} centre ({x}, {y})") print("bars at y =", bars) # which bar each clip hangs off, and how far its head sits from it clips = [] for n, x, y, r in layout: for kind, ty in (("hook", y - r), ("cradle", y + r)): mid = ty - HOOK_UP / 2 if kind == "hook" else ty + CRADLE_DOWN / 2 yc = min(bars, key=lambda b: abs(b - mid)) clips.append((n, kind, x, ty, yc, ty - yc)) for c in clips: print(" {} {:6} x {:5.1f} rim y {:6.1f} bar {:4d} stem {:+6.1f}".format(*c)) assert all(abs(c[5]) <= STEM_MAX + HOOK_UP for c in clips) # ---- cad/layout.scad ---- with open("cad/layout.scad", "w") as f: f.write("// Generated by diagrams/door_layout.py; do not edit by hand.\n") f.write("// Door coordinates: x from the hinge edge, y down from the top.\n") f.write("lids = [" + ", ".join(f'["{n}", {x}, {y}, {2*r}]' for n, x, y, r in layout) + "];\n") f.write("bars = " + str(bars) + ";\n") f.write("bar_x = " + str(list(BAR_X)) + ";\n") f.write("clips = [" + ", ".join(f'["{n}", "{k}", {x}, {ty}, {yc}]' for n, k, x, ty, yc, _ in clips) + "];\n") f.write("board = " + str([list(p) for p in board]) + ";\n") # ---- SVG: backboard on the left, bars on the right ---- W, H = DOOR s = [f'', f''] for ox, title in ((0, "A · Backboard"), (W + 40, "B · Printed bars")): g = [f'', f'{title}', f'', f'', f'', f''] for a, b, c, d in HINGES: g.append(f'') if ox == 0: g.append('') else: for yc in bars: g.append(f'') for n, x, y, r in layout: g.append(f'') g.append(f'{n}') for a, b, c, d in heads(x, y, r): g.append(f'') if ox: for n, k, x, ty, yc, dy in clips: hy = ty - HOOK_UP / 2 if k == "hook" else ty + CRADLE_DOWN / 2 if abs(hy - yc) > BAR_H / 2: g.append(f'') g.append("") s += g s.append(f'495 × 715 door seen from inside, hinges (pink) on the left. Dashed: cupboard opening. ' 'Grey band: the shelf behind (55 clear).') s.append(f'Orange: clips (hook above each lid, cradle below). A: clips stuck/screwed to a {board[3][0]-board[0][0]} wide ' f'aluminium board. B: {len(bars)} printed bars, stile to stile, clips on stems.') s.append("") open("diagrams/door-layout.svg", "w").write("\n".join(s))