From: Jan "Yenya" Kasprzak <kas@fi.muni.cz>
Date: Mon, 28 Oct 2013 21:18:09 +0000 (+0100)
Subject: Merge branch 'master' of ssh://calypso.fi.muni.cz/home/kas/html/git/bike-lights
X-Git-Url: https://www.fi.muni.cz/~kas/git//home/kas/public_html/git/?p=bike-lights.git;a=commitdiff_plain;h=74c8418108d14042c710aedcc0b9d0f0331c142f;hp=6d9e2053eb39ebbe70df69c1faf3384ac2aa99fa

Merge branch 'master' of ssh://calypso.fi.muni.cz/home/kas/html/git/bike-lights
---

diff --git a/firmware/ambient.c b/firmware/ambient.c
index b1b726c..37aaa77 100644
--- a/firmware/ambient.c
+++ b/firmware/ambient.c
@@ -34,8 +34,8 @@ static ambient_zone_t ambient_zones[N_AMBIENT_ZONES] = {
 #else
 	{ 0x0000, 0x0250 }, // dark
 	{ 0x0230, 0x02e0 }, // evening
-	{ 0x02c0, 0x0304 }, // dawn
-	{ 0x02fc, 0xffff }, // day
+	{ 0x02c0, 0x0302 }, // dawn
+	{ 0x02fa, 0xffff }, // day
 #endif
 };
 
diff --git a/parts/rearlight.scad b/parts/rearlight.scad
new file mode 100644
index 0000000..938c381
--- /dev/null
+++ b/parts/rearlight.scad
@@ -0,0 +1,364 @@
+// Holder for Fraen FHS-HEB1-LB01-x lens for Luxeon LEDs.
+// I use it for my rear lights.
+
+epsilon = 0.01;
+infty = 100;
+debug = 0;
+
+heatsink_thickness = 2.5;
+heatsink_width = 18-3.4;
+heatsink_length = 58;
+
+module fraen_lens_pin() {
+	cylinder(r=4/2, h=23, $fn=32);
+	translate([epsilon, 0, -5])
+		cylinder(r=3.4/2, h=5+epsilon);
+};
+
+module fraen_lens() {
+	cylinder(r1=6, r2=30.9/2, h=23);
+	assign(off=10.35) {
+	translate([off, off, 0])   fraen_lens_pin();
+	translate([off, -off, 0])  fraen_lens_pin();
+	translate([-off, off, 0])  fraen_lens_pin();
+	translate([-off, -off, 0]) fraen_lens_pin();
+	};
+};
+
+module heatsink() {
+	translate([-heatsink_length+ 5 +heatsink_width/2, -heatsink_width/2, 0])
+		cube([heatsink_length, heatsink_width, heatsink_thickness]);
+}
+
+module seat_holder() {
+	translate([-41, 8, 29])
+		cube([3, 30, 60], center=true);
+};
+
+module stem_ellipse(h, w, x, y) {
+	translate([x, y, 0])
+	difference() {
+		translate([0, 0, 6])
+			scale([1, w/2, h-6])
+				rotate([0, 90, 0])
+					cylinder(r=1, h=epsilon);
+		translate([0, 0, -100]) cube([200, 200, 200], center=true);
+	};
+}
+
+module main() {
+	difference() {
+		union() {
+			hull() {
+				cylinder(r=34/2, h=33);
+				stem_ellipse(h = 15, w = 10, x = -21, y=-5);
+			};
+			hull() {
+				stem_ellipse(h = 15, w = 10, x = -21-epsilon, y=-5);
+				stem_ellipse(h = 15, w = 10, x = -33, y=-5);
+			};
+			hull() {
+				stem_ellipse(h = 15, w = 10, x = -33-epsilon, y=-5);
+				stem_ellipse(h = 25, w = 15, x = -40+epsilon, y=-2.5);
+			};
+			translate([-41, 5, 52/2])
+				cube([7, 30, 52], center=true);
+			// bolt hole ring
+			translate([-44+epsilon, 10, 40]) rotate([0, -90, 0]) difference() {
+				cylinder(r1=9, r2=6, h=3);
+				translate([0, 0, -epsilon])
+					cylinder(r=5, h=3+2*epsilon, $fn=6);
+			}
+			// screw hole ring
+			translate([-38-epsilon, 10, 40]) rotate([0, 90, 0]) difference() {
+				cylinder(r1=9, r2=6, h=3);
+				translate([0, 0, -epsilon])
+					cylinder(r=5, h=3+2*epsilon);
+			}
+		};
+		translate([-47, 10, 40]) rotate([0, 90, 0])
+			cylinder(r=2.5, h=12);
+		translate([0, 0, 6-heatsink_thickness])
+			cylinder(r=31/2, h=32);
+		translate([0, 0, 6])
+			fraen_lens();
+		heatsink();
+		seat_holder();
+	}
+	if (debug == 1) {
+		translate([0, 0, 6]) color("gray") fraen_lens();
+		color("lightblue") heatsink();
+		color("lightgreen") seat_holder();
+	}
+}
+
+module bolt_mount(d, h, w1, w2, fn) {
+	difference() {
+		translate([0, 0, -epsilon])
+			cylinder(r1=w2/2, r2=w1/2, h=h+epsilon);
+		translate([0, 0, -2*epsilon])
+		cylinder(r=d/2, h=h+3*epsilon, $fn=fn);
+	};
+};
+
+clip_h1 = 25; // inner height
+clip_h2 = 18; // inner height
+clip_l  = 35;
+clip_wall = 2;
+clip_space = 4;
+clip_bolt1_x = 10;
+clip_bolt2_x = 25;
+
+module clip_top_circle() {
+	rotate([-90, 0, 0])
+	difference() {
+		translate([-clip_space/2, 0, 0])
+			cylinder(r=clip_wall, h = epsilon, $fn=32);
+		translate([-infty/2, clip_wall/2-epsilon, -epsilon])
+			cube(infty);
+		translate([clip_wall+epsilon, -infty/2, -epsilon])
+			cube(infty);
+	};
+};
+
+module clip_top() {
+	hull() {
+		translate([0, 0, clip_h1/2+clip_wall])
+			clip_top_circle();
+		translate([0, clip_l-epsilon, clip_h2/2+clip_wall])
+			clip_top_circle();
+	};
+};
+
+module seat_clip() {
+	difference() {
+		polyhedron(points = [
+			[-clip_wall-clip_space/2, 0, clip_h1/2+clip_wall],
+			[-clip_wall-clip_space/2, clip_l, clip_h2/2+clip_wall],
+			[-clip_wall-clip_space/2, clip_l, -clip_h2/2],
+			[-clip_wall-clip_space/2, 0, -clip_h1/2],
+			[ clip_wall+clip_space/2,  0, clip_h1/2+clip_wall],
+			[ clip_wall+clip_space/2, clip_l, clip_h2/2+clip_wall],
+			[ clip_wall+clip_space/2, clip_l, -clip_h2/2],
+			[ clip_wall+clip_space/2, 0, -clip_h1/2],
+		], triangles = [
+			[0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
+			[0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
+			[1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
+		]);
+		polyhedron(points = [
+			[-clip_space/2, -epsilon, clip_h1/2],
+			[-clip_space/2, clip_l+epsilon, clip_h2/2],
+			[-clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
+			[-clip_space/2, -epsilon, -clip_h1/2-epsilon],
+			[ clip_space/2, -epsilon, clip_h1/2],
+			[ clip_space/2, clip_l+epsilon, clip_h2/2],
+			[ clip_space/2, clip_l+epsilon, -clip_h2/2-epsilon],
+			[ clip_space/2, -epsilon, -clip_h1/2-epsilon],
+		], triangles = [
+			[0, 2, 1], [3, 2, 0], [4, 5, 6], [6, 7, 4],
+			[0, 1, 5], [5, 4, 0], [2, 3, 7], [7, 6, 2],
+			[1, 2, 6], [6, 5, 1], [0, 7, 3], [7, 0, 4],
+		]);
+		// bolt holes
+		translate([0, clip_bolt1_x, 0])
+			rotate([0, 90, 0])
+			translate([0, 0, -clip_wall-clip_space/2-epsilon])
+			cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
+				$fn = 6);
+		translate([0, clip_bolt2_x, 0])
+			rotate([0, 90, 0])
+			translate([0, 0, -clip_wall-clip_space/2-epsilon])
+			cylinder(r=2, h=2*clip_wall+clip_space+2*epsilon,
+				$fn=6);
+	};
+
+	translate([-clip_space, clip_bolt1_x, 0])
+	rotate([0, -90, 0])
+	bolt_mount(6, 3, 7, 14, 6);
+
+	translate([-clip_space, clip_bolt2_x, 0])
+	rotate([0, -90, 0])
+	bolt_mount(6, 3, 7, 14, 6);
+
+	translate([clip_space, clip_bolt1_x, 0])
+	rotate([0, 90, 0])
+	bolt_mount(6, 3, 7, 14, 128);
+
+	translate([clip_space, clip_bolt2_x, 0])
+	rotate([0, 90, 0])
+	bolt_mount(6, 3, 7, 14, 128);
+
+	clip_top();
+};
+
+/*
+seat_clip();
+
+difference() {
+	union() {
+		hull() {
+			translate([40, epsilon, 2])
+				clip_top();
+			clip_top();
+		};
+
+		translate([40, 0, 25])
+			rotate([-90, 0, 0])
+				cylinder(r=34/2, h=clip_l);
+
+		hull() {
+			translate([clip_space/2+epsilon, 0, 0])
+				cube([clip_wall-epsilon, clip_wall, clip_h1/2+2*clip_wall-epsilon]);
+			translate([40, 0, 14+epsilon])
+				cube([clip_wall-epsilon, clip_wall, 34/2]);
+		};
+	};
+	translate([40, 6, 25])
+		rotate([-90, 0, 0]) {
+			cylinder(r=31/2, h=clip_l);
+			fraen_lens();
+			heatsink();
+		};
+};
+*/
+
+wall_thickness = 1.5;
+fraen_diam = 30.75;
+fraen_h = 29.8;
+pin_diam = 4;
+pin_offset = 10.35*1.4142;
+pin_len = 9.2;
+front_add = 4;
+
+side_barrier_x_offset = 13;
+side_barrier_pin_z_offset = 4.2;
+side_barrier_thickness = 2;
+
+module round_part() {
+	difference() {
+		cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
+			h = front_add + pin_len + wall_thickness);
+		translate([0, 0, -epsilon])
+			cylinder(r = fraen_diam/2,
+			h = pin_len + wall_thickness + front_add + 2*epsilon);
+		// front cone
+		translate([0, 0, pin_len + 1.5*wall_thickness - epsilon])
+			cylinder(r1 = fraen_diam/2,
+				r2 = (fraen_diam+pin_diam + wall_thickness)/2,
+				h = front_add + 2*epsilon);
+		// pin holes
+		for (angle = [0, 90, 180, 270]) {
+			rotate([0, 0, angle+45])
+				translate([pin_offset, 0, wall_thickness-epsilon])
+					cylinder(r=pin_diam/2,
+						h=pin_len+epsilon, $fn=32);
+		};
+	};
+
+	// side barriers
+	for (angle = [0, 90, 180]) // omit the bottom one
+		rotate([0, 0, angle])
+			intersection() {
+				cylinder(r=fraen_diam/2+epsilon, h=infty);
+				translate([-infty/2, side_barrier_x_offset,
+					wall_thickness + pin_len - side_barrier_pin_z_offset - side_barrier_thickness ])
+					cube([infty, infty, side_barrier_thickness]);
+		};
+};
+
+module square_cone() {
+	difference() {
+		hull() {
+			translate([0, 0, fraen_h - pin_len - wall_thickness])
+				cylinder(r = fraen_diam/2 + pin_diam/2 + wall_thickness,
+					h = epsilon);
+			for (angle = [0, 90, 180, 270])
+				rotate([0, 0, angle])
+					translate([9, 9, 0])
+						cylinder(r=wall_thickness+3.5/2, h = epsilon);
+		}
+		hull() {
+			translate([0, 0, fraen_h - pin_len - wall_thickness+epsilon])
+				cylinder(r = fraen_diam/2,
+					h = epsilon);
+			for (angle = [0, 90, 180, 270])
+				rotate([0, 0, angle])
+					translate([9, 9, -epsilon])
+						cylinder(r=3.5/2, h = epsilon);
+		}
+	}
+}
+
+rear_spring_w = 4;
+
+module rear_spring() {
+	translate([0, 0, wall_thickness/2])
+		cube([18+2*wall_thickness+3.5, rear_spring_w, wall_thickness], center=true);
+	difference() {
+		rotate([90, 0, 0])
+			translate([0, 0, -rear_spring_w/2])
+			cylinder(r=6-heatsink_thickness, h = rear_spring_w);
+		translate([0, 0, -infty/2+epsilon])
+			cube(infty, center=true);
+	};
+};
+
+module heatsink_holder() {
+	for (angle = [0, 180]) {
+		rotate([0, 0, angle])
+			translate([9+wall_thickness, 0, 6/2])
+			cube([3.5/2+wall_thickness, 2*9-3.5-0.5, 6], center=true);
+	}
+}
+
+module lens_holder() {
+	difference() {
+		union() {
+			translate([0, 0, fraen_h - pin_len - wall_thickness])
+				round_part();
+			square_cone();
+		};
+		
+		// 0.5mm hole in the bottom
+		// translate([side_barrier_x_offset-epsilon, -0.25, -epsilon])
+		translate([0, -0.25, (fraen_h - pin_len - wall_thickness)/2])
+			cube([infty, 0.5, infty]);
+
+		// cable hole, 2*3mm
+		translate([9, 0, 6+3])
+			rotate([0, 0, 60])
+				cube([infty, 2, 3]);
+	};
+		
+	rear_spring();
+	heatsink_holder();
+};
+
+lens_holder($fn = 128);
+
+translate([20, 40, 0])
+	rotate([90, 0, -90])
+		seat_clip(, $fn=128);
+
+hull() {
+	translate([0, 9+3.5/2+epsilon, wall_thickness/2])
+		cube([2*9+3.5, epsilon, wall_thickness], center=true);
+	translate([20-clip_wall/2, 40-clip_space/2-clip_wall+epsilon, wall_thickness/2])
+		cube([clip_h1+clip_wall, epsilon/2, wall_thickness], center=true);
+};
+
+translate([7.5, 13.3, 0])
+	cube([wall_thickness, 23, fraen_h - pin_len - wall_thickness]);
+
+	// vnitrni prumer kruhu by mel byt 30.75mm
+	// vnejsi prumer aspon 35 mm
+	// pin od stredu 10.35mm na x a y
+	// prumer pinu 4 mm
+	// pin ma od cela do zabrany 4.2mm, celkove by mel mit 9.2mm
+
+	// piny by mely pokracovat jeste tak 4mm pod nulu,
+	// a pak uz muze jit konv.obal do ctverce
+	// vnitrni rozmery ctverce 21.5x21.5, zakulacene rohy prumer 3.5
+	// vrch chladice (s LEDkou) -18.5
+	// konec nozicek -24.5
diff --git a/parts/statuslights.scad b/parts/statuslights.scad
new file mode 100644
index 0000000..e46673b
--- /dev/null
+++ b/parts/statuslights.scad
@@ -0,0 +1,157 @@
+debug = 1;
+tube_diam = 25;
+tube_angle = 35;
+view_angle = 15;
+
+wall = 2;
+led_w = 3;
+screw_hole = 3.5;
+screw_head = 5;
+screw_base = 3;
+epsilon=0.01;
+
+module outer_shape() {
+	difference() {
+		hull() {
+			translate([-26, 0, 5])
+			rotate([0, -70, 0])
+			scale([2, 1, 1])
+				cylinder(r=6, h=1);
+
+			scale([1, 1, 1/2])
+				sphere(r=tube_diam/2, center=true);
+		}
+
+		translate([0, 0, -100+epsilon])
+			cube(200, center=true);
+
+		translate([-25, 0, 0])
+			rotate([0, -35, 0])
+			translate([-100, 0, 0])
+			cube(200, center=true);
+	}
+}
+
+module inner_shape() {
+	difference() {
+		hull() {
+			translate([-26-epsilon, 0, 5])
+			rotate([0, -70, 0])
+			scale([2.5, 1, 1])
+				cylinder(r=4, h=1);
+
+			scale([1, 1, 1/2])
+				sphere(r=tube_diam/2 - 4, center=true);
+		}
+
+		translate([0, 0, 2+-100+epsilon])
+			cube(200, center=true);
+
+		translate([-22, 0, 0])
+			rotate([0, -35, 0])
+			translate([-100, 0, 0])
+			cube(200, center=true);
+	}
+}
+
+module screw_hole(d1, d2, z_base) {
+	union() {
+		// body
+		translate([0, 0, -epsilon])
+			cylinder(r=d1/2, h=z_base + 2*epsilon);
+		// head
+		translate([0, 0, z_base])
+			cylinder(r=d2/2, h=20);
+	}
+}
+
+module front_hole() {
+	difference() {
+		inner_shape();
+		translate([-35, 0, 0])
+		rotate([0, view_angle + tube_angle, 0])
+		translate([100, 0, 0]) cube([200, 200, 200], center=true);
+	}
+}
+
+module inner_hole() {
+	intersection() {
+		inner_shape();
+
+		translate([-32, 0, 0])
+		rotate([0, view_angle + tube_angle, 0])
+		translate([100, 0, 0]) cube([200, 200, 200], center=true);
+
+		translate([-27, 0, 0])
+		rotate([0, 20, 0])
+		translate([100, 0, 0]) cube([200, 200, 200], center=true);
+
+		translate([-108, 0, 0]) cube([200, 200, 200], center=true);
+	}
+}
+
+module cable_hole() {
+	translate([-10, 0, -epsilon])
+	difference() {
+		cylinder(r=6.5, h=3);
+		translate([12-epsilon, 0, 0]) cube(20, center=true);
+	}
+}
+
+module tube() {
+	// presmykacova trubka
+	color("grey") {
+		rotate([0, -tube_angle, 0])
+		translate([0, 0, -50])
+		cylinder(r=tube_diam/2, h=50);
+	}
+}
+
+module led(h, w, h1, w1) {
+	union() {
+		translate([0, 0, h-w/2])
+			sphere(r=w/2, $fn=64);
+		cylinder(r=w/2, h=h-w/2, $fn=64);
+		translate([0, 0, -h1])
+			cylinder(r=w1/2, h=h1+epsilon, $fn=64);
+	}
+}
+
+module illum_led() {
+	translate([-24, 0, 3])
+	rotate([0, 180+tube_angle, 0])
+		led(h=5,w=3.5,h1=2,w1=4);
+};
+
+module status_led() {
+	translate([-21, 0, 8.5])
+	rotate([0, 270+view_angle+tube_angle, 0])
+		led(h=5,w=3.5,h1=2,w1=4);
+}
+
+module main() {
+	difference() {
+		outer_shape();
+		screw_hole(d1=4, d2=8, z_base=4);
+		front_hole();
+		inner_hole();
+		cable_hole($fn=8);
+		status_led();
+		illum_led();
+	};
+};
+
+if (debug == 1) {
+	rotate([0, -tube_angle, 0]) {
+		difference() {
+			main($fn=16);
+			translate([0, -100, 0]) cube([200, 200, 200], center=true);
+		};
+		color("red") status_led();
+		color("deepskyblue") illum_led();
+	};
+	color("gray") tube();
+} else {
+	main($fn=32);
+}
+