battery-1.scad

   1 eps = 0.01;
   2 infty = 200;
   3
   4 // 2x 10180
   5 // batt_d_real = 10;
   6 // batt_l = 36 + 0.5;
   7
   8 // 2x 18650 side by side
   9 batt_d_real = 18;
  10 batt_l = 65 + 1.5;
  11
  12 batt_sep = 0.65;
  13
  14 wall = 1;
  15
  16 batt_d = batt_d_real + batt_sep;
  17
  18 wire_sep = 1.5;
  19 wire_w = 3;
  20 wire_h = 1.5;
  21
  22 body_h = 0.8*batt_d_real;
  23 cyl_center_h = batt_l/3;
  24
  25 // z-offset from the widest point of the battery to the widest
  26 // point of the clip
  27 top_clip_h = 0.25*batt_d;
  28
  29 spring_sep = 0.7;
  30 // outer part of the spring
  31 d_out = batt_d/2-spring_sep/2;
  32 // inner part of the spring
  33 d_in = d_out/2-wall/2-spring_sep/2; // batt_d/4-3*wall/4;
  34 // straight part length
  35 straight_l = batt_l + 3*wall/2 + d_out/2;
  36
  37 module cyl_arc(d, h, beg, end) {
  38         difference() {
  39                 cylinder(r = d/2+wall/2, h = h, $fn = 64);
  40                 translate([0, 0, -eps])
  41                         cylinder(r = d/2-wall/2, h=h+2*eps, $fn = 64);
  42                 if (end-beg > 180) {
  43                         intersection() {
  44                                 rotate([0, 0, beg])
  45                                         scale([1, -1, 1])
  46                                         translate([-infty/2, 0, -eps])
  47                                         cube(infty);
  48                                 rotate([0, 0, end])
  49                                         translate([-infty/2, 0, -eps])
  50                                         cube(infty);
  51                         }
  52                 } else {
  53                         union() {
  54                                 rotate([0, 0, beg])
  55                                         scale([1, -1, 1])
  56                                         translate([-infty/2, 0, -eps])
  57                                         cube(infty);
  58                                 rotate([0, 0, end-180])
  59                                         scale([1, -1, 1])
  60                                         translate([-infty/2, 0, -eps])
  61                                         cube(infty);
  62                         }
  63                 }
  64         }
  65 }
  66
  67
  68 // main box
  69 module main_box() {
  70         difference() {
  71                 translate([-batt_d/2-wall, 0, 0])
  72                         cube([batt_d + 2*wall, straight_l, body_h]);
  73                 // upper part at the - pole
  74                 translate([-batt_d/2, wall, batt_d/2])
  75                         cube([batt_d, (batt_l-cyl_center_h)/2, batt_d + 2*eps]);
  76                 // the battery itself
  77                 translate([0, wall, batt_d_real/2])
  78                 rotate([-90, 0, 0])
  79                         cylinder(r = batt_d/2, h = straight_l, $fn = 64);
  80                 // upper part of the clip
  81                 translate([0, wall, batt_d_real/2+2*top_clip_h])
  82                 rotate([-90, 0, 0])
  83                         cylinder(r = batt_d/2, h = straight_l, $fn = 64);
  84                 // upper part at the + pole
  85                 translate([-batt_d/2, wall+(batt_l-cyl_center_h)/2+cyl_center_h, batt_d/2])
  86                         cube([batt_d, (batt_l-cyl_center_h)/2, batt_d + 2*eps]);
  87                 // at the clip - sides only
  88                 translate([-batt_d/2, batt_l, -eps])
  89                         cube([batt_d, straight_l-batt_l+eps, batt_d + 2*eps]);
  90
  91         }
  92 }
  93
  94 // spring, x-axis cenered, to be connected by y-minus axis
  95 module spring() {
  96         for (x = [-1, 1]) scale([x, 1, 1]) {
  97                 // outmost d_out arc
  98                 translate([d_out/2+wall/2+spring_sep/2, 0, 0])
  99                         cyl_arc(d_out, body_h, 0-eps, 180+eps);
 100                 // inner center d_in arc
 101                 translate([spring_sep/2+wall/2+d_in/2, 0, 0])
 102                         cyl_arc(d_in, body_h, 180, 360+eps);
 103                 // outer center d_in arc
 104                 translate([spring_sep/2+wall/2+3*d_in/2, 0, 0])
 105                         cyl_arc(d_in, body_h, -eps, 180+eps);
 106                 // innermost d_out arc
 107                 translate([2*d_in+wall/2+spring_sep/2-d_out/2, 0, 0])
 108                         cyl_arc(d_out, body_h, 270-eps, 360+eps);
 109         }
 110         // center beam
 111         translate([-2*d_in-spring_sep/2-wall/2+d_out/2, -d_out/2-wall/2, 0])
 112                 cube([4*d_in+spring_sep+wall-d_out, wall, body_h]);
 113 }
 114
 115 module holder()
 116 {
 117         difference() {
 118                 union() {
 119                         main_box();
 120                         translate([0, straight_l, 0])
 121                                 spring();
 122                 }
 123
 124                 for (z = [batt_d_real/2-wire_h-wire_sep/2,
 125                         batt_d_real/2+wire_sep/2]) {
 126                         translate([-wire_w/2, -eps, z])
 127                                 cube([wire_w, batt_l+2*wall+2*eps, wire_h]);
 128                 }
 129         }
 130 }
 131
 132 holder();
 133 translate([batt_d+wall, straight_l + d_out/2, 0])
 134 scale([1, -1, 1])
 135         holder();
 136