case.scad

   1 /* TODO
   2 - vybrani pro otevreni
   3 - mozna sirsi misto na baterku?
   4 - vetsi vybrani pro baterku ve vicku
   5 - kuzelova dira pro tlacitka
   6 - jine diry pro uchyceni
   7 - zvetsit vybrani na strane tlacitek
   8 - mozna prilis velky klip zasunovaciho konce baterky
   9 - diry pro neizolovany drat muzou byt mensi
  10 - sirsi zakladna
  11 - mensi horni cast klipu baterky - pri 0.7 je sirka nahore 16 mm.
  12 */
  13
  14 lowres = 1;
  15
  16 eps = 0.01;
  17 infty = 300;
  18
  19 wall = 1.5; // generic wall thickness
  20
  21 // 18650 is ~18mm diameter, ~65mm length,
  22 batt_diam = 18 + 0.6;
  23 batt_len = 65 + 1.5;
  24
  25 cable_sep = 2.5;
  26
  27 // front flat area
  28 front_flat_len = batt_len + 2*wall + 2*cable_sep;
  29
  30 // PCB-related dimensions
  31 pcb_len = 36 + 1;       // length of the board
  32 pcb_width = 11 + 0.5;   // width of the board
  33 pcb_thick = 1.2 + 0.3;  // thickness of the board
  34 pcb_comp_h = 2.2;       // height of the components on board
  35 pcb_groove = 0.5;
  36
  37 body_top_h = 0.30 * batt_diam; // cube-shaped part of the body
  38
  39 wire_thick = 2.2;
  40 wire_sep = 3.5;
  41 cable_out_diam = 5.2;
  42
  43 pcbside_protrusion_len = 20;
  44 pcbside_protrusion_diam = 2.5;
  45 battside_protrusion_len = 10;
  46 battside_protrusion_diam = 2;
  47
  48 base_batt_extend = wall + pcb_thick; // extend the base on the battery side
  49
  50 cover_sep = 0.1;
  51
  52 sw_diam = 2.5 + 0.5;
  53 led_diam = 3 + 0.5;
  54 sw_xoff =  250 * 25.4/1000; // x offset of microswitches
  55
  56 pcb_clip_w = 7;
  57 pcb_clip_off = led_xoff + pcb_clip_w/2;
  58
  59
  60 module battery() {
  61         translate([-batt_len/2, 0, 0])
  62                 rotate([0, 90, 0])
  63                 cylinder(r=batt_diam/2, h = batt_len);
  64 };
  65
  66 module case_body() {
  67         hull() {
  68                 translate([-batt_len/2-wall-cable_sep, -batt_diam/2-wall, 0])
  69                         cube([batt_len + 2*wall + 2*cable_sep,
  70                                 batt_diam+2*wall, body_top_h]);
  71                 difference() {
  72                         translate([-batt_len/2-wall-cable_sep, 0, 0])
  73                                 rotate([0, 90, 0])
  74                                 cylinder(r=batt_diam/2+wall,
  75                                         h = batt_len + 2*wall + 2*cable_sep);
  76                         translate([-infty/2, -infty/2, eps]) cube(infty);
  77                 };
  78                 translate([-front_flat_len/2,
  79                         batt_diam/2 - pcb_width,
  80                         -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
  81                         cube([front_flat_len, pcb_width+wall, eps]);
  82 /*
  83                 translate([-batt_len/2 - 2*wall - cable_sep, 0, 0])
  84                         rotate([0, 90, 0])
  85                         cylinder(r = 1.414*wire_sep + wire_thick,
  86                                 h = batt_len + 4*wall + 2*cable_sep);
  87 */
  88         };
  89 };
  90
  91 module case() {
  92         difference() {
  93                 case_body();
  94                 // upper cube-shaped part
  95                 // rotate([20, 0, 0])
  96                 translate([-batt_len/2, -batt_diam/2, 0])
  97                         cube([batt_len, batt_diam, batt_diam]);
  98
  99                 // battery cylinder for the lower part
 100                 translate([-batt_len/2, 0, 0])
 101                         rotate([0, 90, 0])
 102                         cylinder(r=batt_diam/2, h = batt_len);
 103
 104                 // hole for PCB
 105                 translate([-pcb_len/2,
 106                         batt_diam/2-pcb_width,
 107                         -batt_diam/2-pcb_thick - pcb_comp_h])
 108                         cube([pcb_len, pcb_width,
 109                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 110                 // hole under the PCB
 111                 translate([-pcb_len/2+pcb_groove,
 112                         batt_diam/2-pcb_width + pcb_groove,
 113                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 114                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 115                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 116                 // LED hole
 117                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 118                         cylinder(r=led_diam/2, h=infty, $fn=6);
 119                         translate([sw_xoff, 0, 0])
 120                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 121                         translate([-sw_xoff, 0, 0])
 122                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 123                 };
 124                 // space under the wire holes for battery contacts
 125                 translate([-batt_len/2-wall-cable_sep-eps, 0, 0])
 126                         difference() {
 127                                 rotate([0, 90, 0])
 128                                         cylinder(r = batt_diam/2-wall, h = batt_len + 2*wall + 2*cable_sep + 2*eps);
 129                                 translate([-infty/2, -infty/2, -body_top_h])
 130                                         cube(infty);
 131                         };
 132                 // wire holes for battery contacts
 133                 for (x = [-1, 1])
 134                 for (y = [-1, 1])
 135                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 136                         rotate([0, 90, 0])
 137                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 138                 // wire hole from PCB to battery contacts
 139                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
 140                 rotate([40, 0, 0])
 141                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 142                         rotate([0, 90, 0])
 143                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 144                 // hole behind the battery contacts
 145                 for(x=[1, -1])
 146                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
 147                         translate([0, -batt_diam/2, 0])
 148                                 cube([cable_sep + eps, batt_diam, infty]);
 149                         rotate([0, 90, 0])
 150                                 cylinder(r = batt_diam/2, h = cable_sep+eps);
 151                         translate([0, batt_diam/2 - pcb_width,
 152                                 -batt_diam/2-pcb_comp_h-pcb_thick])
 153                                 cube([cable_sep + eps, pcb_width, eps]);
 154                 };
 155         };
 156 };
 157
 158 module lid_body() {
 159         translate([-batt_len/2 + eps, -batt_diam/2, -batt_diam/2-eps])
 160                 cube([batt_len - 2*eps, batt_diam, batt_diam/2 - body_top_h + wall + eps]);
 161         translate([-batt_len/2 - wall - cable_sep, -batt_diam/2 - wall,
 162                 -batt_diam/2-wall])
 163                 cube([batt_len + 2*wall + 2*cable_sep, batt_diam + 2*wall,
 164                         wall + batt_diam/2 - body_top_h]);
 165         // clip behind the battery contacts
 166         for(x=[1, -1])
 167                 scale([x, 1, 1]) translate([batt_len/2+cable_sep, 0, 0]) hull() {
 168                         translate([0, -batt_diam/2, -batt_diam/2])
 169                                 cube([wall, batt_diam, eps]);
 170                         rotate([0, 90, 0])
 171                                 cylinder(r = batt_diam/2, h = wall);
 172                         translate([0, batt_diam/2 - pcb_width,
 173                                 batt_diam/2+pcb_comp_h+pcb_thick])
 174                                 cube([wall, pcb_width, eps]);
 175                 };
 176 };
 177
 178 module lid() {
 179         difference() {
 180                 lid_body();
 181                 translate([-batt_len/2-eps, 0, 0]) rotate([0, 90, 0])
 182                         cylinder(r=batt_diam/2, h=batt_len+2*eps);
 183         };
 184 };
 185
 186 /*
 187 color("lightblue", 0.2)
 188         translate([-65/2, 0, 0])
 189         rotate([0, 90, 0])
 190         cylinder(r=18/2, h=65);
 191 */
 192 translate([0, 30, 0]) case($fn=128);
 193 lid($fn=128);
 194
 195