case.scad: alternative mounting holes, thicker side clips, clip pretension
[heater.git] / case.scad
1 lowres = 0; // fast rendering or fine printing with print-friendly orientation
2
3 eps = 0.01;
4 infty = 300;
5
6 wall = 1.5; // generic wall thickness
7
8 // 18650 is ~18mm diameter, ~65mm length, 
9 batt_diam = 18 + 1.0;
10 batt_len = 65 + 2.0;
11
12 cable_sep = 2;
13
14 // front flat area
15 front_flat_len = batt_len + 4*wall + 2*cable_sep;
16
17 // PCB-related dimensions
18 pcb_len = 36 + 1;       // length of the board
19 pcb_width = 11 + 0.5;   // width of the board
20 pcb_thick = 1.2 + 0.3;  // thickness of the board
21 pcb_comp_h = 2.2;       // height of the components on board
22 pcb_groove = 1;
23
24 body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
25
26 wire_thick = 2.2;
27 wire_sep = 3.5;
28
29 batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
30
31 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
32
33 sw_diam = 2.5 + 0.5;
34 led_diam = 3 + 0.5;
35 sw_xoff =  250 * 25.4/1000; // x offset of microswitches
36 pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
37
38 prg_len = 10; // programming connector
39 prg_width = 7;
40
41 outcable_h = 4.5;
42 outcable_w = 2.5;
43
44 // mounting cylinder + holes
45 mounthole_w = 5;
46 mounthole_h = 3;
47 mountcyl_w = mounthole_w + 4*wall;
48 mountcyl_h = 2*wall;
49 mountcone_h = mounthole_h + 2*wall;
50
51 clip_pretension = 0.5;
52
53 module case_body() {
54         hull() {
55                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
56                         cube([batt_len + 4*wall + 2*cable_sep,
57                                 batt_diam+2*wall, body_top_h]);
58                 difference() {
59                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
60                                 rotate([0, 90, 0])
61                                 cylinder(r=batt_diam/2+wall,
62                                         h = batt_len + 4*wall + 2*cable_sep);
63                         translate([-infty/2, -infty/2, eps]) cube(infty);
64                 };
65                 translate([-front_flat_len/2,
66                         batt_diam/2 - pcb_width,
67                         -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
68                         cube([front_flat_len, pcb_width+wall, eps]);
69         };
70         // mounting cylinders
71         for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
72                 batt_diam/2+wall, 0]) {
73                         translate([0, 0, -batt_diam/2-wall-2*pcb_comp_h-pcb_thick])
74                                 mount_cyl(); // front
75                         translate([0, 0, body_top_h]) // rear
76                                 scale([1, 1, -1])
77                                 mount_cyl();
78         };
79 };
80
81 module mount_cyl() {
82         assign(h = mounthole_h+wall)
83         hull () {
84                 translate([0, -mountcyl_w/2+mounthole_h + wall])
85                         cylinder(r = mountcyl_w/2, h = mountcyl_h);
86                 assign(l = 2*sqrt(h*(mountcyl_w-h)))
87                 translate([-l/2, 0, mountcyl_h + mountcone_h])
88                         cube([l, eps, eps]);
89         };
90 };
91         
92 module case() {
93         difference() {
94                 case_body();
95                 // upper cube-shaped part
96                 // rotate([20, 0, 0])
97                 translate([-batt_len/2, -batt_diam/2, 0])
98                         cube([batt_len, batt_diam, batt_diam]);
99
100                 // battery cylinder for the lower part
101                 translate([-batt_len/2, 0, 0])
102                         rotate([0, 90, 0])
103                         cylinder(r=batt_diam/2, h = batt_len);
104
105                 // hole for PCB
106                 translate([-pcb_len/2-pcb_xoff,
107                         batt_diam/2-pcb_width,
108                         -batt_diam/2-pcb_thick - pcb_comp_h])
109                         cube([pcb_len, pcb_width,
110                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
111                 // hole above the PCB for the outgoing cable
112                 translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
113                         batt_diam/2-pcb_width,
114                         -batt_diam/2-pcb_comp_h])
115                         cube([pcb_len, pcb_width,
116                                 batt_diam/2 + pcb_comp_h + eps]);
117                 // cable outlet
118                 translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
119                         -pcb_width+batt_diam/2,
120                         -batt_diam/2-outcable_h])
121                         cube([outcable_w, infty, outcable_h]);
122                 // hole under the PCB
123                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
124                         batt_diam/2-pcb_width + pcb_groove,
125                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
126                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
127                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
128                 // hole for prog connector
129                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
130                         batt_diam/2-pcb_width/2-prg_width/2,
131                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
132                         difference() {
133                                 cube([prg_len+pcb_groove+eps, prg_width,
134                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
135                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
136                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
137                         };
138                 // LED hole
139                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
140                         cylinder(r=led_diam/2, h=infty, $fn=6);
141                         translate([sw_xoff, 0, 0])
142                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
143                         translate([-sw_xoff, 0, 0])
144                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
145                 };
146                 // space under the wire holes for battery contacts
147                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
148                         difference() {
149                                 rotate([0, 90, 0])
150                                         cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
151                                 translate([-infty/2, -infty/2, -batt_end_h])
152                                         cube(infty);
153                         };
154                 // space above the wire holes for battery contacts
155                 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
156                         cube([batt_len + 4*wall + 2*cable_sep + 2*eps, 
157                                 batt_diam,
158                                 batt_end_h]);
159                 // wire holes for battery contacts
160                 for (x = [-1, 1])
161                 for (y = [-1, 1])
162                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
163                         rotate([0, 90, 0])
164                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
165                 // wire hole from PCB to battery contacts
166                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
167                 rotate([40, 0, 0])
168                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
169                         rotate([0, 90, 0])
170                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
171                 // hole behind the battery contacts
172                 for(x=[1, -1])
173                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
174                         translate([0, -batt_diam/2, 0])
175                                 cube([wall + cable_sep + eps, batt_diam, infty]);
176                         rotate([0, 90, 0])
177                                 cylinder(r = batt_diam/2, h = wall+cable_sep+eps);
178                         translate([0, batt_diam/2 - pcb_width,
179                                 -batt_diam/2-pcb_comp_h-pcb_thick])
180                                 cube([wall + cable_sep + eps, pcb_width, eps]);
181                         translate([cable_sep, batt_diam/2 - pcb_width + wall,
182                                 -batt_diam/2-pcb_comp_h-pcb_thick-wall])
183                                 cube([wall + eps, pcb_width-2*wall, eps]);
184                 };
185                 // cable lead to battery contacts
186                 for (x=[1, -1]) scale([x, 1, 1])
187                         rotate([-140, 0, 0])
188                         translate([batt_len/2+wire_thick/2, 0, batt_diam/2-2.7])
189                                 cylinder(r=wire_thick/2, h = 5.4);
190                 
191                 // mounting holes
192                 for(x=[-1,1]) scale([x, 1, 1])
193                 translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
194                         scale([1, mounthole_h/mounthole_w, 1])
195                         cylinder(r = mounthole_w/2, h = infty);
196         };
197         // clip barrier
198         for (x = [-1, 1]) scale([x, 1, 1]) hull () {
199                 translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
200                         -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
201                         cube([wall+eps, pcb_width-2*wall-2*lid_sep, wall]);
202                 translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep,
203                         -batt_diam/2-pcb_thick-pcb_comp_h + 3*wall + lid_sep])
204                         cube([eps, pcb_width-4*wall-2*lid_sep, eps]);
205         };
206 };
207
208 module lid_body() {
209         translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
210                 cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
211         translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2 - wall,
212                 -batt_diam/2-wall])
213                 cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall,
214                         wall + batt_diam/2 - body_top_h - lid_sep]);
215         // clip behind the battery contacts
216         for(x=[1, -1])
217                 scale([x, 1, 1]) translate([batt_len/2+wall+lid_sep, 0, 0]) hull() {
218                         translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
219                                 cube([wall+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]);
220                         rotate([0, 90, 0])
221                                 cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep);
222                         translate([-clip_pretension, batt_diam/2 - pcb_width+lid_sep,
223                                 batt_diam/2+pcb_comp_h+pcb_thick-lid_sep])
224                                 cube([wall+cable_sep-lid_sep, pcb_width-2*lid_sep, eps]);
225                         translate([cable_sep+wall/2-clip_pretension, batt_diam/2 - pcb_width + 1.5*wall +lid_sep,
226                                 batt_diam/2+pcb_comp_h+pcb_thick+wall/2-lid_sep])
227                                 cube([wall/2-lid_sep, pcb_width-2*wall-2*lid_sep, eps]);
228                         // rear cone
229                         translate([cable_sep+wall-lid_sep, 0, -batt_diam/2-wall]) difference() {
230                                 scale([0.5, 1, 1])
231                                 cylinder(r = batt_diam/2 - lid_sep,  h = eps);
232                                 translate([-infty, -infty/2, -infty/2]) cube(infty);
233                         };
234                 };
235 };
236
237 module lid() {
238         difference() {
239                 lid_body();
240                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
241                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
242                 hull() {
243                         difference() {
244                                 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
245                                         cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
246                                 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
247                                         cube([infty, batt_diam, infty]);
248                         };
249                         translate([-batt_len/2-cable_sep-wall, batt_diam/2-pcb_width+0.5*wall+0.5*lid_sep, batt_diam/2 + pcb_comp_h+pcb_thick-wall-lid_sep])
250                         cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
251                 };
252         };
253 };
254
255 if (lowres) {
256         translate([0, 15, 0]) case();
257         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
258 } else {
259         translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
260                 case($fn=128);
261         translate([0, -15, batt_diam/2+wall])
262                 lid($fn=128);
263 }
264