case.scad

   1 /* TODO
   2    - nabeh zaklapavaciho hranolu by mel byt zkoseny
   3    - vystup pro kabel leze do vystupu pro snuru pri vetsim wall
   4    - diry pro uchyceni jsou mozna prilis male
   5 */
   6 lowres = 1; // fast rendering or fine printing with print-friendly orientation
   7
   8 eps = 0.01;
   9 infty = 300;
  10
  11 wall = 2.0; // generic wall thickness
  12
  13 // 18650 is ~18mm diameter, ~65mm length,
  14 batt_diam = 18 + 0.6;
  15 batt_len = 65 + 1.5;
  16
  17 cable_sep = 2;
  18
  19 // front flat area
  20 front_flat_len = batt_len + 4*wall + 2*cable_sep;
  21
  22 // PCB-related dimensions
  23 pcb_len = 36 + 1;       // length of the board
  24 pcb_width = 11 + 0.5;   // width of the board
  25 pcb_thick = 1.2 + 0.3;  // thickness of the board
  26 pcb_comp_h = 2.2;       // height of the components on board
  27 pcb_groove = 1;
  28
  29 body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
  30
  31 outwire_thick = 2.2;
  32 wire_thick = 2.2;
  33 wire_sep = 3.5;
  34 cable_out_diam = 5.2;
  35
  36 batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
  37
  38 lid_sep = 0.1; // the lid is made this much smaller to separate from the body
  39
  40 sw_diam = 2.5 + 0.5;
  41 led_diam = 3 + 0.5;
  42 sw_xoff =  250 * 25.4/1000; // x offset of microswitches
  43 pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
  44
  45 prg_len = 10; // programming connector
  46 prg_width = 7;
  47
  48 rear_clip_hole_dist = 10; // distance between the holes in the rear clip
  49 rear_clip_aspect = 0.35; // w/h aspect ratio of the ellipse of the rear clip
  50
  51 module case_body() {
  52         hull() {
  53                 translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
  54                         cube([batt_len + 4*wall + 2*cable_sep,
  55                                 batt_diam+2*wall, body_top_h]);
  56                 difference() {
  57                         translate([-batt_len/2-2*wall-cable_sep, 0, 0])
  58                                 rotate([0, 90, 0])
  59                                 cylinder(r=batt_diam/2+wall,
  60                                         h = batt_len + 4*wall + 2*cable_sep);
  61                         translate([-infty/2, -infty/2, eps]) cube(infty);
  62                 };
  63                 translate([-front_flat_len/2,
  64                         batt_diam/2 - pcb_width,
  65                         -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
  66                         cube([front_flat_len, pcb_width+wall, eps]);
  67         };
  68         for (x = [-1, 1]) scale([x, 1, 1]) hull() {
  69                 for (x0 = [0-wall, 10+wall])
  70                         translate([batt_len/2-wall-wire_thick-x0, batt_diam/2, 0])
  71                                 rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1])
  72                                 cylinder(r=batt_diam/2 + 2*wall + wire_thick, h=wall);
  73                 };
  74 };
  75
  76 module case() {
  77         difference() {
  78                 case_body();
  79                 // upper cube-shaped part
  80                 // rotate([20, 0, 0])
  81                 translate([-batt_len/2, -batt_diam/2, 0])
  82                         cube([batt_len, batt_diam, batt_diam]);
  83
  84                 // battery cylinder for the lower part
  85                 translate([-batt_len/2, 0, 0])
  86                         rotate([0, 90, 0])
  87                         cylinder(r=batt_diam/2, h = batt_len);
  88
  89                 // hole for PCB
  90                 translate([-pcb_len/2-pcb_xoff,
  91                         batt_diam/2-pcb_width,
  92                         -batt_diam/2-pcb_thick - pcb_comp_h])
  93                         cube([pcb_len, pcb_width,
  94                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
  95                 // hole above the PCB
  96                 translate([-pcb_len/2-pcb_xoff-wall-2*outwire_thick,
  97                         batt_diam/2-pcb_width,
  98                         -batt_diam/2-pcb_comp_h])
  99                         cube([pcb_len, pcb_width,
 100                                 batt_diam/2 + pcb_comp_h + eps]);
 101                 // hole under the PCB
 102                 translate([-pcb_len/2+pcb_groove-pcb_xoff,
 103                         batt_diam/2-pcb_width + pcb_groove,
 104                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 105                         cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
 106                                 batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 107                 // hole for prog connector
 108                 translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
 109                         batt_diam/2-pcb_width/2-prg_width/2,
 110                         -batt_diam/2-pcb_thick - 2*pcb_comp_h])
 111                         difference() {
 112                                 cube([prg_len+pcb_groove+eps, prg_width,
 113                                         batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
 114                                 translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
 115                                         cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 116                         };
 117                 // LED hole
 118                 translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
 119                         cylinder(r=led_diam/2, h=infty, $fn=6);
 120                         translate([sw_xoff, 0, 0])
 121                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 122                         translate([-sw_xoff, 0, 0])
 123                                 cylinder(r=sw_diam/2, h=infty, $fn=6);
 124                 };
 125                 // cable outlet
 126                 translate([-pcb_xoff-pcb_len/2-outwire_thick-wall, -6, 0])
 127                         rotate([40, 0, 0])
 128                         scale([2, 1, -1])
 129                         cylinder(r=outwire_thick/2, h = infty, $fn=12);
 130                 // space under the wire holes for battery contacts
 131                 translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
 132                         difference() {
 133                                 rotate([0, 90, 0])
 134                                         cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
 135                                 translate([-infty/2, -infty/2, -batt_end_h])
 136                                         cube(infty);
 137                         };
 138                 // space above the wire holes for battery contacts
 139                 translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
 140                         cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
 141                                 batt_diam,
 142                                 batt_end_h]);
 143                 // wire holes for battery contacts
 144                 for (x = [-1, 1])
 145                 for (y = [-1, 1])
 146                         translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
 147                         rotate([0, 90, 0])
 148                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 149                 // wire hole from PCB to battery contacts
 150                 // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
 151                 rotate([40, 0, 0])
 152                 translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
 153                         rotate([0, 90, 0])
 154                                 cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 155                 // hole behind the battery contacts
 156                 for(x=[1, -1])
 157                 scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
 158                         translate([0, -batt_diam/2, 0])
 159                                 cube([wall + cable_sep + eps, batt_diam, infty]);
 160                         rotate([0, 90, 0])
 161                                 cylinder(r = batt_diam/2, h = wall+cable_sep+eps);
 162                         translate([0, batt_diam/2 - pcb_width,
 163                                 -batt_diam/2-pcb_comp_h-pcb_thick])
 164                                 cube([wall + cable_sep + eps, pcb_width, eps]);
 165                         translate([cable_sep, batt_diam/2 - pcb_width + wall,
 166                                 -batt_diam/2-pcb_comp_h-pcb_thick-wall])
 167                                 cube([wall + eps, pcb_width-2*wall, eps]);
 168                 };
 169                 // cable lead to battery contacts
 170                 for (x=[1, -1]) scale([x, 1, 1])
 171                         rotate([-140, 0, 0])
 172                         translate([batt_len/2+wire_thick/2, 0, batt_diam/2-2.7])
 173                                 cylinder(r=wire_thick/2, h = 5.4);
 174
 175                 // mounting holes
 176                 for(x=[-1,1]) scale([x, 1, 1])
 177                 translate([batt_len/2-wall-wire_thick, batt_diam/2+2*wall, -batt_diam/2-pcb_thick-2*pcb_comp_h-wall])
 178                         vert_torus();
 179
 180                 for (x = [-1, 1]) scale([x, 1, 1]) for (x0 = [0, 10])
 181                         translate([batt_len/2-wall-wire_thick-x0, 0, batt_diam/2+wire_thick/2+wall])
 182                         rotate([-90, 0, 0])
 183                         scale([2,1,1]) cylinder (r=wire_thick/2, h=infty, $fn=16);
 184         };
 185         // clip barrier
 186         for (x = [-1, 1]) scale([x, 1, 1])
 187                 translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
 188                         -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
 189                         cube([cable_sep+eps, pcb_width-2*wall-2*lid_sep, wall]);
 190 };
 191
 192 module lid_body() {
 193         translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
 194                 cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
 195         translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2 - wall,
 196                 -batt_diam/2-wall])
 197                 cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall,
 198                         wall + batt_diam/2 - body_top_h - lid_sep]);
 199         // clip behind the battery contacts
 200         for(x=[1, -1])
 201                 scale([x, 1, 1]) translate([batt_len/2+wall+lid_sep, 0, 0]) hull() {
 202                         translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
 203                                 cube([wall+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]);
 204                         rotate([0, 90, 0])
 205                                 cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep);
 206                         translate([0, batt_diam/2 - pcb_width+lid_sep,
 207                                 batt_diam/2+pcb_comp_h+pcb_thick-lid_sep])
 208                                 cube([wall+cable_sep-lid_sep, pcb_width-2*lid_sep, eps]);
 209                         translate([cable_sep+wall/2, batt_diam/2 - pcb_width + 1.5*wall +lid_sep,
 210                                 batt_diam/2+pcb_comp_h+pcb_thick+wall/2-lid_sep])
 211                                 cube([wall/2-lid_sep, pcb_width-2*wall-2*lid_sep, eps]);
 212                         // rear cone
 213                         translate([cable_sep+wall-lid_sep, 0, -batt_diam/2-wall]) difference() {
 214                                 scale([0.5, 1, 1])
 215                                 cylinder(r = batt_diam/2 - lid_sep,  h = eps);
 216                                 translate([-infty, -infty/2, -infty/2]) cube(infty);
 217                         };
 218                 };
 219 };
 220
 221 module lid() {
 222         difference() {
 223                 lid_body();
 224                 translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
 225                         cylinder(r=batt_diam/2, h=batt_len-2*eps);
 226                 hull() {
 227                         difference() {
 228                                 translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
 229                                         cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
 230                                 translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
 231                                         cube([infty, batt_diam, infty]);
 232                         };
 233                         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])
 234                         cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
 235                 };
 236                 // holes for the mounting clips on the body
 237                 for (x = [-1, 1]) scale([x, 1, 1]) hull() {
 238                 for (x0 = [0-wall, 10+wall])
 239                         translate([batt_len/2-wall-wire_thick-x0, batt_diam/2-lid_sep+eps, 0])
 240                                 rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1])
 241                                 cylinder(r=batt_diam/2 + 2*wall + wire_thick+lid_sep/rear_clip_aspect, h=wall+lid_sep+eps);
 242                 };
 243         };
 244 };
 245
 246 module vert_torus() {
 247         rotate([0, 90, 0])
 248         scale([1, 1, 2])
 249         rotate_extrude() translate([5, 0, 0]) circle(r=wire_thick/2, $fn=16);
 250 };
 251
 252 if (lowres) {
 253         translate([0, 15, 0]) case();
 254         translate([0, -15, 0]) rotate([180, 0, 0]) lid();
 255 } else {
 256         translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
 257                 case($fn=128);
 258         translate([0, -15, batt_diam/2+wall])
 259                 lid($fn=128);
 260 }
 261