case.scad: alternative lid clips
[heater.git] / case.scad
index 2b5a351..653a79a 100644 (file)
--- a/case.scad
+++ b/case.scad
-// 18650 is ~18mm diameter, ~65mm length, 
-batt_diam = 18 + 0.3;
-batt_len = 65+1;
-batt_clip_h = 0.75 * batt_diam;
-wall = 2.2;
-base_h = 4;
-cable_sep = 2.5;
+lowres = 0; // fast rendering or fine printing with print-friendly orientation
 
 eps = 0.01;
 infty = 300;
 
 
 eps = 0.01;
 infty = 300;
 
-pcb_len = 36;
-pcb_thick = 1.3;
-pcb_groove = 2;
-pcb_width = 11;
-
-wire_thick = 2;
-wire_sep = 3;
-cable_out_diam = 4;
-
-side_protrusion_len = 10;
-side_protrusion_diam = 2;
-
-base_batt_extend = wall+pcb_thick; // extend the base on the battery side
-
-cover_sep = 0.2;
-
-uswitch_diam = 2.5;
-led_diam = 3.2;
-s2_xoff = -160 * 25.4/1000;
-led_xoff = 90 * 25.4/1000;
-s1_xoff = 340 * 25.4/1000;
-
-pcb_clip_w = 7;
-pcb_clip_off = led_xoff + pcb_clip_w/2;
-
-module base() {
-       translate([0, 0, base_h/2]) {
-               hull() {
-                       cube([batt_len + 2*wall + 2*cable_sep, batt_diam + 2*wall, base_h], center=true);
-                       // under the PCB
-                       translate([0, -batt_diam/2-wall-pcb_thick/2-wall/2, 0])
-                               cube([pcb_len + 2*wall, pcb_thick + wall + eps, base_h], center=true);
-                       // battery-side extension
-                       translate([0, batt_diam/2 + wall + base_batt_extend, -base_h/4+side_protrusion_diam/4])
-                               cube([batt_len + 2*wall, eps, base_h/2+side_protrusion_diam/2], center=true);
-               };
-       };
-}
-module base_protrusions() {
-       // pcb-side side protrusion
-       translate([-side_protrusion_len/2, -batt_diam/2-2*wall-pcb_thick, base_h/2])
-               rotate([0, 90, 0])
-               cylinder(r = side_protrusion_diam/2, h = side_protrusion_len, $fn = 6);
-       
-       // battery-side side protrusion
-       translate([-side_protrusion_len/2, batt_diam/2+wall+base_batt_extend, base_h/2])
-               rotate([0, 90, 0])
-               cylinder(r = side_protrusion_diam/2, h = side_protrusion_len, $fn = 6);
-};
+wall = 1.5; // generic wall thickness
 
 
-module pcb_clips() {
-       // rear part of the PCB holder (behind S1)
-       translate([pcb_clip_off, -batt_diam/2-wall-pcb_thick+eps, 0])
-               cube([pcb_clip_w, pcb_thick+wall, pcb_width + wall + base_h - pcb_groove]);
-       // side part of the PCB holder (near the battery wires)
-       translate([-pcb_len/2-wall, -batt_diam/2-pcb_thick-2*wall, 0])
-               cube([pcb_groove+wall, pcb_thick+2*wall+eps, pcb_width + wall + base_h - pcb_groove]);
-};
+// 18650 is ~18mm diameter, ~65mm length, 
+batt_diam = 18 + 0.8;
+batt_len = 65 + 2.0;
 
 
-module batt_clips() {
-       difference() {
-               union() {
-                       // rear part of the battery clip
-                       translate([-(batt_len/2-pcb_len/2+pcb_groove+wall)/2-pcb_len/2+pcb_groove, 0, batt_clip_h/2+wall/2])
-                               cube([batt_len/2-pcb_len/2+pcb_groove + wall, batt_diam + 2*wall, batt_clip_h + wall], center=true);
-                       // front (+) part of the battery clip
-                       translate([batt_len/2+wall/2, 0, batt_clip_h/2+wall/2])
-                               hull() {
-                                       cube([wall, batt_diam + 2*wall, batt_clip_h + wall], center=true); 
-                                       translate([-10/2, 0, -batt_clip_h/2])
-                                       cube([10, batt_diam+2*wall, wall], center=true);
-                               };
-                       // middle clips
-                       translate([pcb_clip_off+pcb_clip_w/2, 0, batt_clip_h/2+wall/2])
-                               hull() {
-                                       cube([pcb_clip_w, batt_diam + 2*wall, batt_clip_h + wall], center=true);
-                                       translate([0, 0, -batt_clip_h/2])
-                                       cube([2*pcb_clip_w, batt_diam+2*wall, wall], center=true);
-                               };
-               }
-               // top part rounded
+cable_sep = 1.5;
+
+// front flat area
+front_flat_len = batt_len + 4*wall + 2*cable_sep;
+
+// PCB-related dimensions
+pcb_len = 36 + 1;      // length of the board
+pcb_width = 11 + 0.5;  // width of the board
+pcb_thick = 1.2 + 0.3;         // thickness of the board
+pcb_comp_h = 2.2;      // height of the components on board
+pcb_comp_h2 = 4.5;     // height of the components on board - component side
+pcb_groove = 1;
+
+body_top_h = 0.38 * batt_diam; // cube-shaped part of the body
+
+wire_thick = 2.5;
+wire_sep = 3.5;
+
+lid_sep = 0.2; // the lid is made this much smaller to separate from the body
+
+// sw_diam = 2.5 + 0.5;
+sw_diam = 3.5 + 0.5;
+led_diam = 3 + 0.5;
+sw_xoff =  250 * 25.4/1000; // x offset of microswitches
+pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
+
+prg_len = 10; // programming connector
+prg_width = 7;
+
+outcable_h = 4.5;
+outcable_w = 2.5;
+
+// mounting cylinder + holes
+mounthole_w = 5;
+mounthole_h = 3;
+mountcyl_w = mounthole_w + 4*wall;
+mountcyl_h = 2*wall;
+mountcone_h = mounthole_h + 2*wall;
+
+clip_pretension = 0.5;
+
+plus_width = 4.5; // width of the + sign
+
+batt_contact_w = 12;
+batt_contact_h = 14;
+batt_contact_h_lid = batt_contact_h-2;
+clip_cyl_r = 0.7;
+batt_end_h = body_top_h - 4*clip_cyl_r;;
+
+
+module case_body() {
+       hull() {
+               translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
+                       cube([batt_len + 4*wall + 2*cable_sep,
+                               batt_diam+2*wall, body_top_h]);
                difference() {
                difference() {
-                       translate([0, 0, infty/4 + wall + batt_diam/2])
-                               cube([infty/2, infty/2, infty/2], center=true);
-                       translate([-infty/2, 0, batt_diam/2+wall])
+                       translate([-batt_len/2-2*wall-cable_sep, 0, 0])
                                rotate([0, 90, 0])
                                rotate([0, 90, 0])
-                               cylinder(r=batt_diam/2+wall, h = infty);
+                               cylinder(r=batt_diam/2+wall,
+                                       h = batt_len + 4*wall + 2*cable_sep);
+                       translate([-infty/2, -infty/2, eps]) cube(infty);
                };
                };
+               translate([-front_flat_len/2,
+                       batt_diam/2 - pcb_width-0.5*wall,
+                       -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall])
+                       cube([front_flat_len, pcb_width+1.5*wall, eps]);
+       };
+       // mounting cylinders
+       for (x = [-1, 1]) translate([x*(batt_len/2-mounthole_w/2),
+               batt_diam/2+wall, 0]) {
+                       translate([0, 0, -batt_diam/2-wall-pcb_comp_h-pcb_comp_h2-pcb_thick])
+                               mount_cyl(); // front
+                       translate([0, 0, body_top_h]) // rear
+                               scale([1, 1, -1])
+                               mount_cyl();
        };
 };
 
        };
 };
 
-module battery() {
-       // battery
-       translate([-batt_len/2, 0, batt_diam/2+wall])
-               rotate([0, 90, 0])
-               cylinder(r=batt_diam/2, h = batt_len);
+module mount_cyl() {
+       assign(h = mounthole_h+wall)
+       hull () {
+               translate([0, -mountcyl_w/2+mounthole_h + wall])
+                       cylinder(r = mountcyl_w/2, h = mountcyl_h);
+               assign(l = 2*sqrt(h*(mountcyl_w-h)))
+               translate([-l/2, 0, mountcyl_h + mountcone_h])
+                       cube([l, eps, eps]);
+       };
 };
 };
-
-module main() {
+       
+module case() {
        difference() {
        difference() {
-               union() {
-                       base();
-                       base_protrusions();
-                       pcb_clips();
-                       batt_clips();
-               };
-               // the PCB itself
-               translate([0, -batt_diam/2-wall-pcb_thick/2, base_h - pcb_groove + pcb_width/2])
-                       cube([pcb_len, pcb_thick, pcb_width], center=true);
-               // battery
-               battery();
-               // 4 wire holes at the battery ends
-               for (j=[-wire_sep/2, wire_sep/2]) 
-               for (i=[-wire_sep/2, wire_sep/2]) 
-               translate([-infty/2, i, batt_diam/2 + wall+j])
-                       rotate([0, 90, 0])
-                       rotate([0, 0, 90])
-                       cylinder(r=wire_thick/2, h = infty, $fn=6);
-
-               // holes for wire from battery to the PCB
-               translate([-infty/2, -batt_diam/2, wall + pcb_groove + wire_thick/2])
+               case_body();
+               // upper cube-shaped part
+               // rotate([20, 0, 0])
+               translate([-batt_len/2, -batt_diam/2, 0])
+                       cube([batt_len, batt_diam, batt_end_h+eps]);
+               // upper longer cube-shaped part
+               difference() {
+                       translate([-batt_len/2-cable_sep-wall, -batt_diam/2, batt_end_h])
+                               cube([batt_len+2*cable_sep+2*wall, batt_diam, batt_diam]);
+                       // clips
+                       for (x = [-1,1]) scale([1, x, 1])
+                               translate([batt_len/6, batt_diam/2, batt_end_h + 3*clip_cyl_r])
+                               rotate([0, -90, 0])
+                               cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
+               }
+               // grabbing holes
+               for (x=[-1,1]) scale([x,1,1])
+               translate([batt_len/2 + 2*wall + cable_sep+10-wall, 0, 0])
+                       cylinder(r1 = 7, r2 = 10, h = body_top_h + eps);
+               // battery cylinder for the lower part
+               translate([-batt_len/2, 0, 0])
                        rotate([0, 90, 0])
                        rotate([0, 90, 0])
-                       rotate([0, 0, 90])
-                       cylinder(r=wire_thick/2, h = infty, $fn=6);
-               // hole for the cable outlet
-               translate([-pcb_len/2+pcb_groove+cable_out_diam/2, -batt_diam/2-pcb_thick-2*wall, -infty/2])
-                       cylinder(r=cable_out_diam/2, h = infty, $fn=6);
-               // holes for binding to the shoe
-               for (x = [
-                        pcb_len/2 + wall + wire_thick/2 + wire_sep,
-                        pcb_len/2 + wall + wire_thick/2,
-                       -pcb_len/2 - wall - wire_thick/2 - wire_sep,,
-                       -pcb_len/2 - wall - wire_thick/2 ]) {
-                       for (y = [-1,1]) {
-                               translate([x, y*(batt_diam/2 + wall + wire_thick/2), -infty/2])
-                                       cylinder(r=wire_thick/2, h=infty, $fn=6);
+                       cylinder(r=batt_diam/2, h = batt_len);
+
+               // hole for PCB
+               translate([-pcb_len/2-pcb_xoff,
+                       batt_diam/2-pcb_width,
+                       -batt_diam/2-pcb_thick - pcb_comp_h])
+                       cube([pcb_len, pcb_width,
+                               batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
+               // hole above the PCB for the outgoing cable
+               translate([-pcb_len/2-pcb_xoff-2*wall-outcable_w,
+                       batt_diam/2-pcb_width,
+                       -batt_diam/2-pcb_comp_h])
+                       cube([pcb_len, pcb_width,
+                               batt_diam/2 + pcb_comp_h + eps]);
+               // cable outlet
+               translate([-pcb_xoff-pcb_len/2-wall-outcable_w,
+                       -pcb_width+batt_diam/2,
+                       -batt_diam/2-outcable_h])
+                       cube([outcable_w, infty, outcable_h]);
+               // hole under the PCB (groove)
+               translate([-pcb_len/2+pcb_groove-pcb_xoff,
+                       batt_diam/2-pcb_width + pcb_groove,
+                       -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
+                       cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
+                               batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
+               // hole under the PCB (pcb-width)
+               translate([-pcb_len/2+2*pcb_groove-pcb_xoff,
+                       batt_diam/2-pcb_width,
+                       -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
+                       cube([pcb_len-4*pcb_groove, pcb_width,
+                               batt_diam/2 + pcb_thick + pcb_comp_h2 + eps]);
+               // hole for prog connector
+               translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
+                       batt_diam/2-pcb_width/2-prg_width/2,
+                       -batt_diam/2-pcb_thick - pcb_comp_h - pcb_comp_h2])
+                       difference() {
+                               cube([prg_len+pcb_groove+eps, prg_width,
+                                       batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
+                               translate([prg_len/2+pcb_groove, -eps, pcb_comp_h2])
+                                       cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
                        };
                        };
+                // LED and button holes
+               translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
+                       cylinder(r=led_diam/2, h=infty, $fn=6);
+                       translate([sw_xoff, 0, 0])
+                               cylinder(r=sw_diam/2, h=infty, $fn=6);
+                       translate([-sw_xoff, 0, 0])
+                               cylinder(r=sw_diam/2, h=infty, $fn=6);
                };
                };
+               // wire hole from PCB to battery contacts
+               rotate([-48, 0, 0])
+               translate([-batt_len/2-wall-cable_sep, 0, -wire_thick/2-wall/2])
+                       cube([batt_len + 2*wall + 2* cable_sep, batt_diam/2 + wire_thick + wall, wire_thick]);
+               // mounting holes
+               for(x=[-1,1]) scale([x, 1, 1])
+               translate([batt_len/2-mounthole_w/2, batt_diam/2+wall+mounthole_h/2, -infty/2])
+                       scale([1, mounthole_h/mounthole_w, 1])
+                       cylinder(r = mounthole_w/2, h = infty);
+               // holes in front of battery contacts
+               for(x=[-1,1]) scale([x, 1, 1])
+               translate([batt_len/2-eps, wall/2-batt_contact_w/2,
+                       wall/2-batt_contact_h/2])
+                       cube([wall+2*eps, batt_contact_w-wall, infty]);
+               // holes for battery contacts
+               for(x=[-1,1]) scale([x, 1, 1])
+               translate([batt_len/2+wall-eps, -batt_contact_w/2,
+                       -batt_contact_h/2])
+                       cube([cable_sep+2*eps, batt_contact_w, infty]);
+               // internal plus sign - vertical line
+               translate([-batt_len/2 + 0.5*wall+plus_width/2, -plus_width/2, -batt_diam/2-wall])
+                       cube([wall, plus_width, infty]);
+               // internal plus and minus signs - horizontal line
+               for(x=[-1,1]) scale([x, 1, 1])
+               translate([batt_len/2 - wall - plus_width, -wall/2, -batt_diam/2-wall])
+                       cube([plus_width, wall, infty]);
+               // button + label
+               scale([-1, 1, 1])
+               translate([sw_xoff + sw_diam/2 + wall/2 + plus_width/2, batt_diam/2-pcb_width/2-plus_width/2, -batt_diam/2-pcb_thick-pcb_comp_h-pcb_comp_h2-wall-eps])
+                       cube([wall, plus_width, wall/2]);
+               // button +/- label - horizontal line
+               for (x=[-1, 1]) scale([x, 1, 1])
+               translate([sw_xoff + sw_diam/2 + wall, batt_diam/2-pcb_width/2-wall/2, -batt_diam/2-pcb_thick-pcb_comp_h-pcb_comp_h2-wall-eps])
+                       cube([plus_width, wall, wall/2]);
        };
 };
 
        };
 };
 
-module cover_internal() {
-       hull() { 
-               base();
-               // battery + wall + cable space
-               translate([-batt_len/2-wall, 0, batt_diam/2+wall])
-                       rotate([0, 90, 0])
-                       cylinder(r=batt_diam/2+wall, h = batt_len + 2*wall);
-               // space for PCB
-               translate([-pcb_len/2-wall, -batt_diam/2-2*wall-pcb_thick, base_h-pcb_groove])
-                       cube([pcb_len+2*wall, wall+pcb_thick, pcb_width+wall]);
+module lid_body() {
+       // outer part
+       hull() {
+               // smaller outermost part
+               translate([-batt_len/2 - wall - cable_sep, -batt_diam/2, -batt_diam/2 - wall])
+                       cube([batt_len + 2*wall + 2*cable_sep, batt_diam, eps]);
+               // this part goes above the main body
+               translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2-wall, -body_top_h - lid_sep])
+                       cube([batt_len + 4*wall + 2*cable_sep, batt_diam+2*wall, eps]);
        };
        };
-};
+       // the part which goes inside the main body
+       translate([-batt_len/2 - wall - cable_sep + lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
+               cube([batt_len + 2*wall + 2*cable_sep - 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
+       // clips
+       for (x = [-1, 1]) scale([1, x, 1])
+               translate([batt_len/6, batt_diam/2-lid_sep, - batt_end_h - clip_cyl_r - lid_sep])
+               rotate([0, -90, 0])
+               cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
+       // translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
+}
 
 
-module cover_hole() {
+module lid() {
        difference() {
        difference() {
-               cover_internal();
-               translate([-infty/2, -infty/2, wall + batt_clip_h])
-                       cube(infty);
+               lid_body();
+               translate([-batt_len/2-lid_sep, 0, 0]) rotate([0, 90, 0])
+                       cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep);
+               // holes for battery contacts
+               for(x=[-1,1]) scale([x, 1, 1])
+               translate([batt_len/2+wall-eps, -batt_contact_w/2,
+                       -batt_contact_h_lid/2])
+                       cube([cable_sep+2*eps, batt_contact_w, infty]);
        };
        };
-       base_protrusions();
-       // battery();
-       translate([-batt_len/2-cable_sep, 0, batt_diam/2+wall])
-               rotate([0, 90, 0])
-               cylinder(r=batt_diam/2, h = batt_len + 2*cable_sep);
 };
 
 };
 
-module cover() {
-       difference() {
-               minkowski() {
-                       cover_internal();
-                       sphere(wall+cover_sep, $fn=16);
-               }
-               minkowski() {
-                       cover_hole();
-                       sphere(cover_sep, $fn=8);
-               };
-               // s2 hole
-               translate([s2_xoff, 0, base_h-pcb_groove + pcb_width/2])
-                       rotate([90, 0, 0])
-                       cylinder(r=uswitch_diam/2, h = infty, $fn=6);
-               // LED hole
-               translate([led_xoff, 0, base_h-pcb_groove + pcb_width/2])
-                       rotate([90, 0, 0])
-                       cylinder(r=led_diam/2, h = infty, $fn=6);
-               // s1 hole
-               translate([s1_xoff, 0, base_h-pcb_groove + pcb_width/2])
-                       rotate([90, 0, 0])
-                       cylinder(r=uswitch_diam/2, h = infty, $fn=6);
-               // xy plane
-               translate([0, 0, -infty/2]) cube(infty, center=true);
-       }
-};
-
-translate([0, -19, 0])
-       main($fn=128);
-
-// translate([0, -40, 0])
-//     cover_hole();
-
-// cover($fn=128);
-// translate([0, 17, batt_diam + 3*wall + cover_sep])
-// rotate([180, 0, 0])
-//     cover($fn=128);
+if (lowres) {
+       translate([0, 15, 0]) case();
+       translate([0, -15, 0]) rotate([180, 0, 0]) lid();
+} else {
+       translate([0, 15, batt_diam/2+pcb_thick+pcb_comp_h+pcb_comp_h2+wall])
+               case($fn=128);
+       translate([0, -15, batt_diam/2+wall])
+               lid($fn=128);
+}
 
 
-translate([0, 19, 0])
-       cover($fn=128);