-/* TODO
-- vybrani pro otevreni
-- mozna sirsi misto na baterku?
-- vetsi vybrani pro baterku ve vicku
-- kuzelova dira pro tlacitka
-- jine diry pro uchyceni
-- zvetsit vybrani na strane tlacitek
-- mozna prilis velky klip zasunovaciho konce baterky
-- diry pro neizolovany drat muzou byt mensi
-- sirsi zakladna
-- mensi horni cast klipu baterky - pri 0.7 je sirka nahore 16 mm.
-*/
-
-lowres = 1;
+lowres = 0; // fast rendering or fine printing with print-friendly orientation
eps = 0.01;
infty = 300;
wall = 1.5; // generic wall thickness
// 18650 is ~18mm diameter, ~65mm length,
-batt_diam = 18 + 0.6;
-batt_len = 65 + 1.5;
+batt_diam = 18 + 0.8;
+batt_len = 65 + 2.0;
-cable_sep = 2.5;
+cable_sep = 1.5;
// front flat area
-front_flat_len = batt_len + 2*wall + 2*cable_sep;
+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_groove = 0.5;
+pcb_comp_h2 = 4.5; // height of the components on board - component side
+pcb_groove = 1;
-body_top_h = 0.30 * batt_diam; // cube-shaped part of the body
+body_top_h = 0.38 * batt_diam; // cube-shaped part of the body
-wire_thick = 2.2;
+wire_thick = 2.5;
wire_sep = 3.5;
-cable_out_diam = 5.2;
-pcbside_protrusion_len = 20;
-pcbside_protrusion_diam = 2.5;
-battside_protrusion_len = 10;
-battside_protrusion_diam = 2;
+lid_sep = 0.2; // the lid is made this much smaller to separate from the body
-base_batt_extend = wall + pcb_thick; // extend the base on the battery side
-
-cover_sep = 0.1;
-
-sw_diam = 2.5 + 0.5;
+// 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
-pcb_clip_w = 7;
-pcb_clip_off = led_xoff + pcb_clip_w/2;
+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 battery() {
- translate([-batt_len/2, 0, 0])
- rotate([0, 90, 0])
- cylinder(r=batt_diam/2, h = batt_len);
-};
module case_body() {
hull() {
- translate([-batt_len/2-wall-cable_sep, -batt_diam/2-wall, 0])
- cube([batt_len + 2*wall + 2*cable_sep,
+ 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() {
- translate([-batt_len/2-wall-cable_sep, 0, 0])
+ translate([-batt_len/2-2*wall-cable_sep, 0, 0])
rotate([0, 90, 0])
cylinder(r=batt_diam/2+wall,
- h = batt_len + 2*wall + 2*cable_sep);
+ 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,
- -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
- cube([front_flat_len, pcb_width+wall, eps]);
-/*
- translate([-batt_len/2 - 2*wall - cable_sep, 0, 0])
- rotate([0, 90, 0])
- cylinder(r = 1.414*wire_sep + wire_thick,
- h = batt_len + 4*wall + 2*cable_sep);
-*/
+ 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 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 case() {
difference() {
case_body();
// upper cube-shaped part
// rotate([20, 0, 0])
translate([-batt_len/2, -batt_diam/2, 0])
- cube([batt_len, batt_diam, batt_diam]);
-
+ 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])
cylinder(r=batt_diam/2, h = batt_len);
// hole for PCB
- translate([-pcb_len/2,
+ 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 under the PCB
- translate([-pcb_len/2+pcb_groove,
+ // 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 - 2*pcb_comp_h])
+ -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_h + eps]);
- // LED hole
+ 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])
translate([-sw_xoff, 0, 0])
cylinder(r=sw_diam/2, h=infty, $fn=6);
};
- // space under the wire holes for battery contacts
- translate([-batt_len/2-wall-cable_sep-eps, 0, 0])
- difference() {
- rotate([0, 90, 0])
- cylinder(r = batt_diam/2-wall, h = batt_len + 2*wall + 2*cable_sep + 2*eps);
- translate([-infty/2, -infty/2, -body_top_h])
- cube(infty);
- };
- // wire holes for battery contacts
- for (x = [-1, 1])
- for (y = [-1, 1])
- translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
- rotate([0, 90, 0])
- cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
// wire hole from PCB to battery contacts
- // translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
- rotate([40, 0, 0])
- translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
- rotate([0, 90, 0])
- cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
- // hole behind the battery contacts
- for(x=[1, -1])
- scale([x, 1, 1]) translate([batt_len/2+wall, 0, 0]) hull() {
- translate([0, -batt_diam/2, 0])
- cube([cable_sep + eps, batt_diam, infty]);
- rotate([0, 90, 0])
- cylinder(r = batt_diam/2, h = cable_sep+eps);
- translate([0, batt_diam/2 - pcb_width,
- -batt_diam/2-pcb_comp_h-pcb_thick])
- cube([cable_sep + eps, pcb_width, eps]);
- };
+ 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 lid_body() {
- translate([-batt_len/2 + eps, -batt_diam/2, -batt_diam/2-eps])
- cube([batt_len - 2*eps, batt_diam, batt_diam/2 - body_top_h + wall + eps]);
- translate([-batt_len/2 - wall - cable_sep, -batt_diam/2 - wall,
- -batt_diam/2-wall])
- cube([batt_len + 2*wall + 2*cable_sep, batt_diam + 2*wall,
- wall + batt_diam/2 - body_top_h]);
- // clip behind the battery contacts
- for(x=[1, -1])
- scale([x, 1, 1]) translate([batt_len/2+cable_sep, 0, 0]) hull() {
- translate([0, -batt_diam/2, -batt_diam/2])
- cube([wall, batt_diam, eps]);
- rotate([0, 90, 0])
- cylinder(r = batt_diam/2, h = wall);
- translate([0, batt_diam/2 - pcb_width,
- batt_diam/2+pcb_comp_h+pcb_thick])
- cube([wall, pcb_width, eps]);
- };
-};
+ // 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, $fn=4);
+ // translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
+}
module lid() {
difference() {
lid_body();
- translate([-batt_len/2-eps, 0, 0]) rotate([0, 90, 0])
- cylinder(r=batt_diam/2, h=batt_len+2*eps);
+ translate([-batt_len/2-lid_sep, 0, 0]) rotate([0, 90, 0])
+ cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep);
+ // holes for battery contacts
+ for(x=[-1,1]) scale([x, 1, 1])
+ translate([batt_len/2+wall-eps, -batt_contact_w/2,
+ -batt_contact_h_lid/2])
+ cube([cable_sep+2*eps, batt_contact_w, infty]);
};
};
-/*
-color("lightblue", 0.2)
- translate([-65/2, 0, 0])
- rotate([0, 90, 0])
- cylinder(r=18/2, h=65);
-*/
-translate([0, 30, 0]) case($fn=128);
-lid($fn=128);
-
+if (lowres) {
+ translate([0, 15, 0]) case();
+ translate([0, -15, 0]) rotate([180, 0, 0]) lid();
+} else {
+ translate([0, 15, batt_diam/2+pcb_thick+pcb_comp_h+pcb_comp_h2+wall])
+ case($fn=128);
+ translate([0, -15, batt_diam/2+wall])
+ lid($fn=128);
+}
https://www.fi.muni.cz/~kas/git / heater.git / blobdiff