-// 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;
-pcb_len = 36;
-pcb_thick = 1.3;
-pcb_groove = 2;
-pcb_width = 11;
+wall = 1.5; // generic wall thickness
-wire_thick = 2;
-wire_sep = 3;
-cable_out_diam = 4;
+// 18650 is ~18mm diameter, ~65mm length,
+batt_diam = 18 + 0.8;
+batt_len = 65 + 2.0;
-side_protrusion_len = 10;
-side_protrusion_diam = 2;
+cable_sep = 1.5;
-base_batt_extend = wall+pcb_thick; // extend the base on the battery side
+// front flat area
+front_flat_len = batt_len + 4*wall + 2*cable_sep;
-cover_sep = 0.2;
+// 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 = 1;
-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;
+body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
-pcb_clip_w = 7;
-pcb_clip_off = led_xoff + pcb_clip_w/2;
+wire_thick = 2.2;
+wire_sep = 3.5;
-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);
-};
+batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
-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]);
-};
+lid_sep = 0.2; // the lid is made this much smaller to separate from the body
-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
+sw_diam = 2.5 + 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
+
+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() {
- 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])
- 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,
+ -batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
+ cube([front_flat_len, pcb_width+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-2*pcb_comp_h-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() {
- 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);
+ 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]);
- // holes for wire from battery to the PCB
- translate([-infty/2, -batt_diam/2, wall + pcb_groove + wire_thick/2])
+ // battery cylinder for the lower part
+ translate([-batt_len/2, 0, 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
+ translate([-pcb_len/2+pcb_groove-pcb_xoff,
+ batt_diam/2-pcb_width + pcb_groove,
+ -batt_diam/2-pcb_thick - 2*pcb_comp_h])
+ cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove,
+ batt_diam/2 + pcb_thick + pcb_comp_h + 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 - 2*pcb_comp_h])
+ 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_h])
+ cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
};
+ // LED hole
+ 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);
};
+ // space under the wire holes for battery contacts
+ translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
+ difference() {
+ rotate([0, 90, 0])
+ cylinder(r = batt_diam/2-wall, h = batt_len + 4*wall + 2*cable_sep + 2*eps);
+ translate([-infty/2, -infty/2, -batt_end_h])
+ cube(infty);
+ };
+ // space above the wire holes for battery contacts
+ translate([-batt_len/2-2*wall-cable_sep-eps, -batt_diam/2, batt_end_h])
+ cube([batt_len + 4*wall + 2*cable_sep + 2*eps,
+ batt_diam,
+ batt_end_h]);
+ // 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+cable_sep, 0, 0]) hull() {
+ translate([0, -batt_diam/2, 0])
+ cube([wall + eps, batt_diam, infty]);
+ rotate([0, 90, 0])
+ cylinder(r = batt_diam/2, h = wall+eps);
+ translate([0, batt_diam/2 - pcb_width,
+ -batt_diam/2-pcb_comp_h-pcb_thick])
+ cube([wall + eps, pcb_width, eps]);
+ translate([0, batt_diam/2 - pcb_width + 0.5*wall,
+ -batt_diam/2-2*pcb_comp_h-pcb_thick])
+ cube([wall + eps, pcb_width-0.5*wall, eps]);
+ };
+ // inner 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+wall, 0])
+ cube([cable_sep + eps, batt_diam-2*wall, infty]);
+ rotate([0, 90, 0])
+ cylinder(r = batt_diam/2-wall, h = cable_sep+eps);
+ };
+ // cable lead to battery contacts
+ for (x=[1, -1]) scale([x, 1, 1])
+ rotate([-140, 0, 0])
+ translate([batt_len/2-eps, -wire_thick/2, batt_diam/2-2.7])
+ cube([wall+cable_sep+2*eps, wire_thick, 5.4]);
+
+ // 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);
+ // grabbing gap
+ for(x=[-1,1]) scale([x, 1, 1])
+ translate([batt_len/2+cable_sep+wall+10, batt_diam/2-pcb_width/2, -batt_diam/2-2*pcb_comp_h-pcb_thick-wall-eps])
+ cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps);
+ // plus sign - vertical line
+ translate([batt_len/2 - 1.5*wall-plus_width/2, -plus_width/2, -batt_diam/2-wall])
+ cube([wall, plus_width, infty]);
+ // 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]);
+ };
+ // clip barrier
+ for (x = [-1, 1]) scale([x, 1, 1]) hull () {
+ translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
+ -batt_diam/2-pcb_thick-pcb_comp_h + wall + lid_sep])
+ cube([wall+eps, pcb_width-2*wall-2*lid_sep, wall]);
+ translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep,
+ -batt_diam/2-pcb_thick-pcb_comp_h + 3*wall + lid_sep])
+ cube([eps, pcb_width-4*wall-2*lid_sep, eps]);
};
};
-module cover_internal() {
- hull() {
- base();
- // battery + wall + cable space
- translate([-batt_len/2-wall, 0, batt_diam/2+wall])
+module lid_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]);
+ hull () {
+ translate([-batt_len/2 - 2*wall - cable_sep,
+ -batt_diam/2, -batt_diam/2-wall])
+ cube([batt_len + 4*wall + 2*cable_sep,
+ batt_diam, eps]);
+ translate([-batt_len/2 - 3*wall - cable_sep,
+ -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
+ cube([batt_len + 6*wall + 2*cable_sep,
+ batt_diam + 2*wall, wall/2]);
+ };
+ // clip behind the battery contacts
+ for(x=[1, -1])
+ scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep+lid_sep, 0, 0]) hull() {
+ translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
+ cube([wall-lid_sep, batt_diam-2*lid_sep, eps]);
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]);
+ cylinder(r = batt_diam/2-lid_sep, h = wall-lid_sep);
+ translate([-clip_pretension, batt_diam/2 - pcb_width + 0.5*wall + lid_sep,
+ batt_diam/2+2*pcb_comp_h+pcb_thick-lid_sep])
+ cube([wall+clip_pretension, pcb_width-0.5*wall-1.5*lid_sep, eps]);
+ };
+ // outer part of the clip behind the battery contacts
+ for (x=[1, -1]) scale([x, 1, 1]) translate([batt_len/2+2*wall+cable_sep+lid_sep, 0, 0]) hull() {
+ translate([0, -batt_diam/2 - wall, -body_top_h-wall/2-lid_sep])
+ cube([wall-lid_sep, batt_diam + 2*wall, wall/2]);
+ difference() {
+ scale([0.3, 1, 1])
+ sphere(batt_diam/2+wall);
+ translate([-infty/2, -infty/2, -infty-body_top_h-lid_sep+2*wall])
+ cube(infty);
+ translate([-infty-clip_pretension, -infty/2, -infty/2])
+ cube(infty);
+ };
+ translate([-clip_pretension,
+ batt_diam/2 - pcb_width,
+ batt_diam/2+2*pcb_comp_h+pcb_thick+wall])
+ cube([wall-lid_sep, pcb_width+wall, eps]);
};
};
-module cover_hole() {
+module lid() {
difference() {
- cover_internal();
- translate([-infty/2, -infty/2, wall + batt_clip_h])
- cube(infty);
+ lid_body();
+ translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
+ cylinder(r=batt_diam/2, h=batt_len-2*eps);
+ // clip barrier
+ for (x = [-1, 1]) scale([x, 1, 1]) hull () {
+ translate([batt_len/2+wall+cable_sep-clip_pretension, batt_diam/2-pcb_width+wall/2,
+ batt_diam/2+pcb_thick+pcb_comp_h-2*wall])
+ cube([wall+clip_pretension+eps, pcb_width-2*wall, wall]);
+ translate([batt_len/2+wall+cable_sep-eps, batt_diam/2-pcb_width+wall/2,
+ batt_diam/2+pcb_thick+pcb_comp_h-4*wall + lid_sep])
+ cube([eps, pcb_width-2*wall, eps]);
};
- 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);
+/*
+ hull() {
+ difference() {
+ translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
+ cylinder(r=batt_diam/2-wall-lid_sep, h=batt_len+2*wall+2*cable_sep);
+ translate([-infty/2, -batt_diam/2, -infty-wire_sep/2-wire_thick/2])
+ cube([infty, batt_diam, infty]);
+ };
+ 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])
+ cube([batt_len + 2*wall + 2* cable_sep, pcb_width-1.5*wall-1.5*lid_sep, eps]);
};
- // 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+2*pcb_comp_h+wall])
+ case($fn=128);
+ translate([0, -15, batt_diam/2+wall])
+ lid($fn=128);
+}
-translate([0, 19, 0])
- cover($fn=128);
https://www.fi.muni.cz/~kas/git / heater.git / blobdiff