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 = 1;
+cable_sep = 1.5;
// front flat area
front_flat_len = batt_len + 4*wall + 2*cable_sep;
body_top_h = 0.35 * batt_diam; // cube-shaped part of the body
-outwire_thick = 2.2;
wire_thick = 2.2;
wire_sep = 3.5;
-cable_out_diam = 5.2;
batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
-lid_sep = 0.5; // the lid is made this much smaller to separate from the body
+lid_sep = 0.2; // the lid is made this much smaller to separate from the body
sw_diam = 2.5 + 0.5;
led_diam = 3 + 0.5;
prg_len = 10; // programming connector
prg_width = 7;
-rear_clip_hole_dist = 10; // distance between the holes in the rear clip
-rear_clip_aspect = 0.35; // w/h aspect ratio of the ellipse of the rear clip
+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() {
-batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
cube([front_flat_len, pcb_width+wall, eps]);
};
- for (x = [-1, 1]) scale([x, 1, 1]) hull() {
- for (x0 = [0-wall, 10+wall])
- translate([batt_len/2-wall-wire_thick-x0, batt_diam/2, 0])
- rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1])
- cylinder(r=batt_diam/2 + 2*wall + wire_thick, h=wall);
- };
+ // 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 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();
-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
- translate([-pcb_len/2-pcb_xoff-wall-2*outwire_thick,
+ // 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,
translate([-sw_xoff, 0, 0])
cylinder(r=sw_diam/2, h=infty, $fn=6);
};
- // cable outlet
- translate([-pcb_xoff-pcb_len/2-outwire_thick-wall, -6, 0])
- rotate([40, 0, 0])
- scale([2, 1, -1])
- cylinder(r=outwire_thick/2, h = infty, $fn=12);
// space under the wire holes for battery contacts
translate([-batt_len/2-2*wall-cable_sep-eps, 0, 0])
difference() {
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() {
+ scale([x, 1, 1]) translate([batt_len/2+wall+cable_sep, 0, 0]) hull() {
translate([0, -batt_diam/2, 0])
- cube([wall + cable_sep + eps, batt_diam, infty]);
+ cube([wall + eps, batt_diam, infty]);
rotate([0, 90, 0])
- cylinder(r = batt_diam/2, h = wall+cable_sep+eps);
+ 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 + cable_sep + eps, pcb_width, eps]);
- translate([cable_sep, batt_diam/2 - pcb_width + 1.5*wall,
- -batt_diam/2-pcb_comp_h-pcb_thick-wall])
- cube([wall + eps, pcb_width-2*wall, eps]);
+ 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+wire_thick/2, 0, batt_diam/2-2*wall])
- cylinder(r=wire_thick/2, h = 5);
+ 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-wall-wire_thick, batt_diam/2+2*wall, -batt_diam/2-pcb_thick-2*pcb_comp_h-wall])
- vert_torus();
-
- for (x = [-1, 1]) scale([x, 1, 1]) for (x0 = [0, 10])
- translate([batt_len/2-wall-wire_thick-x0, 0, batt_diam/2+wire_thick/2+wall])
- rotate([-90, 0, 0])
- scale([2,1,1]) cylinder (r=wire_thick/2, h=infty, $fn=16);
+ 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])
- translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall+lid_sep,
+ 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([cable_sep+eps, pcb_width-2*wall-2*lid_sep, wall]);
+ 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 lid_body() {
- translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
- cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
- translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2 - wall,
- -batt_diam/2-wall])
- cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall,
- wall + batt_diam/2 - body_top_h - lid_sep]);
+ 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+lid_sep, 0, 0]) hull() {
+ 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+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]);
+ cube([wall-lid_sep, batt_diam-2*lid_sep, eps]);
rotate([0, 90, 0])
- cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep);
- translate([0, batt_diam/2 - pcb_width+lid_sep,
- batt_diam/2+pcb_comp_h+pcb_thick-lid_sep])
- cube([wall+cable_sep-lid_sep, pcb_width-2*lid_sep, eps]);
- translate([cable_sep+wall/2, batt_diam/2 - pcb_width + 1.5*wall +lid_sep,
- batt_diam/2+pcb_comp_h+pcb_thick+wall/2-lid_sep])
- cube([wall/2-lid_sep, pcb_width-2*wall-2*lid_sep, eps]);
+ 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 lid() {
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]);
+ };
+/*
hull() {
difference() {
translate([-batt_len/2-cable_sep-wall, 0, 0]) rotate([0, 90, 0])
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]);
};
- // holes for the mounting clips on the body
- for (x = [-1, 1]) scale([x, 1, 1]) hull() {
- for (x0 = [0-wall, 10+wall])
- translate([batt_len/2-wall-wire_thick-x0, batt_diam/2-lid_sep+eps, 0])
- rotate([-90, 0, 0]) scale([rear_clip_aspect, 1, 1])
- cylinder(r=batt_diam/2 + 2*wall + wire_thick+lid_sep/rear_clip_aspect, h=wall+lid_sep+eps);
- };
+*/
};
};
-module vert_torus() {
- rotate([0, 90, 0])
- scale([1, 1, 2])
- rotate_extrude() translate([5, 0, 0]) circle(r=wire_thick/2, $fn=16);
-};
-
if (lowres) {
translate([0, 15, 0]) case();
translate([0, -15, 0]) rotate([180, 0, 0]) lid();
https://www.fi.muni.cz/~kas/git / heater.git / blobdiff