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[heater.git] / case.scad
index e4acfcb..f96549a 100644 (file)
--- a/case.scad
+++ b/case.scad
@@ -1,20 +1,15 @@
-/* TODO
-   - nabeh zaklapavaciho hranolu by mel byt zkoseny
-   - vystup pro kabel leze do vystupu pro snuru pri vetsim wall
-   - diry pro uchyceni jsou mozna prilis male
-*/
-lowres = 1; // fast rendering or fine printing with print-friendly orientation
+lowres = 0; // fast rendering or fine printing with print-friendly orientation
 
 eps = 0.01;
 infty = 300;
 
-wall = 2.0; // generic wall thickness
+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;
+cable_sep = 1.5;
 
 // front flat area
 front_flat_len = batt_len + 4*wall + 2*cable_sep;
@@ -28,14 +23,12 @@ pcb_groove = 1;
 
 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 = 0.1; // 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;
@@ -45,8 +38,19 @@ pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
 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() {
@@ -65,14 +69,28 @@ module case_body() {
                        -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();
@@ -92,12 +110,17 @@ module case() {
                        -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,
@@ -122,11 +145,6 @@ module case() {
                        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() {
@@ -154,68 +172,101 @@ module case() {
                                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 + 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/2-2.7])
-                               cylinder(r=wire_thick/2, h = 5.4);
+                       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/2+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]);
-                       // rear cone
-                       translate([cable_sep+wall-lid_sep, 0, -batt_diam/2-wall]) difference() {
-                               scale([0.5, 1, 1])
-                               cylinder(r = batt_diam/2 - lid_sep,  h = eps);
-                               translate([-infty, -infty/2, -infty/2]) cube(infty);
-                       };
+                               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() {
@@ -223,6 +274,16 @@ 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])
@@ -233,22 +294,10 @@ module lid() {
                        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();