X-Git-Url: https://www.fi.muni.cz/~kas/git//home/kas/public_html/git/?p=heater.git;a=blobdiff_plain;f=case.scad;h=596b0daf59fbb3639c767c6f5155f57166471686;hp=a5d6347fb218efe465d02563fd1e8c3a5407d9ff;hb=444a06ece7f2f468445e188b5f9801850564a19d;hpb=4bb08ddf38fd72518684972dd82853c6e820cf62

diff --git a/case.scad b/case.scad
index a5d6347..596b0da 100644
--- a/case.scad
+++ b/case.scad
@@ -6,10 +6,10 @@ infty = 300;
 wall = 1.5; // generic wall thickness
 
 // 18650 is ~18mm diameter, ~65mm length, 
-batt_diam = 18 + 1.0;
+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;
@@ -19,6 +19,7 @@ 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 = 0.35 * batt_diam; // cube-shaped part of the body
@@ -30,7 +31,8 @@ batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
 
 lid_sep = 0.2; // the lid is made this much smaller to separate from the body
 
-sw_diam = 2.5 + 0.5;
+// sw_diam = 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
@@ -50,6 +52,8 @@ 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])
@@ -64,13 +68,13 @@ module case_body() {
 		};
 		translate([-front_flat_len/2,
 			batt_diam/2 - pcb_width,
-			-batt_diam/2-2*pcb_comp_h-pcb_thick-wall])
+			-batt_diam/2-pcb_comp_h-pcb_comp_h2-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])
+			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])
@@ -119,23 +123,29 @@ module case() {
 			-pcb_width+batt_diam/2,
 			-batt_diam/2-outcable_h])
 			cube([outcable_w, infty, outcable_h]);
-		// hole under the PCB
+		// 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]);
+				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 - 2*pcb_comp_h])
+			-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_h])
+				translate([prg_len/2+pcb_groove, -eps, pcb_comp_h2])
 					cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
 			};
-                // LED hole
+                // 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])
@@ -170,68 +180,109 @@ 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-pcb_comp_h-pcb_comp_h2-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-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-pcb_comp_h-pcb_comp_h2-pcb_thick-wall-eps])
+			cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps);
+		// 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]);
 	};
 	// clip barrier
 	for (x = [-1, 1]) scale([x, 1, 1]) hull () {
-		translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall/2+lid_sep,
+		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-eps, batt_diam/2-pcb_width+3*wall/2+lid_sep,
+		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([-clip_pretension, 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-clip_pretension, 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+pcb_comp_h+pcb_comp_h2+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+pcb_comp_h+pcb_comp_h2+pcb_thick+wall])
+			cube([wall-lid_sep, pcb_width+wall, eps]);
+	};
 };
 
 module lid() {
@@ -239,6 +290,16 @@ 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])
@@ -249,6 +310,7 @@ 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]);
 		};
+*/
 	};
 };
 
@@ -256,7 +318,7 @@ 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])
+	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);