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=a76ae70445eaa57130250c35948053b2fd007fb4;hb=444a06ece7f2f468445e188b5f9801850564a19d;hpb=d8fe6bf8d2535bcbabecb67c91a7a6a4bfc6b949

diff --git a/case.scad b/case.scad
index a76ae70..596b0da 100644
--- a/case.scad
+++ b/case.scad
@@ -1,17 +1,4 @@
-/* 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;
@@ -19,75 +6,93 @@ 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 = 0.35 * batt_diam; // cube-shaped part of the body
 
 wire_thick = 2.2;
 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;
 
-base_batt_extend = wall + pcb_thick; // extend the base on the battery side
+batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
 
-cover_sep = 0.1;
+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
 
-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;
 
-module battery() {
-	translate([-batt_len/2, 0, 0])
-		rotate([0, 90, 0])
-		cylinder(r=batt_diam/2, h = batt_len);
-};
+// 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-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])
+			-batt_diam/2-pcb_comp_h-pcb_comp_h2-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);
-*/
+	};
+	// 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();
@@ -102,18 +107,45 @@ module case() {
 			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])
@@ -122,13 +154,18 @@ module case() {
 				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])
+		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 + 2*wall + 2*cable_sep + 2*eps);
-				translate([-infty/2, -infty/2, -body_top_h])
+					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])
@@ -143,53 +180,147 @@ 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([cable_sep + eps, batt_diam, infty]);
+				cube([wall + eps, batt_diam, infty]);
 			rotate([0, 90, 0])
-				cylinder(r = batt_diam/2, h = 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([cable_sep + eps, pcb_width, 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-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+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 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]);
+	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+cable_sep, 0, 0]) hull() {
-			translate([0, -batt_diam/2, -batt_diam/2])
-				cube([wall, batt_diam, eps]);
+		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, h = wall);
-			translate([0, batt_diam/2 - pcb_width,
-				batt_diam/2+pcb_comp_h+pcb_thick])
-				cube([wall, pcb_width, 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+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() {
 	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+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]);
 	};
-};
-
 /*
-color("lightblue", 0.2)
-	translate([-65/2, 0, 0])
-	rotate([0, 90, 0])
-	cylinder(r=18/2, h=65);
+		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]);
+		};
 */
-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);
+}