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=653a79a088bca941c0422254b9e882e87728af7a;hp=2b5a351ae7e4a97a7c0aca760130117ee9071e41;hb=c9e34f298b058864dcf23965ed46975d6101be57;hpb=8869cb3a648a8e9d90093cd7d936a54e87e0941c;ds=inline

diff --git a/case.scad b/case.scad
index 2b5a351..653a79a 100644
--- a/case.scad
+++ b/case.scad
@@ -1,218 +1,254 @@
-// 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;
-
-wire_thick = 2;
-wire_sep = 3;
-cable_out_diam = 4;
-
-side_protrusion_len = 10;
-side_protrusion_diam = 2;
-
-base_batt_extend = wall+pcb_thick; // extend the base on the battery side
-
-cover_sep = 0.2;
-
-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;
-
-pcb_clip_w = 7;
-pcb_clip_off = led_xoff + pcb_clip_w/2;
-
-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);
-};
+wall = 1.5; // generic wall thickness
 
-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]);
-};
+// 18650 is ~18mm diameter, ~65mm length, 
+batt_diam = 18 + 0.8;
+batt_len = 65 + 2.0;
 
-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
+cable_sep = 1.5;
+
+// front flat area
+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_comp_h2 = 4.5;	// height of the components on board - component side
+pcb_groove = 1;
+
+body_top_h = 0.38 * batt_diam; // cube-shaped part of the body
+
+wire_thick = 2.5;
+wire_sep = 3.5;
+
+lid_sep = 0.2; // the lid is made this much smaller to separate from the body
+
+// sw_diam = 2.5 + 0.5;
+sw_diam = 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
+
+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
+
+batt_contact_w = 12;
+batt_contact_h = 14;
+batt_contact_h_lid = batt_contact_h-2;
+clip_cyl_r = 0.7;
+batt_end_h = body_top_h - 4*clip_cyl_r;;
+
+
+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-0.5*wall,
+			-batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall])
+			cube([front_flat_len, pcb_width+1.5*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-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 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);
-
-		// holes for wire from battery to the PCB
-		translate([-infty/2, -batt_diam/2, wall + pcb_groove + wire_thick/2])
+		case_body();
+		// upper cube-shaped part
+		// rotate([20, 0, 0])
+		translate([-batt_len/2, -batt_diam/2, 0])
+			cube([batt_len, batt_diam, batt_end_h+eps]);
+		// upper longer cube-shaped part
+		difference() {
+			translate([-batt_len/2-cable_sep-wall, -batt_diam/2, batt_end_h])
+				cube([batt_len+2*cable_sep+2*wall, batt_diam, batt_diam]);
+			// clips
+			for (x = [-1,1]) scale([1, x, 1])
+				translate([batt_len/6, batt_diam/2, batt_end_h + 3*clip_cyl_r])
+				rotate([0, -90, 0])
+				cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
+		}
+		// grabbing holes
+		for (x=[-1,1]) scale([x,1,1])
+		translate([batt_len/2 + 2*wall + cable_sep+10-wall, 0, 0])
+			cylinder(r1 = 7, r2 = 10, h = body_top_h + eps);
+		// 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 (groove)
+		translate([-pcb_len/2+pcb_groove-pcb_xoff,
+			batt_diam/2-pcb_width + pcb_groove,
+			-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_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])
+				cylinder(r=sw_diam/2, h=infty, $fn=6);
+			translate([-sw_xoff, 0, 0])
+				cylinder(r=sw_diam/2, h=infty, $fn=6);
 		};
+		// wire hole from PCB to battery contacts
+		rotate([-48, 0, 0])
+		translate([-batt_len/2-wall-cable_sep, 0, -wire_thick/2-wall/2])
+			cube([batt_len + 2*wall + 2* cable_sep, batt_diam/2 + wire_thick + wall, wire_thick]);
+		// 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);
+		// holes in front of battery contacts
+		for(x=[-1,1]) scale([x, 1, 1])
+		translate([batt_len/2-eps, wall/2-batt_contact_w/2,
+			wall/2-batt_contact_h/2])
+			cube([wall+2*eps, batt_contact_w-wall, infty]);
+		// holes for battery contacts
+		for(x=[-1,1]) scale([x, 1, 1])
+		translate([batt_len/2+wall-eps, -batt_contact_w/2,
+			-batt_contact_h/2])
+			cube([cable_sep+2*eps, batt_contact_w, infty]);
+		// 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]);
 	};
 };
 
-module cover_internal() {
-	hull() { 
-		base();
-		// battery + wall + cable space
-		translate([-batt_len/2-wall, 0, batt_diam/2+wall])
-			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]);
+module lid_body() {
+	// outer part
+	hull() {
+		// smaller outermost part
+		translate([-batt_len/2 - wall - cable_sep, -batt_diam/2, -batt_diam/2 - wall])
+			cube([batt_len + 2*wall + 2*cable_sep, batt_diam, eps]);
+		// this part goes above the main body
+		translate([-batt_len/2 - 2*wall - cable_sep, -batt_diam/2-wall, -body_top_h - lid_sep])
+			cube([batt_len + 4*wall + 2*cable_sep, batt_diam+2*wall, eps]);
 	};
-};
+	// the part which goes inside the main 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]);
+	// clips
+	for (x = [-1, 1]) scale([1, x, 1])
+		translate([batt_len/6, batt_diam/2-lid_sep, - batt_end_h - clip_cyl_r - lid_sep])
+		rotate([0, -90, 0])
+		cylinder(r = clip_cyl_r, h = batt_len/3, $fn=4);
+	// translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
+}
 
-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-lid_sep, 0, 0]) rotate([0, 90, 0])
+			cylinder(r=batt_diam/2 + lid_sep, h=batt_len+2*lid_sep);
+		// holes for battery contacts
+		for(x=[-1,1]) scale([x, 1, 1])
+		translate([batt_len/2+wall-eps, -batt_contact_w/2,
+			-batt_contact_h_lid/2])
+			cube([cable_sep+2*eps, batt_contact_w, infty]);
 	};
-	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);
-		};
-		// 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+pcb_comp_h+pcb_comp_h2+wall])
+		case($fn=128);
+	translate([0, -15, batt_diam/2+wall])
+		lid($fn=128);
+}
 
-translate([0, 19, 0])
- 	cover($fn=128);