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=f96549a734a789058dadc93c8d96fa2a74bcded0;hb=c9e34f298b058864dcf23965ed46975d6101be57;hpb=138fbcfab1abb032b8b532e845bfb92372a8d827

diff --git a/case.scad b/case.scad
index f96549a..653a79a 100644
--- a/case.scad
+++ b/case.scad
@@ -19,18 +19,18 @@ 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
+body_top_h = 0.38 * batt_diam; // cube-shaped part of the body
 
-wire_thick = 2.2;
+wire_thick = 2.5;
 wire_sep = 3.5;
 
-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
@@ -52,6 +52,13 @@ 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])
@@ -65,14 +72,14 @@ module case_body() {
 			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])
-			cube([front_flat_len, pcb_width+wall, eps]);
+			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-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])
@@ -97,8 +104,21 @@ module case() {
 		// upper cube-shaped part
 		// rotate([20, 0, 0])
 		translate([-batt_len/2, -batt_diam/2, 0])
-			cube([batt_len, batt_diam, batt_diam]);
-
+			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])
@@ -121,23 +141,29 @@ 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])
@@ -145,156 +171,74 @@ module case() {
 			translate([-sw_xoff, 0, 0])
 				cylinder(r=sw_diam/2, h=infty, $fn=6);
 		};
-		// space under the wire holes for battery contacts
-		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 + 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])
-			translate([-batt_len/2-wall-eps, x*wire_sep/2, y*wire_sep/2])
-			rotate([0, 90, 0])
-				cylinder(r = wire_thick/2, h = batt_len + 2*wall + 2*eps, $fn=6);
 		// wire hole from PCB to battery contacts
-		// translate([-batt_len/2-wall-eps, 0, -batt_diam/2-pcb_comp_h + wire_thick/2])
-		rotate([40, 0, 0])
-		translate([-batt_len/2-wall-eps, 0, -batt_diam/2 - wall/2 - wire_thick/2])
-			rotate([0, 90, 0])
-				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+cable_sep, 0, 0]) hull() {
-			translate([0, -batt_diam/2, 0])
-				cube([wall + eps, batt_diam, infty]);
-			rotate([0, 90, 0])
-				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 + 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-eps, -wire_thick/2, batt_diam/2-2.7])
-				cube([wall+cable_sep+2*eps, wire_thick, 5.4]);
-		
+		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);
-		// grabbing gap
+		// 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+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])
+		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]);
-		// plus and minus signs - horizontal line
+		// 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]);
-	};
-	// 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]);
+		// 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 lid_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]);
-	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+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-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]);
+	// 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 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);
-	// 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])
-					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([-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]);
 	};
 };
 
@@ -302,7 +246,7 @@ 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);