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=f96549a734a789058dadc93c8d96fa2a74bcded0;hp=cb028f6ddabe21961602af0fa515ac93ce368444;hb=b30695c8b29227d4de4624940982d94899e8a348;hpb=114123230346ffb55488189a1a95182e8cece162

diff --git a/case.scad b/case.scad
index cb028f6..f96549a 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 + 0.6;
-batt_len = 65 + 1.5;
+batt_diam = 18 + 0.8;
+batt_len = 65 + 2.0;
 
-cable_sep = 1;
+cable_sep = 1.5;
 
 // front flat area
 front_flat_len = batt_len + 4*wall + 2*cable_sep;
@@ -23,14 +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 = 0.5; // 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;
@@ -40,8 +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() {
@@ -60,14 +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();
@@ -87,12 +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,
@@ -117,11 +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() {
@@ -149,62 +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 + 1.5*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*wall])
-				cylinder(r=wire_thick/2, h = 5);
+			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+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]);
+				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() {
@@ -212,6 +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])
@@ -222,22 +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();