case.scad: both parts of the case

diff --git a/case.scad b/case.scad
new file mode 100644 (file)
index 0000000..2b5a351
--- /dev/null
+++ b/case.scad
@@ -0,0 +1,218 @@
+// 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;
+
+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);
+};
+
+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]);
+};
+
+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
+               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])
+                               rotate([0, 90, 0])
+                               cylinder(r=batt_diam/2+wall, h = infty);
+               };
+       };
+};
+
+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 main() {
+       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])
+                       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);
+                       };
+               };
+       };
+};
+
+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 cover_hole() {
+       difference() {
+               cover_internal();
+               translate([-infty/2, -infty/2, wall + batt_clip_h])
+                       cube(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);
+
+translate([0, 19, 0])
+       cover($fn=128);

diff --git a/heater-base.scad b/heater-base.scad
deleted file mode 100644 (file)
index a3a5706..0000000
--- a/heater-base.scad
+++ /dev/null
@@ -1,87 +0,0 @@
-// 18650 is ~18mm diameter, ~65mm length, 
-batt_diam = 18;
-batt_len = 65+1;
-batt_clip_h = 0.75 * batt_diam;
-wall = 2.2;
-
-eps = 0.01;
-infty = 300;
-
-pcb_len = 36;
-pcb_thick = 1.3;
-pcb_groove = 2;
-pcb_width = 11;
-pcb_clip_off = 5;
-pcb_clip_w = 8;
-
-wire_thick = 2;
-wire_sep = 3;
-
-translate([0, -batt_diam/2-wall-pcb_thick/2+eps, 0])
-difference() {
-       union() {
-               // lower part of the PCB holder
-               translate([0, 0, (pcb_groove + wall) / 2])
-                       cube([pcb_len + 2*wall, pcb_thick + 2*wall, pcb_groove + wall], center=true);
-               // rear part of the PCB holder (behind S1)
-               translate([pcb_clip_off, 0, 0])
-                       cube([pcb_clip_w, pcb_thick/2+wall/2, pcb_width + 2*wall]);
-               // side part of the PCB holder (near the battery wires)
-               translate([-pcb_len/2-wall, -pcb_thick/2-wall, 0])
-                       cube([pcb_groove+wall, pcb_thick+1.5*wall, pcb_width + 2*wall]);
-       };
-       // the PCB itself
-       translate([0, 0, wall + pcb_width/2])
-               cube([pcb_len, pcb_thick, pcb_width+eps], center=true);
-};
-
-difference() {
-       union() {
-               // lower part of the battery holder
-               translate([0, 0, pcb_groove/2 + wall/2])
-                       cube([batt_len + 2*wall, batt_diam + 2*wall, pcb_groove + wall],
-                       center=true);
-               // 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);
-                       };
-       };
-       // battery
-       translate([-batt_len/2, 0, batt_diam/2+wall])
-               rotate([0, 90, 0])
-               cylinder(r=batt_diam/2, h = batt_len);
-       // top part rounded
-       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])
-                       rotate([0, 90, 0])
-                       cylinder(r=batt_diam/2+wall, h = infty);
-       };
-       // wire holes
-       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);
-
-       translate([-infty/2, -batt_diam/2, wall + pcb_groove + wire_thick/2])
-               rotate([0, 90, 0])
-               rotate([0, 0, 90])
-               cylinder(r=wire_thick/2, h = infty, $fn=6);
-};
-