From: Jan "Yenya" Kasprzak <kas@fi.muni.cz>
Date: Wed, 15 Jan 2014 15:23:12 +0000 (+0100)
Subject: case.scad: both parts of the case
X-Git-Url: https://www.fi.muni.cz/~kas/git//home/kas/public_html/git/?p=heater.git;a=commitdiff_plain;h=8869cb3a648a8e9d90093cd7d936a54e87e0941c

case.scad: both parts of the case
---

diff --git a/case.scad b/case.scad
new file mode 100644
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
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);
-};
-