From d8fe6bf8d2535bcbabecb67c91a7a6a4bfc6b949 Mon Sep 17 00:00:00 2001 From: "Jan \"Yenya\" Kasprzak" Date: Thu, 16 Jan 2014 17:16:06 +0100 Subject: [PATCH 1/1] case.scad: different approach --- case.scad | 319 +++++++++++++++++++++--------------------------------- 1 file changed, 126 insertions(+), 193 deletions(-) diff --git a/case.scad b/case.scad index 6a000e8..a76ae70 100644 --- a/case.scad +++ b/case.scad @@ -13,23 +13,28 @@ lowres = 1; +eps = 0.01; +infty = 300; + +wall = 1.5; // generic wall thickness + // 18650 is ~18mm diameter, ~65mm length, batt_diam = 18 + 0.6; batt_len = 65 + 1.5; -wall = 2.2; -base_h = 3; + cable_sep = 2.5; +// front flat area +front_flat_len = batt_len + 2*wall + 2*cable_sep; -eps = 0.01; -infty = 300; - -pcb_len = 36 + 1; -pcb_thick = 1.2 + 0.3; -pcb_groove = 1; -pcb_width = 11 + 0.5; +// 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_groove = 0.5; -batt_clip_h = base_h + pcb_width - pcb_groove; +body_top_h = 0.30 * batt_diam; // cube-shaped part of the body wire_thick = 2.2; wire_sep = 3.5; @@ -44,219 +49,147 @@ base_batt_extend = wall + pcb_thick; // extend the base on the battery side cover_sep = 0.1; -uswitch_diam = 2.5 + 0.5; +sw_diam = 2.5 + 0.5; led_diam = 3 + 0.5; -s2_xoff = -160 * 25.4/1000; -led_xoff = 90 * 25.4/1000; -s1_xoff = 340 * 25.4/1000; +sw_xoff = 250 * 25.4/1000; // x offset of microswitches 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([batt_len + 2*wall, pcb_thick + wall + eps, base_h], center=true); - // battery-side extension - translate([0, batt_diam/2 + wall + base_batt_extend, 0]) - cube([batt_len + 2*wall, eps, base_h], center=true); - }; - }; -} -module base_protrusions() { - // pcb-side side protrusion - translate([-pcbside_protrusion_len/2, -batt_diam/2-2*wall-pcb_thick, base_h-pcbside_protrusion_diam/2]) - rotate([0, 90, 0]) - cylinder(r = pcbside_protrusion_diam/2, h = pcbside_protrusion_len, $fn = 6); - - // battery-side side protrusion - translate([-battside_protrusion_len/2, batt_diam/2+wall+base_batt_extend, base_h-battside_protrusion_diam/2]) - rotate([0, 90, 0]) - cylinder(r = battside_protrusion_diam/2, h = battside_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 battery() { + translate([-batt_len/2, 0, 0]) + rotate([0, 90, 0]) + cylinder(r=batt_diam/2, h = batt_len); }; -module batt_clips() { - difference() { - union() { - // frot + rear part of the battery clip - for (r = [0, 180]) { - rotate([0, 0, r]) - 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([-15/2, 0, -batt_clip_h/2]) - cube([15, 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); - }; - // pcb holder - pcb side only - translate([-pcb_len/2-wall, -batt_diam/2-wall, 0]) - hull() { - cube([pcb_groove + wall, batt_diam/2 + wall, base_h + pcb_width + wall - pcb_groove]); - translate([-3*(pcb_groove+wall), 0, 0]) - cube([4*(pcb_groove+wall), batt_diam/2 + wall, base_h]); - }; - } - // top part rounded +module case_body() { + hull() { + translate([-batt_len/2-wall-cable_sep, -batt_diam/2-wall, 0]) + cube([batt_len + 2*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-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 + 2*wall + 2*cable_sep); + 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]); +/* + translate([-batt_len/2 - 2*wall - cable_sep, 0, 0]) + rotate([0, 90, 0]) + cylinder(r = 1.414*wire_sep + wire_thick, + h = batt_len + 4*wall + 2*cable_sep); +*/ }; }; -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() { +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]) + case_body(); + // upper cube-shaped part + // rotate([20, 0, 0]) + translate([-batt_len/2, -batt_diam/2, 0]) + cube([batt_len, batt_diam, batt_diam]); + + // 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); + cylinder(r=batt_diam/2, h = batt_len); - // holes for wire from battery to the PCB - translate([-infty/2, -batt_diam/2, base_h + 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); + // hole for PCB + translate([-pcb_len/2, + 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 under the PCB + translate([-pcb_len/2+pcb_groove, + batt_diam/2-pcb_width + pcb_groove, + -batt_diam/2-pcb_thick - 2*pcb_comp_h]) + cube([pcb_len-2*pcb_groove, pcb_width-2*pcb_groove, + batt_diam/2 + pcb_thick + pcb_comp_h + eps]); + // LED hole + 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); + }; + // space under the wire holes for battery contacts + translate([-batt_len/2-wall-cable_sep-eps, 0, 0]) + difference() { + rotate([0, 90, 0]) + cylinder(r = batt_diam/2-wall, h = batt_len + 2*wall + 2*cable_sep + 2*eps); + translate([-infty/2, -infty/2, -body_top_h]) + cube(infty); }; + // 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, 0, 0]) hull() { + translate([0, -batt_diam/2, 0]) + cube([cable_sep + eps, batt_diam, infty]); + rotate([0, 90, 0]) + cylinder(r = batt_diam/2, h = cable_sep+eps); + translate([0, batt_diam/2 - pcb_width, + -batt_diam/2-pcb_comp_h-pcb_thick]) + cube([cable_sep + eps, pcb_width, eps]); }; - // hole for easy opening - translate([-battside_protrusion_len/2, batt_diam/2+wall+base_batt_extend, base_h-3*battside_protrusion_diam/2]) - rotate([0, 90, 0]) - cylinder(r = battside_protrusion_diam/2, h = battside_protrusion_len, $fn = 4); - }; }; -module cover_internal() { - hull() { - base(); - // battery + wall + cable space - translate([-batt_len/2, 0, batt_diam/2+wall]) +module lid_body() { + translate([-batt_len/2 + eps, -batt_diam/2, -batt_diam/2-eps]) + cube([batt_len - 2*eps, batt_diam, batt_diam/2 - body_top_h + wall + eps]); + translate([-batt_len/2 - wall - cable_sep, -batt_diam/2 - wall, + -batt_diam/2-wall]) + cube([batt_len + 2*wall + 2*cable_sep, batt_diam + 2*wall, + wall + batt_diam/2 - body_top_h]); + // clip behind the battery contacts + for(x=[1, -1]) + scale([x, 1, 1]) translate([batt_len/2+cable_sep, 0, 0]) hull() { + translate([0, -batt_diam/2, -batt_diam/2]) + cube([wall, batt_diam, eps]); rotate([0, 90, 0]) - cylinder(r=batt_diam/2, h = batt_len); - // battery top - translate([0, 0, wall + batt_clip_h]) - cube([batt_len+2*wall + cable_sep, batt_diam + 2*wall, eps], center=true); - // 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]); - }; + cylinder(r = batt_diam/2, h = wall); + translate([0, batt_diam/2 - pcb_width, + batt_diam/2+pcb_comp_h+pcb_thick]) + cube([wall, pcb_width, eps]); + }; }; -module cover_hole() { +module lid() { difference() { - cover_internal(); - for (r = [0, 180]) { - rotate([0, 0, r]) - translate([batt_len/2, -infty/2, wall + batt_clip_h]) - cube(infty); - } + lid_body(); + translate([-batt_len/2-eps, 0, 0]) rotate([0, 90, 0]) + cylinder(r=batt_diam/2, h=batt_len+2*eps); }; - base_protrusions(); }; -module cover() { - difference() { - minkowski() { - cover_internal(); - if (lowres == 1) { - sphere(wall+cover_sep, $fn=6); - } else { - 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, 19, 0]) - cover_hole(); +color("lightblue", 0.2) + translate([-65/2, 0, 0]) + rotate([0, 90, 0]) + cylinder(r=18/2, h=65); */ +translate([0, 30, 0]) case($fn=128); +lid($fn=128); -// cover($fn=128); -// translate([0, 17, batt_diam + 3*wall + cover_sep]) -// rotate([180, 0, 0]) -// cover($fn=128); -translate([0, 19, 0]) { - if (lowres == 1) { - cover($fn=16); - } else { - cover($fn=128); - } -} -- 2.39.3