case.scad: version for metal springs

diff --git a/case.scad b/case.scad
index 596b0daf59fbb3639c767c6f5155f57166471686..43583c421d94b2cf58f0d88a3ff2be388cecb098 100644 (file)
--- a/case.scad
+++ b/case.scad
@@ -22,13 +22,11 @@ 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;
@@ -54,6 +52,11 @@ clip_pretension = 0.5;
 
 plus_width = 4.5; // width of the + sign
 
+batt_contact_w = 12;
+clip_cyl_r = 1;
+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])
@@ -100,7 +103,19 @@ module case() {
                // rotate([20, 0, 0])
                translate([-batt_len/2, -batt_diam/2, 0])
                        cube([batt_len, batt_diam, batt_diam]);
-
+               // 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]);
+                       for (x = [-1,1]) scale([x, 1, 1])
+                               translate([batt_len/2 + wall + cable_sep, -infty/2, batt_end_h + 3*clip_cyl_r])
+                               rotate([-90, 0, 0])
+                               cylinder(r = clip_cyl_r, h = infty, $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-wall/4, h = body_top_h + eps);
                // battery cylinder for the lower part
                translate([-batt_len/2, 0, 0])
                        rotate([0, 90, 0])
@@ -153,68 +168,25 @@ 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-pcb_comp_h-pcb_comp_h2-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+cable_sep+wall+10, batt_diam/2-pcb_width/2, -batt_diam/2-pcb_comp_h-pcb_comp_h2-pcb_thick-wall-eps])
-                       cylinder(r1 = 10, r2 = 10 - wall, h = wall + 2*eps);
+               translate([batt_len/2-eps, wall/2-batt_contact_w/2,
+                       wall/2-batt_contact_w/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+wall-eps, -batt_contact_w/2,
+                       -batt_contact_w/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]);
@@ -231,86 +203,33 @@ module case() {
                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]);
        };
-       // 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]);
-       };
 };
 
 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+pcb_comp_h+pcb_comp_h2+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+pcb_comp_h+pcb_comp_h2+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([x, 1, 1])
+       translate([batt_len/2 + wall + cable_sep - lid_sep, batt_diam/2 - lid_sep, -batt_end_h-lid_sep-clip_cyl_r])
+               rotate([90, 0, 0])
+               cylinder(r = clip_cyl_r, h = batt_diam-2*lid_sep, $fn = 4);
+}
 
 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);
        };
 };