case.scad: alternative mounting holes, thicker side clips, clip pretension

diff --git a/case.scad b/case.scad
index e4acfcb8313a0df44c1b116dc14586a280b7a10e..a5d6347fb218efe465d02563fd1e8c3a5407d9ff 100644 (file)
--- a/case.scad
+++ b/case.scad
@@ -1,18 +1,13 @@
-/* TODO
-   - nabeh zaklapavaciho hranolu by mel byt zkoseny
-   - vystup pro kabel leze do vystupu pro snuru pri vetsim wall
-   - diry pro uchyceni jsou mozna prilis male
-*/
-lowres = 1; // fast rendering or fine printing with print-friendly orientation
+lowres = 0; // fast rendering or fine printing with print-friendly orientation
 
 eps = 0.01;
 infty = 300;
 
-wall = 2.0; // generic wall thickness
+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 + 1.0;
+batt_len = 65 + 2.0;
 
 cable_sep = 2;
 
@@ -28,14 +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 = 0.1; // 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;
@@ -45,8 +38,17 @@ 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;
 
 module case_body() {
        hull() {
@@ -65,14 +67,28 @@ 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();
@@ -92,12 +108,17 @@ 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,
@@ -122,11 +143,6 @@ 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() {
@@ -174,19 +190,19 @@ module case() {
                
                // 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);
        };
        // clip barrier
-       for (x = [-1, 1]) scale([x, 1, 1])
+       for (x = [-1, 1]) scale([x, 1, 1]) hull () {
                translate([batt_len/2+wall-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-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() {
@@ -203,10 +219,10 @@ module lid_body() {
                                cube([wall+cable_sep-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,
+                       translate([-clip_pretension, 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,
+                       translate([cable_sep+wall/2-clip_pretension, 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]);
                        // rear cone
@@ -233,22 +249,9 @@ 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();