case.scad: more improvements

diff --git a/case.scad b/case.scad
index a76ae70445eaa57130250c35948053b2fd007fb4..b1e5a3f61ddab292b1731be9170bda8aed93defe 100644 (file)
--- a/case.scad
+++ b/case.scad
@@ -1,17 +1,4 @@
-/* TODO
-- vybrani pro otevreni
-- mozna sirsi misto na baterku?
-- vetsi vybrani pro baterku ve vicku
-- kuzelova dira pro tlacitka
-- jine diry pro uchyceni
-- zvetsit vybrani na strane tlacitek
-- mozna prilis velky klip zasunovaciho konce baterky
-- diry pro neizolovany drat muzou byt mensi
-- sirsi zakladna
-- mensi horni cast klipu baterky - pri 0.7 je sirka nahore 16 mm.
-*/
-
-lowres = 1;
+lowres = 0;
 
 eps = 0.01;
 infty = 300;
@@ -22,69 +9,53 @@ wall = 1.5; // generic wall thickness
 batt_diam = 18 + 0.6;
 batt_len = 65 + 1.5;
 
-cable_sep = 2.5;
+cable_sep = 1;
 
 // front flat area
-front_flat_len = batt_len + 2*wall + 2*cable_sep;
+front_flat_len = batt_len + 4*wall + 2*cable_sep;
 
 // 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;
+pcb_groove = 1;
 
-body_top_h = 0.30 * batt_diam; // cube-shaped part of the body
+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;
 
-pcbside_protrusion_len = 20;
-pcbside_protrusion_diam = 2.5;
-battside_protrusion_len = 10;
-battside_protrusion_diam = 2;
+batt_end_h = wire_sep/2 + wire_thick/2 + 1.5;;
 
-base_batt_extend = wall + pcb_thick; // extend the base on the battery side
-
-cover_sep = 0.1;
+lid_sep = 0.5; // the lid is made this much smaller to separate from the body
 
 sw_diam = 2.5 + 0.5;
 led_diam = 3 + 0.5;
 sw_xoff =  250 * 25.4/1000; // x offset of microswitches
+pcb_xoff = 90 * 25.4/1000; // offset of the LED from the middle of the PCB
 
-pcb_clip_w = 7;
-pcb_clip_off = led_xoff + pcb_clip_w/2;
-
-
-module battery() {
-       translate([-batt_len/2, 0, 0])
-               rotate([0, 90, 0])
-               cylinder(r=batt_diam/2, h = batt_len);
-};
+prg_len = 10; // programming connector
+prg_width = 7;
 
 module case_body() {
        hull() {
-               translate([-batt_len/2-wall-cable_sep, -batt_diam/2-wall, 0])
-                       cube([batt_len + 2*wall + 2*cable_sep,
+               translate([-batt_len/2-2*wall-cable_sep, -batt_diam/2-wall, 0])
+                       cube([batt_len + 4*wall + 2*cable_sep,
                                batt_diam+2*wall, body_top_h]);
                difference() {
-                       translate([-batt_len/2-wall-cable_sep, 0, 0])
+                       translate([-batt_len/2-2*wall-cable_sep, 0, 0])
                                rotate([0, 90, 0])
                                cylinder(r=batt_diam/2+wall,
-                                       h = batt_len + 2*wall + 2*cable_sep);
+                                       h = batt_len + 4*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);
-*/
        };
 };
 
@@ -102,17 +73,33 @@ module case() {
                        cylinder(r=batt_diam/2, h = batt_len);
 
                // hole for PCB
-               translate([-pcb_len/2,
+               translate([-pcb_len/2-pcb_xoff,
                        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 above the PCB
+               translate([-pcb_len/2-pcb_xoff-wall-2*outwire_thick,
+                       batt_diam/2-pcb_width,
+                       -batt_diam/2-pcb_comp_h])
+                       cube([pcb_len, pcb_width,
+                               batt_diam/2 + pcb_comp_h + eps]);
                // hole under the PCB
-               translate([-pcb_len/2+pcb_groove,
+               translate([-pcb_len/2+pcb_groove-pcb_xoff,
                        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]);
+               // hole for prog connector
+               translate([pcb_len/2-pcb_xoff-pcb_groove-eps,
+                       batt_diam/2-pcb_width/2-prg_width/2,
+                       -batt_diam/2-pcb_thick - 2*pcb_comp_h])
+                       difference() {
+                               cube([prg_len+pcb_groove+eps, prg_width,
+                                       batt_diam/2 + pcb_thick + pcb_comp_h + eps]);
+                               translate([prg_len/2+pcb_groove, -eps, pcb_comp_h])
+                                       cube([prg_len/2+eps, prg_width+2*eps, pcb_thick]);
+                       };
                 // LED hole
                translate([0, batt_diam/2-pcb_width/2, -infty/2]) {
                        cylinder(r=led_diam/2, h=infty, $fn=6);
@@ -121,14 +108,24 @@ 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-wall-cable_sep-eps, 0, 0])
+               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 + 2*wall + 2*cable_sep + 2*eps);
-                               translate([-infty/2, -infty/2, -body_top_h])
+                                       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])
@@ -145,51 +142,93 @@ module case() {
                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]);
+                               cube([wall + cable_sep + eps, batt_diam, infty]);
                        rotate([0, 90, 0])
-                               cylinder(r = batt_diam/2, h = cable_sep+eps);
+                               cylinder(r = batt_diam/2, h = wall+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]);
+                               cube([wall + cable_sep + eps, pcb_width, eps]);
+                       translate([cable_sep, batt_diam/2 - pcb_width + 1.5*wall,
+                               -batt_diam/2-pcb_comp_h-pcb_thick-wall])
+                               cube([wall + eps, pcb_width-2*wall, eps]);
                };
+               // cable lead to battery contacts
+               for (x=[1, -1]) scale([x, 1, 1])
+                       rotate([-140, 0, 0])
+                       translate([batt_len/2+wire_thick/2, 0, batt_diam/2-2*wall])
+                               cylinder(r=wire_thick/2, h = 5);
+               
+               // 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_end_h-wire_thick/2])
+                       rotate([-90, 0, 0])
+                       scale([2,1,1]) cylinder (r=wire_thick/2, h=infty, $fn=16);
        };
+       // clip barrier
+       for (x = [-1, 1]) scale([x, 1, 1])
+               translate([batt_len/2+wall-eps, batt_diam/2-pcb_width+wall+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]);
 };
 
 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,
+       translate([-batt_len/2 - wall - lid_sep, -batt_diam/2+lid_sep, -batt_diam/2 -wall])
+               cube([batt_len + 2*wall + 2*lid_sep, batt_diam-2*lid_sep, batt_diam/2 - batt_end_h + wall - lid_sep]);
+       translate([-batt_len/2 - 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]);
+               cube([batt_len + 4*wall + 2*cable_sep, batt_diam + 2*wall,
+                       wall + batt_diam/2 - body_top_h - lid_sep]);
        // 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]);
+               scale([x, 1, 1]) translate([batt_len/2+wall+lid_sep, 0, 0]) hull() {
+                       translate([0, -batt_diam/2+lid_sep, -batt_diam/2])
+                               cube([wall+cable_sep-lid_sep, batt_diam-2*lid_sep, eps]);
                        rotate([0, 90, 0])
-                               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]);
+                               cylinder(r = batt_diam/2-lid_sep, h = wall+cable_sep-lid_sep);
+                       translate([0, 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,
+                               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]);
                };
 };
 
 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);
+               translate([-batt_len/2+eps, 0, 0]) rotate([0, 90, 0])
+                       cylinder(r=batt_diam/2, h=batt_len-2*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]);
+               };
        };
 };
 
-/*
-color("lightblue", 0.2)
-       translate([-65/2, 0, 0])
+module vert_torus() {
        rotate([0, 90, 0])
-       cylinder(r=18/2, h=65);
-*/
-translate([0, 30, 0]) case($fn=128);
-lid($fn=128);
+       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();
+} else {
+       translate([0, 15, batt_diam/2+pcb_thick+2*pcb_comp_h+wall])
+               case($fn=128);
+       translate([0, -15, batt_diam/2+wall])
+               lid($fn=128);
+}