From: Jan "Yenya" Kasprzak <kas@fi.muni.cz>
Date: Thu, 16 Jan 2014 16:16:06 +0000 (+0100)
Subject: case.scad: different approach
X-Git-Url: https://www.fi.muni.cz/~kas/git//home/kas/public_html/git/?a=commitdiff_plain;h=d8fe6bf8d2535bcbabecb67c91a7a6a4bfc6b949;p=heater.git

case.scad: different approach
---

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);
-	}
-}