adafruit-powerboost-common.scad

   1 // -*- C -*-
   2
   3 include <nutbox.scad>
   4 include <utils.scad>
   5
   6 psu_sz  = psu_sz_nom + [ 0.11, 0.44 ] + [ 0.25, 0.25 ];
   7
   8 psu_hole_pos = [ 2.05, // from back edge of psu_sz[0]
   9                  0.55 * 0.5 * 25.4, // from centreline
  10                  ];
  11
  12 psu_th = 1.70 + 0.25;
  13 psu_th_for_clamp = 1.50;
  14
  15 psu_hole_dia = 2.5 - 0.3;
  16 psu_connector_z = 2.9 + 0.1;
  17 psu_connector_z_overlap = 0.15;
  18 psu_connector_depth = 6.25;
  19 psu_connector_w = 8.0 + 0.5;
  20 psu_usb_protr = 0.6;
  21
  22 psu_clamp_th = 4.0 + 0.75;
  23 psu_clamp_w = 8.0;
  24 psu_clamp_gap = 0.4;
  25
  26 psu_board_clamp_ovlp = 4.5;
  27 psu_board_nutbox = nutbox_data_M3;
  28
  29 psu_board_gap = 0.5;
  30 psu_board_support_wall = 2;
  31 psu_board_support_ovlp = 4.5;
  32 psu_board_support_ovlp_ceil = 2;
  33 psu_board_support_z = 2;
  34
  35 psu_baffle_gap = 1.0 + 0.5;
  36
  37 psu_y = +psu_sz[1]/2 + psu_usb_protr;
  38
  39 // ----- calculated -----
  40
  41 psu_z = NutBox_h_base(psu_board_nutbox);
  42 psu_z_down = psu_z + 0.1;
  43 psu_fix_sz = NutBox_outer_size(psu_board_nutbox);
  44
  45 module PsuBoardRepresentation(){
  46   linear_extrude(height= psu_th)
  47     square(center=true, [psu_sz[0],psu_sz[1]]);
  48 }
  49
  50 module PsuRepresentation(){
  51   PsuBoardRepresentation();
  52   translate([0, -psu_sz[1]/2, -psu_connector_z])
  53     linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
  54     rectfromto([ -psu_connector_w/2, -10 ],
  55                [ +psu_connector_w/2, psu_connector_depth ]);
  56 }
  57
  58 module AtPsuMountCorner(mx,my){
  59   mirror([mx,0,0])
  60     mirror([0,my,0])
  61       translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
  62                 -1 * [0,0, psu_z_down])
  63         children();
  64 }
  65
  66 module PsuMountCornerExtrude(mx,my, plus_z=psu_board_support_z){
  67   AtPsuMountCorner(mx,my){
  68     linear_extrude(height= psu_z_down + plus_z, convexity=10) {
  69       children();
  70     }
  71   }
  72 }
  73
  74 module PsuMountPositiveMain(){
  75   for (mx=[0,1]) {
  76     for (my=[0,1]) {
  77       PsuMountCornerExtrude(mx,my){
  78         rectfromto(-[1,1]*psu_board_support_wall,
  79                    +[1,1]*psu_board_support_ovlp);
  80       }
  81     }
  82     // mount above at plug end
  83     PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
  84       rectfromto(-[1,1]*psu_board_support_wall,
  85                  [psu_board_support_ovlp,
  86                   psu_board_support_ovlp_ceil]);
  87     }
  88   }
  89   translate([0,0, -psu_z_down])
  90     linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
  91       PsuLedBafflePlan();
  92 }
  93
  94 module PsuMountNegative(){
  95   axis = [0, -psu_sz[1]/2, psu_th];
  96   PsuRepresentation();
  97   translate(axis)
  98     rotate([atan(2 * psu_board_support_z / psu_sz[1]),
  99             0,0])
 100     translate(-axis)
 101     PsuBoardRepresentation();
 102 }
 103
 104 module PsuMountPositive(){
 105   difference(){
 106     intersection(){
 107       PsuMountPositiveMain();
 108       linextr_y_xz(-psu_y, psu_sz[1]*2) square(100, center=true);
 109     }
 110     PsuMountNegative();
 111     intersection(){
 112       hull(){
 113         PsuBoardRepresentation();
 114         translate([0,0,5]) PsuBoardRepresentation();
 115       }
 116       translate([-20,0,-20]) cube(40);
 117     }
 118   }
 119   for (mx=[0,1]) {
 120     PsuMountCornerExtrude(mx,1){
 121       translate([psu_sz[0]/2 - psu_hole_pos[1],
 122                  psu_hole_pos[0]]
 123                 + psu_board_gap * [1,1] )
 124         circle(r= psu_hole_dia/2);
 125     }
 126   }
 127   translate([0, psu_sz[1]/2 + psu_board_nutbox[0]/2, 0])
 128     rotate([0,0,180])
 129     NutBox(psu_board_nutbox, psu_z_down);
 130 }
 131
 132 module PsuClamp(){ ////toplevel
 133   rotate([180,0,0]) difference(){
 134     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
 135       difference(){
 136         hull(){
 137           circle(r = psu_fix_sz/2);
 138           translate([ -psu_board_nutbox[0]/2, 0])
 139             square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
 140         }
 141         circle(r = psu_board_nutbox[0]/2);
 142       }
 143     }
 144     translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
 145       translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
 146         mirror([1,0])
 147         translate([0,-20]) square(40);
 148     }
 149   }
 150 }
 151
 152 module PsuLedWindowsPlan(){
 153   difference(){
 154     PsuLedWindowsPlanCore();
 155     PsuLedBafflePlan();
 156   }
 157 }
 158
 159 module PsuMountDemo(ceil = 2.5) { ////toplevel
 160   translate([0, psu_y, psu_z]) {
 161     difference(){
 162       PsuMountPositive();
 163       linextr(-20, 0.1)
 164         PsuLedWindowsPlan();
 165     }
 166     %PsuMountNegative();
 167     color("yellow") translate([0,0, -psu_z - ceil])
 168       linear_extrude(height=0.4, convexity=10)
 169       PsuLedWindowsPlan();
 170   }
 171 }
 172
 173 module PsuMountTest(ceil = 2.5) { ////toplevel
 174   $fs = 0.1;
 175   $fa = 3;
 176   difference(){
 177     union(){
 178       translate([0, psu_y, psu_z])
 179         PsuMountPositive();
 180       difference(){
 181         linextr_x_yz(-(psu_sz[0]/2 + 5),
 182                      +(psu_sz[0]/2 + 5)){
 183           difference(){
 184             rectfromto([-ceil, -ceil], [psu_sz[1] + 10, psu_z + 10]);
 185             rectfromto([0,0], 400*[1,1]);
 186           }
 187         }
 188         translate([0, psu_y, psu_z]) {
 189           PsuMountNegative();
 190         }
 191       }
 192     }
 193     translate([0, psu_y, psu_z]) {
 194       linextr(-10, 0.1)
 195         PsuLedWindowsPlan();
 196     }
 197   }
 198 }