bike-lipo-box.scad

   1 // -*- C -*-
   2
   3 include <commitid.scad>
   4 include <utils.scad>
   5 include <sealing-box.scad>
   6 include <bike-lipo-box-gland.scad>
   7
   8 pxp6012_rad = 22.5 / 2 + 0.5; // make circular hole this size in outer wall
   9 pxp6012_rad_outer = 32.0 / 2 - 0.5;
  10
  11 s1930_y = 30.2 + 0.2;
  12 s1930_x =   22 + 0.2;
  13 s1930_y_outer = 36.4 + 0.2;
  14 s1930_x_outer = 27.6 + 0.2;
  15
  16 s1930_recess = 3;
  17 s1930_around = 3;
  18 s1930_behind = 3;
  19
  20 totx_inner = 180;
  21 toty_outer = 95;
  22 totz_inner = 27.0;
  23
  24 wallthick = 2.5;
  25
  26 cabledia = 8.7;
  27
  28 strap_w = 5 + 1;
  29 strap_th = 4 + 1;
  30 strap_pillar = 3;
  31 strap_pillard = 5;
  32 strap_over = 2;
  33
  34 lipokeeper_w = 10;
  35 lipokeeper_h = 8;
  36 lipokeeper_d_min = 2;
  37 lipokeeper_slope = 0.75;
  38
  39 straps_at_box = [45, 95, 125, 160];
  40 straps_every = 30;
  41
  42 // calculated
  43
  44 totx_outer = totx_inner + wallthick*2;
  45 toty_inner = toty_outer - wallthick*2;
  46 totz_outer = totz_inner + wallthick*2;
  47
  48 sb_box_sz = [totx_outer, totz_outer, toty_inner];
  49
  50 // origin is at centre on outer face wall
  51 // outside is towards positive x
  52 // mounting is vertical
  53 module S1930_Positive(){
  54   d = s1930_recess + s1930_behind;
  55   translate([-d/2, 0,0])
  56     cube([d,
  57           s1930_x_outer + s1930_around,
  58           s1930_y_outer + s1930_around], center=true);
  59 }
  60 module S1930_Negative(){
  61   cube([60, s1930_x, s1930_y],
  62        center=true);
  63   translate([1, 0,0])
  64     cube([s1930_recess*2+2, s1930_x_outer, s1930_y_outer],
  65          center=true);
  66 }
  67
  68 module TestWall(){ ////toplevel
  69   sw_ctr = [25, wallthick, 25];
  70
  71   rotate([0,0,-90]){
  72     difference(){
  73       union(){
  74         cube([50, wallthick, 42]);
  75       }
  76
  77       translate([30, -1, 20])
  78         rotate([-90,0,0])
  79         cylinder(r = pxp6012_rad, h=10, $fn=60);
  80
  81       rotate([90,0,0])
  82         Commitid_BestCount([15,40]);
  83     }
  84   }
  85
  86   difference(){
  87     union(){
  88       cube([50, wallthick, 50]);
  89       translate(sw_ctr)
  90         rotate([0,0,90])
  91         S1930_Positive();
  92     }
  93
  94     translate(sw_ctr) {
  95       rotate([0,0,90])
  96         S1930_Negative();
  97     }
  98   }
  99 }
 100
 101 ts_totx = 30;
 102 ts_toty = 25;
 103 ts_totz_inner = 8;
 104
 105 ts_box_sz = [ts_totx, ts_toty, ts_totz_inner];
 106
 107 $sealingbox_wallth = wallthick;
 108 $sealingbox_floorth = wallthick;
 109 $sealingbox_ceilth = wallthick;
 110
 111 module TestSealBox(){ ////toplevel
 112   $sealingbox_sz = ts_box_sz;
 113
 114   SealingBox_RectBox();
 115   ts_cidoff = ($sealingbox_cnrrad * (1-.7) + wallthick * .8) * [1,1];
 116   translate(ts_cidoff)
 117     Commitid_BestCount([ts_totx,ts_toty] - 2*ts_cidoff);
 118 }
 119
 120 module TestSealLid(){ ////toplevel
 121   $sealingbox_sz = ts_box_sz;
 122
 123   difference(){
 124     SealingBox_RectLid();
 125
 126     translate([ts_totx * .75, ts_toty/2, 0])
 127       cylinder(h=100, r=5);
 128
 129     translate([-wallthick + $sealingbox_cnrrad*.5,
 130                $sealingbox_cnrrad*.5 - wallthick,
 131                ts_totz_inner + $sealingbox_ceilth])
 132       Commitid_BestCount([ts_totx * .75 - 2.5 - ($sealingbox_cnrrad*.5),
 133                           ts_toty - ($sealingbox_cnrrad*.5 - wallthick)*2]);
 134   }
 135 }
 136
 137 module TestSealLidPrint(){ ////toplevel
 138   rotate([180,0,0]) TestSealLid();
 139 }
 140
 141 module ProfileDemos(){ ////toplevel
 142   $sealingbox_sz = ts_box_sz;
 143
 144   SealingBox_WallProfile();
 145   color("blue") SealingBox_FloorProfile();
 146   SealingBox_LidProfile();
 147   color("blue") SealingBox_CeilProfile();
 148   color("red") translate([-5,0]) square([1,ts_totz_inner]);
 149 }
 150
 151 module AtGlands(){
 152   for (dgy=[-15,-45]) {
 153     translate([totx_inner + wallthick - $sealingbox_cnrrad * .3,
 154                toty_inner + dgy,
 155                totz_inner/2])
 156       children();
 157   }
 158 }
 159
 160 module StrapKeepers(at){
 161   strap_x_tot = strap_w + strap_pillar*2;
 162
 163   for (sx= at) {
 164     echo("strapkeeper at ",sx);
 165     translate([sx - strap_x_tot, 0, 0])
 166       difference(){
 167       translate([0,0, -0.1])
 168         cube([strap_x_tot, strap_pillard, strap_th + strap_over]);
 169       translate([strap_pillar, -1, 0])
 170         cube([strap_w, strap_pillard+2, strap_th]);
 171     }
 172   }
 173 }
 174
 175 chargingconn_x = pxp6012_rad_outer + 1 + $sealingbox_cnrrad;
 176 switch_x = chargingconn_x + pxp6012_rad_outer
 177   + s1930_y_outer/2 + s1930_around;
 178
 179 module AtSealingBox(){
 180   rotate([90,0,0])
 181     translate([-wallthick,-wallthick, -toty_inner])
 182     children();
 183 }
 184
 185 module Box(){ ////toplevel
 186   $sealingbox_sz = sb_box_sz;
 187
 188   difference(){
 189     union(){
 190       AtSealingBox()
 191         SealingBox_RectBox();
 192
 193       translate([switch_x, toty_inner, totz_inner/2])
 194         rotate([90,0,90])
 195         S1930_Positive();
 196
 197       // keepers for lipo
 198       for (kx= [ 10, 40, 80, 120 ]) {
 199         translate([kx, 40, -1])
 200           hull(){
 201             cube([lipokeeper_w, lipokeeper_d_min, lipokeeper_h +1]);
 202             cube([lipokeeper_w,
 203                   lipokeeper_d_min + lipokeeper_h / lipokeeper_slope,
 204                   1]);
 205           }
 206       }
 207
 208       AtGlands()
 209         GlandPositive(cabledia);
 210
 211       translate([0, toty_inner+wallthick, -wallthick])
 212         rotate([180, 0,0])
 213         StrapKeepers(straps_at_box);
 214     }
 215
 216     // charging connector
 217     translate([chargingconn_x,
 218                toty_inner - (pxp6012_rad_outer + 5),
 219                10])
 220       cylinder(r= pxp6012_rad, h= totz_outer);
 221
 222     translate([switch_x, toty_inner, totz_inner/2])
 223       rotate([90,0,90])
 224       S1930_Negative();
 225
 226     AtGlands()
 227       GlandNegative(cabledia);
 228
 229     translate($sealingbox_cnrrad * [1,1,0] +
 230               [0, toty_inner/2, -wallthick])
 231       Commitid_Full16_M();
 232   }
 233 }
 234
 235 module BoxPrint(){ ////toplevel
 236   rotate([-90,0,-90])
 237     Box();
 238 }
 239
 240 module Lid(){ ////toplevel
 241   $sealingbox_sz = sb_box_sz;
 242   difference(){
 243     union(){
 244       AtSealingBox()
 245         SealingBox_RectLid();
 246       translate([0, -wallthick, -SealingBox_lidbigger()])
 247         mirror([0,0,1])
 248         StrapKeepers([ straps_every : straps_every
 249                        : totx_inner-straps_every ]);
 250     }
 251
 252     translate($sealingbox_cnrrad * [1,0,1])
 253       rotate([90,0,0])
 254       Commitid_Full16_M();
 255   }
 256 }
 257
 258 module LidPrint(){ ////toplevel
 259   rotate([90,0,-90])
 260     Lid();
 261 }
 262
 263 module Demo(){ ////toplevel
 264   color("blue") Box();
 265   color("red") Lid();
 266 }
 267
 268 //TestWall();
 269 //ProfileDemos();
 270 //TestSealBox();
 271 //TestSealLid();
 272 //FArcSegment_mask(350);
 273 //StrapKeepers();