bike-lipo-box.scad

   1 // -*- C -*-
   2
   3 include <commitid.scad>
   4 include <utils.scad>
   5 include <sealing-box.scad>
   6
   7 pxp6012_rad = 22.5 / 2 + 0.5; // make circular hole this size in outer wall
   8 pxp6012_rad_outer = 32.0 / 2 - 0.5;
   9
  10 s1930_y = 30.2 + 0.2;
  11 s1930_x =   22 + 0.2;
  12 s1930_y_outer = 36.4 + 0.2;
  13 s1930_x_outer = 27.6 + 0.2;
  14
  15 s1930_recess = 3;
  16 s1930_around = 3;
  17 s1930_behind = 3;
  18
  19 totx_inner = 180;
  20 toty_outer = 95;
  21 totz_outer = 31;
  22
  23 wallthick = 2.5;
  24
  25 // calculated
  26
  27 totx_outer = totx_inner + wallthick*2;
  28 toty_inner = toty_outer - wallthick*2;
  29 totz_inner = totz_outer - wallthick*2;
  30
  31 sb_box_sz = [totx_outer, totz_outer, toty_inner];
  32
  33 // origin is at centre on outer face wall
  34 // outside is towards positive x
  35 // mounting is vertical
  36 module S1930_Positive(){
  37   d = s1930_recess + s1930_behind;
  38   translate([-d/2, 0,0])
  39     cube([d,
  40           s1930_x_outer + s1930_around,
  41           s1930_y_outer + s1930_around], center=true);
  42 }
  43 module S1930_Negative(){
  44   cube([60, s1930_x, s1930_y],
  45        center=true);
  46   translate([1, 0,0])
  47     cube([s1930_recess*2+2, s1930_x_outer, s1930_y_outer],
  48          center=true);
  49 }
  50
  51 module TestWall(){ ////toplevel
  52   sw_ctr = [25, wallthick, 25];
  53
  54   rotate([0,0,-90]){
  55     difference(){
  56       union(){
  57         cube([50, wallthick, 42]);
  58       }
  59
  60       translate([30, -1, 20])
  61         rotate([-90,0,0])
  62         cylinder(r = pxp6012_rad, h=10, $fn=60);
  63
  64       rotate([90,0,0])
  65         Commitid_BestCount([15,40]);
  66     }
  67   }
  68
  69   difference(){
  70     union(){
  71       cube([50, wallthick, 50]);
  72       translate(sw_ctr)
  73         rotate([0,0,90])
  74         S1930_Positive();
  75     }
  76
  77     translate(sw_ctr) {
  78       rotate([0,0,90])
  79         S1930_Negative();
  80     }
  81   }
  82 }
  83
  84 ts_totx = 30;
  85 ts_toty = 25;
  86 ts_totz_inner = 8;
  87
  88 ts_box_sz = [ts_totx, ts_toty, ts_totz_inner];
  89
  90 $sealingbox_wallth = wallthick;
  91 $sealingbox_floorth = wallthick;
  92 $sealingbox_ceilth = wallthick;
  93
  94 module TestSealBox(){ ////toplevel
  95   $sealingbox_sz = ts_box_sz;
  96
  97   SealingBox_RectBox();
  98   ts_cidoff = ($sealingbox_cnrrad * (1-.7) + wallthick * .8) * [1,1];
  99   translate(ts_cidoff)
 100     Commitid_BestCount([ts_totx,ts_toty] - 2*ts_cidoff);
 101 }
 102
 103 module TestSealLid(){ ////toplevel
 104   $sealingbox_sz = ts_box_sz;
 105
 106   difference(){
 107     SealingBox_RectLid();
 108
 109     translate([ts_totx * .75, ts_toty/2, 0])
 110       cylinder(h=100, r=5);
 111
 112     translate([-wallthick + $sealingbox_cnrrad*.5,
 113                $sealingbox_cnrrad*.5 - wallthick,
 114                ts_totz_inner + $sealingbox_ceilth])
 115       Commitid_BestCount([ts_totx * .75 - 2.5 - ($sealingbox_cnrrad*.5),
 116                           ts_toty - ($sealingbox_cnrrad*.5 - wallthick)*2]);
 117   }
 118 }
 119
 120 module TestSealLidPrint(){ ////toplevel
 121   rotate([180,0,0]) TestSealLid();
 122 }
 123
 124 module ProfileDemos(){ ////toplevel
 125   $sealingbox_sz = ts_box_sz;
 126
 127   SealingBox_WallProfile();
 128   color("blue") SealingBox_FloorProfile();
 129   SealingBox_LidProfile();
 130   color("blue") SealingBox_CeilProfile();
 131   color("red") translate([-5,0]) square([1,ts_totz_inner]);
 132 }
 133
 134 module Box(){ ////toplevel
 135   $sealingbox_sz = sb_box_sz;
 136
 137   chargingconn_x = pxp6012_rad_outer + 1 + $sealingbox_cnrrad;
 138   switch_x = chargingconn_x + pxp6012_rad_outer
 139     + s1930_y_outer/2 + s1930_around;
 140
 141   difference(){
 142     union(){
 143       rotate([90,0,0])
 144         translate([-wallthick,-wallthick, -toty_inner])
 145         SealingBox_RectBox();
 146
 147       translate([switch_x, toty_inner, totz_inner/2])
 148         rotate([90,0,90])
 149         S1930_Positive();
 150     }
 151
 152     // charging connector
 153     translate([chargingconn_x,
 154                toty_inner - (pxp6012_rad_outer + 5),
 155                10])
 156       cylinder(r= pxp6012_rad, h= totz_outer);
 157
 158     translate([switch_x, toty_inner, totz_inner/2])
 159       rotate([90,0,90])
 160       S1930_Negative();
 161   }
 162 }
 163
 164 //TestWall();
 165 //ProfileDemos();
 166 //TestSealBox();
 167 //TestSealLid();
 168 //FArcSegment_mask(350);