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 jdae12pa_rad = 12 / 2 + 0.5;
  21 jdae12pa_rad_outer = 19 / 2 + 0.5; // head of an "M12 bolt"
  22
  23 totx_inner = 180;
  24 toty_outer = 95;
  25 totz_inner = 27.0;
  26
  27 wallthick = 2.5;
  28
  29 cabledia = 8.7;
  30
  31 strap_w = 5 + 1;
  32 strap_th = 4 + 1;
  33 strap_pillar = 3;
  34 strap_pillard = 5;
  35 strap_over = 2;
  36
  37 lipokeeper_w = 10;
  38 lipokeeper_h = 8;
  39 lipokeeper_d_min = 2;
  40 lipokeeper_slope = 0.75;
  41 lipokeeper_end_h = 12;
  42 lipokeeper_end_d_min = 15;
  43
  44 straps_at_box = [45, 95, 125, 160];
  45 straps_every = 30;
  46
  47 // calculated
  48
  49 totx_outer = totx_inner + wallthick*2;
  50 toty_inner = toty_outer - wallthick*2;
  51 totz_outer = totz_inner + wallthick*2;
  52
  53 sb_box_sz = [totx_outer, totz_outer, toty_inner];
  54
  55 // origin is at centre on outer face wall
  56 // outside is towards positive x
  57 // mounting is vertical
  58 module S1930_Positive(){
  59   d = s1930_recess + s1930_behind;
  60   translate([-d/2, 0,0])
  61     cube([d,
  62           s1930_x_outer + s1930_around,
  63           s1930_y_outer + s1930_around], center=true);
  64 }
  65 module S1930_Negative(){
  66   cube([60, s1930_x, s1930_y],
  67        center=true);
  68   translate([1, 0,0])
  69     cube([s1930_recess*2+2, s1930_x_outer, s1930_y_outer],
  70          center=true);
  71 }
  72
  73 module TestWall(){ ////toplevel
  74   sw_ctr = [25, wallthick, 25];
  75
  76   rotate([0,0,-90]){
  77     difference(){
  78       union(){
  79         cube([50, wallthick, 42]);
  80       }
  81
  82       translate([30, -1, 20])
  83         rotate([-90,0,0])
  84         cylinder(r = pxp6012_rad, h=10, $fn=60);
  85
  86       rotate([90,0,0])
  87         Commitid_BestCount([15,40]);
  88     }
  89   }
  90
  91   difference(){
  92     union(){
  93       cube([50, wallthick, 50]);
  94       translate(sw_ctr)
  95         rotate([0,0,90])
  96         S1930_Positive();
  97     }
  98
  99     translate(sw_ctr) {
 100       rotate([0,0,90])
 101         S1930_Negative();
 102     }
 103   }
 104 }
 105
 106 ts_totx = 30;
 107 ts_toty = 25;
 108 ts_totz_inner = 8;
 109
 110 ts_box_sz = [ts_totx, ts_toty, ts_totz_inner];
 111
 112 $sealingbox_wallth = wallthick;
 113 $sealingbox_floorth = wallthick;
 114 $sealingbox_ceilth = wallthick;
 115
 116 module TestSealBox(){ ////toplevel
 117   $sealingbox_sz = ts_box_sz;
 118
 119   SealingBox_RectBox();
 120   ts_cidoff = ($sealingbox_cnrrad * (1-.7) + wallthick * .8) * [1,1];
 121   translate(ts_cidoff)
 122     Commitid_BestCount([ts_totx,ts_toty] - 2*ts_cidoff);
 123 }
 124
 125 module TestSealLid(){ ////toplevel
 126   $sealingbox_sz = ts_box_sz;
 127
 128   difference(){
 129     SealingBox_RectLid();
 130
 131     translate([ts_totx * .75, ts_toty/2, 0])
 132       cylinder(h=100, r=5);
 133
 134     translate([-wallthick + $sealingbox_cnrrad*.5,
 135                $sealingbox_cnrrad*.5 - wallthick,
 136                ts_totz_inner + $sealingbox_ceilth])
 137       Commitid_BestCount([ts_totx * .75 - 2.5 - ($sealingbox_cnrrad*.5),
 138                           ts_toty - ($sealingbox_cnrrad*.5 - wallthick)*2]);
 139   }
 140 }
 141
 142 module TestSealLidPrint(){ ////toplevel
 143   rotate([180,0,0]) TestSealLid();
 144 }
 145
 146 module ProfileDemos(){ ////toplevel
 147   $sealingbox_sz = ts_box_sz;
 148
 149   SealingBox_WallProfile();
 150   color("blue") SealingBox_FloorProfile();
 151   SealingBox_LidProfile();
 152   color("blue") SealingBox_CeilProfile();
 153   color("red") translate([-5,0]) square([1,ts_totz_inner]);
 154 }
 155
 156 module AtGlands(){
 157   for (dgy=[-15,-45]) {
 158     translate([totx_inner + wallthick - $sealingbox_cnrrad * .3,
 159                toty_inner + dgy,
 160                totz_inner/2])
 161       children();
 162   }
 163 }
 164
 165 module StrapKeepers(at){
 166   strap_x_tot = strap_w + strap_pillar*2;
 167
 168   for (sx= at) {
 169     echo("strapkeeper at ",sx);
 170     translate([sx - strap_x_tot, 0, 0])
 171       difference(){
 172       translate([0,0, -0.1])
 173         cube([strap_x_tot, strap_pillard, strap_th + strap_over]);
 174       translate([strap_pillar, -1, 0])
 175         cube([strap_w, strap_pillard+2, strap_th]);
 176     }
 177   }
 178 }
 179
 180 chargingconn_x = pxp6012_rad_outer + 1 + $sealingbox_cnrrad;
 181 switch_x = chargingconn_x + pxp6012_rad_outer
 182   + s1930_y_outer/2 + s1930_around;
 183
 184 module AtSealingBox(){
 185   rotate([90,0,0])
 186     translate([-wallthick,-wallthick, -toty_inner])
 187     children();
 188 }
 189
 190 module Box(){ ////toplevel
 191   $sealingbox_sz = sb_box_sz;
 192
 193   difference(){
 194     union(){
 195       AtSealingBox()
 196         SealingBox_RectBox();
 197
 198       translate([switch_x, toty_inner, totz_inner/2])
 199         rotate([90,0,90])
 200         S1930_Positive();
 201
 202       // keepers for lipo
 203       for (keepers= [[ 35, lipokeeper_d_min,     lipokeeper_h,
 204                        [ 40, 80, 120, 150 ] ],
 205                      [ 10, lipokeeper_end_d_min, lipokeeper_end_h,
 206                        [ 25 ] ]
 207                      // each entry: [ y, d_min, h, [ x, ...] ]
 208                      ])
 209         for (kx= keepers[3]) {
 210           translate([kx, keepers[0], -1])
 211             hull(){
 212               cube([lipokeeper_w, keepers[1], keepers[2] +1]);
 213               cube([lipokeeper_w,
 214                     keepers[1] + keepers[2] / lipokeeper_slope,
 215                     1]);
 216             }
 217       }
 218
 219       AtGlands()
 220         GlandPositive(cabledia);
 221
 222       translate([0, toty_inner+wallthick, -wallthick])
 223         rotate([180, 0,0])
 224         StrapKeepers(straps_at_box);
 225     }
 226
 227     // charging connector
 228     translate([chargingconn_x,
 229                toty_inner - (pxp6012_rad_outer + 5),
 230                10])
 231       cylinder(r= pxp6012_rad, h= totz_outer);
 232
 233     // vent connector
 234     translate([chargingconn_x,
 235                toty_inner - (pxp6012_rad_outer*2 + 5 + 15 +
 236                              jdae12pa_rad_outer),
 237                10])
 238       cylinder(r= jdae12pa_rad, h= totz_outer);
 239
 240     translate([switch_x, toty_inner, totz_inner/2])
 241       rotate([90,0,90])
 242       S1930_Negative();
 243
 244     AtGlands()
 245       GlandNegative(cabledia);
 246
 247     translate(-$sealingbox_cnrrad * [1,1,0] +
 248               [totx_inner, toty_inner/2, -wallthick])
 249       rotate([0,0,180])
 250       scale([2,2,1])
 251       Commitid_Full16_M();
 252   }
 253 }
 254
 255 module BoxPrint(){ ////toplevel
 256   rotate([-90,0,-90])
 257     Box();
 258 }
 259
 260 module Lid(){ ////toplevel
 261   $sealingbox_sz = sb_box_sz;
 262   difference(){
 263     union(){
 264       AtSealingBox()
 265         SealingBox_RectLid();
 266       translate([0, -wallthick, -SealingBox_lidbigger()])
 267         mirror([0,0,1])
 268         StrapKeepers([ straps_every : straps_every
 269                        : totx_inner-straps_every ]);
 270     }
 271
 272     translate($sealingbox_cnrrad * [1,0,1])
 273       rotate([90,0,0])
 274       scale([1.5, 1.5, 1])
 275       Commitid_Small16_M();
 276   }
 277 }
 278
 279 module LidPrint(){ ////toplevel
 280   rotate([90,0,-90])
 281     Lid();
 282 }
 283
 284 module Demo(){ ////toplevel
 285   color("blue") Box();
 286   color("red") Lid();
 287 }
 288
 289 //TestWall();
 290 //ProfileDemos();
 291 //TestSealBox();
 292 //TestSealLid();
 293 //FArcSegment_mask(350);
 294 //StrapKeepers();