bike-lipo-box: straps for lipo battery assembly

[reprap-play.git] / bike-lipo-box.scad

diff --git a/bike-lipo-box.scad b/bike-lipo-box.scad
index 4cc52de6e24571f45230f23f45520d4e3086642f..c7fc125f06e9780ce65507ebf92f04abc5850cf9 100644 (file)
--- a/bike-lipo-box.scad
+++ b/bike-lipo-box.scad
@@ -2,6 +2,7 @@
 
 include <commitid.scad>
 include <utils.scad>
+include <sealing-box.scad>
 
 pxp6012_rad = 22.5 / 2 + 0.5; // make circular hole this size in outer wall
 pxp6012_rad_outer = 32.0 / 2 - 0.5;
@@ -15,8 +16,26 @@ s1930_recess = 3;
 s1930_around = 3;
 s1930_behind = 3;
 
+totx_inner = 180;
+toty_outer = 95;
+totz_outer = 31;
+
 wallthick = 2.5;
 
+strap_w = 5;
+strap_th = 4;
+strap_pillar = 3;
+strap_pillard = 5;
+strap_over = 2;
+
+// calculated
+
+totx_outer = totx_inner + wallthick*2;
+toty_inner = toty_outer - wallthick*2;
+totz_inner = totz_outer - wallthick*2;
+
+sb_box_sz = [totx_outer, totz_outer, toty_inner];
+
 // origin is at centre on outer face wall
 // outside is towards positive x
 // mounting is vertical
@@ -68,43 +87,39 @@ module TestWall(){ ////toplevel
   }    
 }
 
-totx_outer = 30;
-toty_outer = 25;
-totz_inner = 8;
-
-$sealingbox_wallthick = wallthick;
-$sealingbox_floorth = 2.5;
-$sealingbox_ceilth = 2.5;
-$sealingbox_xbox = totx_outer;
-$sealingbox_ybox = toty_outer;
-$sealingbox_zbox = totz_inner;
+ts_totx = 30;
+ts_toty = 25;
+ts_totz_inner = 8;
 
-innertube = 1.0 + 0.2;
-lidoverlap = 1.5;
-lidoverhang = 6;
-tubesealrad = 2.0;
-ts_cnrrad = 10;
+ts_box_sz = [ts_totx, ts_toty, ts_totz_inner];
 
-include <sealing-box.scad>
+$sealingbox_wallth = wallthick;
+$sealingbox_floorth = wallthick;
+$sealingbox_ceilth = wallthick;
 
 module TestSealBox(){ ////toplevel
-  TestSealBoxBox();
+  $sealingbox_sz = ts_box_sz;
+
+  SealingBox_RectBox();
+  ts_cidoff = ($sealingbox_cnrrad * (1-.7) + wallthick * .8) * [1,1];
   translate(ts_cidoff)
-    Commitid_BestCount([totx_outer,toty_outer] - 2*ts_cidoff);
+    Commitid_BestCount([ts_totx,ts_toty] - 2*ts_cidoff);
 }
 
 module TestSealLid(){ ////toplevel
+  $sealingbox_sz = ts_box_sz;
+
   difference(){
-    TestSealBoxLid();
+    SealingBox_RectLid();
 
-    translate([totx_outer * .75, toty_outer/2, 0])
+    translate([ts_totx * .75, ts_toty/2, 0])
       cylinder(h=100, r=5);
     
-    translate([-wallthick + ts_cnrrad*.5,
-              ts_cnrrad*.5 - wallthick,
-              totz_inner + $sealingbox_ceilth])
-      Commitid_BestCount([totx_outer * .75 - 2.5 - (ts_cnrrad*.5),
-                         toty_outer - (ts_cnrrad*.5 - wallthick)*2]);
+    translate([-wallthick + $sealingbox_cnrrad*.5,
+              $sealingbox_cnrrad*.5 - wallthick,
+              ts_totz_inner + $sealingbox_ceilth])
+      Commitid_BestCount([ts_totx * .75 - 2.5 - ($sealingbox_cnrrad*.5),
+                         ts_toty - ($sealingbox_cnrrad*.5 - wallthick)*2]);
   }
 }
 
@@ -113,13 +128,60 @@ module TestSealLidPrint(){ ////toplevel
 }
 
 module ProfileDemos(){ ////toplevel
+  $sealingbox_sz = ts_box_sz;
+
   SealingBox_WallProfile();
   color("blue") SealingBox_FloorProfile();
   SealingBox_LidProfile();
   color("blue") SealingBox_CeilProfile();
-  color("red") translate([-5,0]) square([1,totz_inner]);
+  color("red") translate([-5,0]) square([1,ts_totz_inner]);
+}
+
+module Box(){ ////toplevel
+  $sealingbox_sz = sb_box_sz;
+
+  chargingconn_x = pxp6012_rad_outer + 1 + $sealingbox_cnrrad;
+  switch_x = chargingconn_x + pxp6012_rad_outer
+    + s1930_y_outer/2 + s1930_around;
+
+  strap_x_tot = strap_w + strap_pillar*2;
+
+  difference(){
+    union(){
+      rotate([90,0,0])
+       translate([-wallthick,-wallthick, -toty_inner])
+       SealingBox_RectBox();
+
+      translate([switch_x, toty_inner, totz_inner/2])
+       rotate([90,0,90])
+       S1930_Positive();
+
+      // straps for lipo
+      for (sx= [ 45, 80, 110 ]) {
+       for (sy= [ 10, 40 ]) {
+         translate([sx - strap_x_tot, sy, 0])
+         difference(){
+           translate([0,0, -0.1])
+             cube([strap_x_tot, strap_pillard, strap_th + strap_over]);
+           translate([strap_pillar, -1, 0])
+             cube([strap_w, strap_pillard+2, strap_th]);
+         }
+       }
+      }
+    }
+
+    // charging connector
+    translate([chargingconn_x,
+              toty_inner - (pxp6012_rad_outer + 5),
+              10])
+      cylinder(r= pxp6012_rad, h= totz_outer);
+
+    translate([switch_x, toty_inner, totz_inner/2])
+      rotate([90,0,90])
+      S1930_Negative();
+  }
 }
-                         
+
 //TestWall();
 //ProfileDemos();
 //TestSealBox();