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 c1322857c9c0251d8e72e0b32a167c4cc01a8bbc..c7fc125f06e9780ce65507ebf92f04abc5850cf9 100644 (file)
--- a/bike-lipo-box.scad
+++ b/bike-lipo-box.scad
@@ -1,8 +1,10 @@
 // -*- C -*-
 
 include <commitid.scad>
+include <utils.scad>
+include <sealing-box.scad>
 
-pxp6012_rad = 22.5 / 2 + 0.5;
+pxp6012_rad = 22.5 / 2 + 0.5; // make circular hole this size in outer wall
 pxp6012_rad_outer = 32.0 / 2 - 0.5;
 
 s1930_y = 30.2 + 0.2;
@@ -12,11 +14,48 @@ s1930_x_outer = 27.6 + 0.2;
 
 s1930_recess = 3;
 s1930_around = 3;
+s1930_behind = 3;
 
-wallthick = 3.0;
+totx_inner = 180;
+toty_outer = 95;
+totz_outer = 31;
 
-module TestWall(){
-  sw_ctr = [25, 0, 25];
+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
+module S1930_Positive(){
+  d = s1930_recess + s1930_behind;
+  translate([-d/2, 0,0])
+    cube([d,
+         s1930_x_outer + s1930_around,
+         s1930_y_outer + s1930_around], center=true);
+}
+module S1930_Negative(){
+  cube([60, s1930_x, s1930_y],
+       center=true);
+  translate([1, 0,0])
+    cube([s1930_recess*2+2, s1930_x_outer, s1930_y_outer],
+        center=true);
+}
+
+module TestWall(){ ////toplevel
+  sw_ctr = [25, wallthick, 25];
 
   rotate([0,0,-90]){
     difference(){
@@ -36,58 +75,115 @@ module TestWall(){
   difference(){
     union(){
       cube([50, wallthick, 50]);
-      translate(sw_ctr) {
-       rotate([90,0,0])
-         cube([s1930_x_outer + s1930_around,
-               s1930_y_outer + s1930_around,
-               s1930_recess*2],
-              center=true);
-      }
+      translate(sw_ctr)
+       rotate([0,0,90])
+       S1930_Positive();
     }
 
     translate(sw_ctr) {
-      rotate([90,0,0]) {
-       cube([s1930_x, s1930_y, 10], center=true);
-       translate([0,0, -5])
-         cube([s1930_x_outer, s1930_y_outer, 10], center=true);
-      }
+      rotate([0,0,90])
+       S1930_Negative();
     }
   }    
 }
 
-ts_floorceil = 1.5;
-ts_outer = [20,20,20];
-ts_wall = [wallthick,wallthick,ts_floorceil];
-
-seal_h = 3;
-seal_w = 1;
-
-module TestSealSelector(){
-  oz = ts_outer[2];
-  muchxy = [30,30,0];
-  seal_horiz_spare = wallthick - seal_w;
-  seal_horiz_flat_outer = seal_horiz_spare/2;
-  seal_horiz_flat_inner = seal_horiz_spare - seal_horiz_flat_outer;
-//  translate([0,0, oz/2]){
-    %translate(-muchxy/2) mirror([0,0,1]) cube(ts_outer + muchxy + [0,0,10]);
-    hull(){
-      translate([1,1,0] * seal_horiz_flat_outer)
-       mirror([0,0,1])
-       cube(ts_outer - 2 * [1,1,0] * seal_horiz_flat_outer);
-      translate([1,1,0] * seal_horiz_flat_inner + [0, 0, seal_h])
-       mirror([0,0,1])
-       cube(ts_outer - 2 * [1,1,0] * seal_horiz_flat_inner);
-    }
-//  }
+ts_totx = 30;
+ts_toty = 25;
+ts_totz_inner = 8;
+
+ts_box_sz = [ts_totx, ts_toty, ts_totz_inner];
+
+$sealingbox_wallth = wallthick;
+$sealingbox_floorth = wallthick;
+$sealingbox_ceilth = wallthick;
+
+module TestSealBox(){ ////toplevel
+  $sealingbox_sz = ts_box_sz;
+
+  SealingBox_RectBox();
+  ts_cidoff = ($sealingbox_cnrrad * (1-.7) + wallthick * .8) * [1,1];
+  translate(ts_cidoff)
+    Commitid_BestCount([ts_totx,ts_toty] - 2*ts_cidoff);
+}
+
+module TestSealLid(){ ////toplevel
+  $sealingbox_sz = ts_box_sz;
+
+  difference(){
+    SealingBox_RectLid();
+
+    translate([ts_totx * .75, ts_toty/2, 0])
+      cylinder(h=100, r=5);
+    
+    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]);
+  }
+}
+
+module TestSealLidPrint(){ ////toplevel
+  rotate([180,0,0]) TestSealLid();
 }
 
-module TestSeal(){
+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,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(){
-    cube(ts_outer);
-    translate(ts_wall) cube(ts_outer - ts_wall*2);
+    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();
-//TestSeal();
-TestSealSelector();
+//ProfileDemos();
+//TestSealBox();
+//TestSealLid();
+//FArcSegment_mask(350);