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 e03d45c7aaca0324b6e825a8d812b5de573cc7f6..c7fc125f06e9780ce65507ebf92f04abc5850cf9 100644 (file)
--- a/bike-lipo-box.scad
+++ b/bike-lipo-box.scad
@@ -1,6 +1,10 @@
 // -*- C -*-
 
-pxp6012_rad = 22.5 / 2 + 0.5;
+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;
 
 s1930_y = 30.2 + 0.2;
@@ -9,10 +13,50 @@ s1930_y_outer = 36.4 + 0.2;
 s1930_x_outer = 27.6 + 0.2;
 
 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;
 
-wallthick = 3.0;
+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];
 
-module TestWall(){
   rotate([0,0,-90]){
     difference(){
       union(){
@@ -22,8 +66,124 @@ module TestWall(){
       translate([30, -1, 20])
        rotate([-90,0,0])
        cylinder(r = pxp6012_rad, h=10, $fn=60);
+
+      rotate([90,0,0])
+       Commitid_BestCount([15,40]);
     }
   }
+
+  difference(){
+    union(){
+      cube([50, wallthick, 50]);
+      translate(sw_ctr)
+       rotate([0,0,90])
+       S1930_Positive();
+    }
+
+    translate(sw_ctr) {
+      rotate([0,0,90])
+       S1930_Negative();
+    }
+  }    
+}
+
+ts_totx = 30;
+ts_toty = 25;
+ts_totz_inner = 8;
+
+ts_box_sz = [ts_totx, ts_toty, ts_totz_inner];
+
+$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 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(){
+    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();
+//TestWall();
+//ProfileDemos();
+//TestSealBox();
+//TestSealLid();
+//FArcSegment_mask(350);