chiark / gitweb /
sleepphone-cable-box: octagonal led
[reprap-play.git] / bike-lipo-box.scad
index 68140dc..edd3701 100644 (file)
@@ -3,6 +3,7 @@
 include <commitid.scad>
 include <utils.scad>
 include <sealing-box.scad>
+include <bike-lipo-box-gland.scad>
 
 pxp6012_rad = 22.5 / 2 + 0.5; // make circular hole this size in outer wall
 pxp6012_rad_outer = 32.0 / 2 - 0.5;
@@ -16,8 +17,41 @@ s1930_recess = 3;
 s1930_around = 3;
 s1930_behind = 3;
 
+jdae12pa_rad = 12 / 2 + 0.5;
+jdae12pa_rad_outer = 19 / 2 + 0.5; // head of an "M12 bolt"
+
+totx_inner = 180;
+toty_outer = 95;
+totz_inner = 27.0;
+
 wallthick = 2.5;
 
+cabledia = 8.7;
+
+strap_w = 5 + 1;
+strap_th = 4 + 1;
+strap_pillar = 3;
+strap_pillard = 5;
+strap_over = 2;
+
+lipokeeper_w = 10;
+lipokeeper_h = 8;
+lipokeeper_d_min = 2;
+lipokeeper_slope = 0.75;
+lipokeeper_end_h = 12;
+lipokeeper_end_d_min = 15;
+
+straps_at_box = [45, 95, 125, 160];
+straps_every = 30;
+
+// calculated
+
+totx_outer = totx_inner + wallthick*2;
+toty_inner = toty_outer - wallthick*2;
+totz_outer = totz_inner + 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
@@ -69,36 +103,39 @@ module TestWall(){ ////toplevel
   }    
 }
 
-totx_outer = 30;
-toty_outer = 25;
-totz_inner = 8;
+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 = 2.5;
-$sealingbox_ceilth = 2.5;
-$sealingbox_xbox = totx_outer;
-$sealingbox_ybox = toty_outer;
-$sealingbox_zbox = totz_inner;
+$sealingbox_floorth = wallthick;
+$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([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(){
     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 + $sealingbox_cnrrad*.5,
               $sealingbox_cnrrad*.5 - wallthick,
-              totz_inner + $sealingbox_ceilth])
-      Commitid_BestCount([totx_outer * .75 - 2.5 - ($sealingbox_cnrrad*.5),
-                         toty_outer - ($sealingbox_cnrrad*.5 - wallthick)*2]);
+              ts_totz_inner + $sealingbox_ceilth])
+      Commitid_BestCount([ts_totx * .75 - 2.5 - ($sealingbox_cnrrad*.5),
+                         ts_toty - ($sealingbox_cnrrad*.5 - wallthick)*2]);
   }
 }
 
@@ -107,15 +144,151 @@ 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 AtGlands(){
+  for (dgy=[-15,-45]) {
+    translate([totx_inner + wallthick - $sealingbox_cnrrad * .3,
+              toty_inner + dgy,
+              totz_inner/2])
+      children();
+  }
+}
+
+module StrapKeepers(at){
+  strap_x_tot = strap_w + strap_pillar*2;
+
+  for (sx= at) {
+    echo("strapkeeper at ",sx);
+    translate([sx - strap_x_tot, 0, 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]);
+    }
+  }
+}
+
+chargingconn_x = pxp6012_rad_outer + 1 + $sealingbox_cnrrad;
+switch_x = chargingconn_x + pxp6012_rad_outer
+  + s1930_y_outer/2 + s1930_around;
+
+module AtSealingBox(){
+  rotate([90,0,0])
+    translate([-wallthick,-wallthick, -toty_inner])
+    children();
+}
+
+module Box(){ ////toplevel
+  $sealingbox_sz = sb_box_sz;
+
+  difference(){
+    union(){
+      AtSealingBox()
+       SealingBox_RectBox();
+
+      translate([switch_x, toty_inner, totz_inner/2])
+       rotate([90,0,90])
+       S1930_Positive();
+
+      // keepers for lipo
+      for (keepers= [[ 35, lipokeeper_d_min,     lipokeeper_h,
+                      [ 40, 80, 120, 150 ] ],
+                    [ 10, lipokeeper_end_d_min, lipokeeper_end_h,
+                      [ 25 ] ]
+                    // each entry: [ y, d_min, h, [ x, ...] ]
+                    ])
+       for (kx= keepers[3]) {
+         translate([kx, keepers[0], -1])
+           hull(){
+             cube([lipokeeper_w, keepers[1], keepers[2] +1]);
+             cube([lipokeeper_w,
+                   keepers[1] + keepers[2] / lipokeeper_slope,
+                   1]);
+           }
+      }
+
+      AtGlands()
+       GlandPositive(cabledia);
+
+      translate([0, toty_inner+wallthick, -wallthick])
+       rotate([180, 0,0])
+       StrapKeepers(straps_at_box);
+    }
+
+    // charging connector
+    translate([chargingconn_x,
+              toty_inner - (pxp6012_rad_outer + 5),
+              10])
+      cylinder(r= pxp6012_rad, h= totz_outer);
+
+    // vent connector
+    translate([chargingconn_x,
+              toty_inner - (pxp6012_rad_outer*2 + 5 + 15 +
+                            jdae12pa_rad_outer),
+              10])
+      cylinder(r= jdae12pa_rad, h= totz_outer);
+
+    translate([switch_x, toty_inner, totz_inner/2])
+      rotate([90,0,90])
+      S1930_Negative();
+
+    AtGlands()
+      GlandNegative(cabledia);
+
+    translate(-$sealingbox_cnrrad * [1,1,0] +
+             [totx_inner, toty_inner/2, -wallthick])
+      rotate([0,0,180])
+      scale([2,2,1])
+      Commitid_Full16_M();
+  }
+}
+
+module BoxPrint(){ ////toplevel
+  rotate([-90,0,-90])
+    Box();
+}
+
+module Lid(){ ////toplevel
+  $sealingbox_sz = sb_box_sz;
+  difference(){
+    union(){
+      AtSealingBox()
+       SealingBox_RectLid();
+      translate([0, -wallthick, -SealingBox_lidbigger()])
+       mirror([0,0,1])
+       StrapKeepers([ straps_every : straps_every
+                      : totx_inner-straps_every ]);
+    }
+
+    translate($sealingbox_cnrrad * [1,0,1])
+      rotate([90,0,0])
+      scale([1.5, 1.5, 1])
+      Commitid_Small16_M();
+  }
+}
+
+module LidPrint(){ ////toplevel
+  rotate([90,0,-90])
+    Lid();
+}
+
+module Demo(){ ////toplevel
+  color("blue") Box();
+  color("red") Lid();
+}
+
 //TestWall();
 //ProfileDemos();
 //TestSealBox();
 //TestSealLid();
 //FArcSegment_mask(350);
+//StrapKeepers();