X-Git-Url: http://www.chiark.greenend.org.uk/ucgi/~ianmdlvl/git?p=reprap-play.git;a=blobdiff_plain;f=bike-lipo-box.scad;h=edd37010cdfd9ac36149516b4d99796deace7ec8;hp=2c6af7947dcf317d9912404156b5f502049fbaf9;hb=d1f9fc4c0e7a12e00138ebb6b899a6a120be3864;hpb=baf353471683aaee30d53725483a73329220e16f diff --git a/bike-lipo-box.scad b/bike-lipo-box.scad index 2c6af79..edd3701 100644 --- a/bike-lipo-box.scad +++ b/bike-lipo-box.scad @@ -1,8 +1,11 @@ // -*- C -*- include +include +include +include -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 +15,63 @@ s1930_x_outer = 27.6 + 0.2; s1930_recess = 3; s1930_around = 3; +s1930_behind = 3; -wallthick = 3.0; +jdae12pa_rad = 12 / 2 + 0.5; +jdae12pa_rad_outer = 19 / 2 + 0.5; // head of an "M12 bolt" -module TestWall(){ - sw_ctr = [25, 0, 25]; +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 +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(){ @@ -36,23 +91,204 @@ 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(); } } } -TestWall(); +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 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();