lipo-flat-mount: from other repo

Signed-off-by: Ian Jackson <ijackson@chiark.greenend.org.uk>

diff --git a/Makefile b/Makefile
index 6d4225ab7a0b52f4d853a6a4bbbfc6bc2a10ca5a..384be3b601c5ff75be6c462803a927c1533321ed 100644 (file)
--- a/Makefile
+++ b/Makefile
@@ -22,7 +22,7 @@ FILAMENTSPOOL_AUTOS += filamentspool-storarm3
 QUACKSES = $(addprefix quacks-ingredients-L, 1 2 3 4 5)
 QUACKS_SCADS = $(addsuffix .scad, $(QUACKSES))
 
-USING_AUTOS ?= $(FILAMENTSPOOL_AUTOS) xeno-drivebay-bracket dungeonquest-cone anke-gps-bracket cable-hole-trunking-cover anglepoise-neck crossbar-computer-led-mount wardrobe-hook knifeblock pandemic-counter pattress-boxes-3-cover bike-lipo-box earring-stand bike-stalk-led-mount sewing-table sewing-table-test sewing-table-jig maglite-holder poster-tube-lid poster-tube-lid-coarse fairphone-case fairphone-battery-case lock-inframe-bracket ksafe-base $(QUACKSES) quacks-ingredients-demos mic-table-clamp nook-case nook-case-test scaffold-clamp-common scaffold-clamp-tensioner scaffold-clamp-straphook powerbank-bike-clamp $(foreach x,500 1000,adafruit-powerboost-$x)
+USING_AUTOS ?= $(FILAMENTSPOOL_AUTOS) xeno-drivebay-bracket dungeonquest-cone anke-gps-bracket cable-hole-trunking-cover anglepoise-neck crossbar-computer-led-mount wardrobe-hook knifeblock pandemic-counter pattress-boxes-3-cover bike-lipo-box earring-stand bike-stalk-led-mount sewing-table sewing-table-test sewing-table-jig maglite-holder poster-tube-lid poster-tube-lid-coarse fairphone-case fairphone-battery-case lock-inframe-bracket ksafe-base $(QUACKSES) quacks-ingredients-demos mic-table-clamp nook-case nook-case-test scaffold-clamp-common scaffold-clamp-tensioner scaffold-clamp-straphook powerbank-bike-clamp lipo-flat-mount $(foreach x,500 1000,adafruit-powerboost-$x)
 
 AUTO_INCS += sealing-box.scad sewing-table.scad nutbox.scad \
             powerbank-anker-10000.dxf \

diff --git a/lipo-flat-mount.scad b/lipo-flat-mount.scad
new file mode 100644 (file)
index 0000000..98d4baa
--- /dev/null
+++ b/lipo-flat-mount.scad
@@ -0,0 +1,168 @@
+// -*- C -*-
+
+include <nutbox.scad>
+
+// pimoroni 3000mAh
+battery = [ 51.5,
+           81.3,
+           8.0 ];
+
+battery_wall = 2.0;
+battery_wall_unsupp = 4.0;
+battery_wall_top_gap = 0.75;
+
+battery_keeper_m_th = 4;
+battery_keeper_m_w = 4;
+battery_keeper_x_gap = 0.75; // each side
+battery_keeper_y_gap_overhang = 0.75;
+battery_keeper_y_gap_nutbox = 1.0;
+battery_keeper_z_gap_nutbox = 0.50;
+battery_keeper_z_gap_overhang = 0.75;
+
+battery_keeper_x_th_min = 1.5 * 1.5;
+battery_keeper_x_th_max = 2.5 * 1.5;
+battery_keeper_x_w  = 5;
+battery_keeper_x_n  = 5;
+
+battery_keeper_screw_x_off = -2.5;
+
+battery_wire_y = 4;
+
+battery_nutbox = nutbox_data_M3;
+
+// calculated
+
+battery_nutbox_z = max( battery[2] + battery_wall_top_gap,
+                       NutBox_h_base(battery_nutbox) );
+battery_keeper_overhang_z = battery[2] + battery_keeper_m_th
+  + battery_keeper_z_gap_overhang;
+battery_keeper_overhang_wall = battery_keeper_m_w;
+battery_keeper_overhang_th = battery_keeper_m_th;
+
+module BatteryPlan(){
+  rectfromto([ -battery[0]/2, 0          ],
+            [ +battery[0]/2, battery[1] ]);
+}
+
+module BatteryBase(){ ////toplevel
+  // wall
+  linextr(-0.1, battery[2] - battery_wall_top_gap, convexity=7) {
+    difference(){
+      union(){
+       offset(r=battery_wall) BatteryPlan();
+       rectfromto([ 0,0 ],
+                  [ -(battery[0]/2 + battery_wall_unsupp), battery[1]/3 ]);
+      }
+      BatteryPlan();
+      rectfromto([ fix_sz/2 - 0.5
+                  + battery_keeper_screw_x_off, -30 ],
+                [ -battery[0], battery_wire_y ]);
+    }
+  }
+
+  // nutbox
+  translate([battery_keeper_screw_x_off, -fix_sz/2, battery_nutbox_z])
+    NutBox(battery_nutbox, battery_nutbox_z + 0.1);
+
+  // overhang for legs at rear
+  for (m=[0,1]) {
+    mirror([m,0,0]) {
+      translate([ battery[0]/2, battery[1], 0]) {
+       difference(){
+         linextr(-0.1,
+                 battery_keeper_overhang_z
+                 + battery_keeper_overhang_th,
+                 convexity=1)
+           rectfromto([ -battery_keeper_m_w*2, -battery_keeper_m_w ],
+                      [ battery_keeper_overhang_wall, battery_wall ]);
+         linextr(-1, battery_keeper_overhang_z,
+                 convexity=1)
+           rectfromto([-20, -20], [0,0]);          
+       }
+      }
+    }
+  }
+}
+
+module BatteryKeeper(){ ////toplevel
+  // A-frame
+  translate([0,0, battery[2]]) {
+    linextr(0, battery_keeper_m_th) {
+      intersection(){
+       // main legs
+       translate([0,  +battery[1], 0])
+         multmatrix([[ 1, -battery_keeper_screw_x_off/battery[1], 0, 0, ],
+                     [ 0,1,0, 0, ],
+                     [ 0,0,1, 0, ]])
+         translate([0, -battery[1], 0])
+       for (sx=[-1,+1]) {
+         multmatrix([[ 1,0,0, 0, ],
+                     [ 0,1,0, 0, ],
+                     [ 0,0,1, 0, ]] +
+                    sx *
+                    ( battery[0]/2 - 0.5 * battery_keeper_m_w
+                      - battery_keeper_x_gap ) /
+                    ( battery[1] - 0.5 * battery_keeper_m_w )
+                    *
+                    [[ 0,1,0, 0, ],
+                     [ 0,0,0, 0, ],
+                     [ 0,0,0, 0, ]])
+           rectfromto([ -battery_keeper_m_w/2,
+                        battery_keeper_y_gap_nutbox ],
+                      [ +battery_keeper_m_w/2,
+                        battery[1] - battery_keeper_y_gap_overhang ]);
+       }
+
+       // shape to round off the leg end corners
+       hull(){
+         for (sx=[-1,+1]) {
+           translate([ sx * ( battery[0]/2 - battery_keeper_m_w/2
+                              -battery_keeper_x_gap) ,
+                       battery[1] - battery_keeper_m_w/2
+                       -battery_keeper_y_gap_overhang ])
+             circle(r = battery_keeper_m_w/2);
+         }
+         square(center=true, [ battery[0], 1 ]);
+       }
+      }
+    }
+
+    // x struts
+    for (i=[0 : battery_keeper_x_n-1]) {
+      linextr(0,
+             battery_keeper_x_th_min +
+             (battery_keeper_x_th_max - battery_keeper_x_th_min)
+             * pow( i/(battery_keeper_x_n-1)*2 - 1 , 2)
+             ) {
+       difference(){
+         translate([0, battery[1] * ((i + 0.5) / battery_keeper_x_n)])
+           square(center=true, [ battery[0], battery_keeper_x_w ]);
+         rectfromto([ -battery[1], -20 ],
+                    [ +pi_sz[1] - pi_usb_from_other_side,
+                      pi_usb_over_battery_proportion * battery[1] ]);
+       }
+      }
+    }
+  }
+
+  // tab for screw and nutbox
+  translate([battery_keeper_screw_x_off,
+            0,
+            battery_nutbox_z + battery_keeper_z_gap_nutbox])
+    linextr(0, battery_keeper_m_th, convexity=4) {
+    difference(){
+      rectfromto([ -fix_sz/2, -fix_sz ],
+                [ +fix_sz/2,
+                  0.5 * battery[1] / battery_keeper_x_n +
+                  0.5 * battery_keeper_m_w ]);
+      translate([ 0, -fix_sz/2 ])
+       circle(r = battery_nutbox[0]/2);
+    }
+  }
+}
+
+module BatteryDemo(){ ////toplevel
+  color("grey") BatteryBase();
+  BatteryKeeper();
+}
+