digispark-with-cable: wip progress

[reprap-play.git] / digispark-with-cable.scad

diff --git a/digispark-with-cable.scad b/digispark-with-cable.scad
index d3a64dc38526e1addb763f549fa0a04ccff02d7d..5e1136b46940749059fd0cb1292bbb39d28a9b69 100644 (file)
--- a/digispark-with-cable.scad
+++ b/digispark-with-cable.scad
@@ -4,13 +4,14 @@ include <utils.scad>
 
 //tongue_w = 11.92 + 0.4;
 
-usb_w = 12.01 - 0.3;
+usb_w = 12.01 + 0.19;
 usb_wall_w = 0.51;
 usb_tongue_d = 8.97 - 0.2;
+usb_tongue_w_slop = +0.5;
 usb_wall_h = 4.54 - 2.04;
 usb_ceil_th = 0.425;
 
-side_wall_th = 1.5;
+side_wall_th = 1.5; // XXXX rename wall_th
 
 board_l = 17.56 + 0.2;
 board_w = 19.14 + 0.2;
@@ -18,21 +19,57 @@ board_th = 1.92 + 0.1;
 
 sw_to_edge = board_w/2 + 0.1;
 
-front_wall_th = 0.4;
-egress_w = 8.0;
+front_wall_th = 0.75;
+// egress_w = 8.0;
 
-wall_y_min = -board_l - side_wall_th;;
+wall_y_min = -board_l - side_wall_th; // XXXX remove
+main_y_min = -board_l - side_wall_th;
 ceil_y_min = wall_y_min - 5;;
 
 small_walls = [
               [ [0, 0], [-sw_to_edge, -1.0] ],
               [ [sw_to_edge-4.5, -4.5], [sw_to_edge, -5.7] ],
-              [ [3.0, -11.72] ,[sw_to_edge, -13.38] ],
+//            [ [3.0, -11.72],              [sw_to_edge, -13.38] ],
               [ [-sw_to_edge+3.85, -14.90], [sw_to_edge, -13.38] ],
               ];
-chip_cutout = [[ -sw_to_edge + 4.20,    -4.50 ],
+chip_cutout = [[ -sw_to_edge + 4.20,    -3.75 ],
               [ -sw_to_edge + 11.95,  -11.90 ]];
 
+strain_w = 2.0 + 0.5;
+strain_t = 1.0 + 0.5;
+strain_pitch_across = 5;
+strain_pitch_along = 10;
+strain_groove_d = 2;
+strain_groove_w = 3;
+
+cable_space_z = 6;
+cable_dia = 5;
+bottom_floor_th = 1.5;
+
+fit_gap_z = 0.5;
+side_x_gap = 0.5;
+
+cover_ceil_th = 0.425;
+
+// calculated
+
+top_top_z = usb_wall_h;
+top_base_z = -board_th;
+bottom_base_z = top_base_z - cable_space_z - bottom_floor_th;;
+
+front_y_max = front_wall_th;
+
+strain_0_y_c = main_y_min - strain_w/2;
+strain_1_y_c = strain_0_y_c - strain_pitch_along;
+total_y_min = strain_1_y_c - strain_w/2 - side_wall_th;
+
+bottom_wall_top_z = (top_top_z + top_base_z) * 0.5 - fit_gap_z/2;
+cover_wall_bot_z  = (top_top_z + top_base_z) * 0.5 + fit_gap_z/2;
+cover_top_z  = top_top_z + cover_ceil_th;
+
+top_side_wall_x = +board_w/2 + side_wall_th;
+total_side_wall_x = top_side_wall_x + side_wall_th + side_x_gap;
+
 module BothSides(){
   for (m=[0,1]) {
     mirror([m,0]) {
@@ -40,6 +77,12 @@ module BothSides(){
     }
   }
 }
+module FrontWallsPlan(slop) {
+  BothSides(){
+    rectfromto([ -board_w/2 - side_wall_th,    0             ],
+               [ -usb_w/2 - slop,              front_wall_th ]);
+  }
+}
 module TopSmallWallsPlan() {
   for (m=[0,1]) {
     mirror([m,0]) {
@@ -47,6 +90,7 @@ module TopSmallWallsPlan() {
                 [ -usb_w/2 + usb_wall_w, usb_tongue_d ]);
     }
   }
+  FrontWallsPlan(0);
   for (w=small_walls) {
     rectfromto(w[0], w[1]);
   }
@@ -66,20 +110,89 @@ module TopMainWallsPlan() {
   BothSides(){
     rectfromto([ -board_w/2 - side_wall_th, 0          ],
               [ -board_w/2,                wall_y_min ]);
-    rectfromto([ -board_w/2 - side_wall_th, 0             ],
-               [ -usb_w/2,                  front_wall_th ]);
   }
-  rectfromto([ -board_w/2 - side_wall_th + egress_w, -board_l   ],
-            [ +board_w/2 + side_wall_th,            wall_y_min ]);
+  FrontWallsPlan(usb_tongue_w_slop);
+  rectfromto([ -board_w/2 - side_wall_th + 0, -      board_l   ],
+            [ +board_w/2 + side_wall_th,            total_y_min ]);
+}
+
+module Top(){ ////toplevel
+  difference(){
+    union(){
+      linextr(0, usb_wall_h)
+       TopSmallWallsPlan();
+      linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
+       TopCeilPlan();
+      linextr(-board_th, usb_wall_h)
+       TopMainWallsPlan();
+    }
+
+    for (y_c = [strain_0_y_c, strain_1_y_c]) {
+      for (x_c = [-1,+1] * strain_pitch_across/2) {
+       translate([x_c, y_c, 0])
+         linextr(-20, 20)
+         square([ strain_t, strain_w ], center=true);
+      }
+    }
+    linextr_y_xz(total_y_min-1, main_y_min)
+      translate([0, top_base_z])
+      scale([1, strain_groove_d/strain_groove_w])
+      circle(strain_groove_w/2, $fn = 8);
+  }
 }
 
-module Top(){
-  linextr(0, usb_wall_h)
-    TopSmallWallsPlan();
-  linextr(usb_wall_h - usb_ceil_th, usb_wall_h)
-    TopCeilPlan();
-  linextr(-board_th, usb_wall_h)
-    TopMainWallsPlan();
+module TopElevationForCutout(){
+    rectfromto([ -(top_side_wall_x + side_x_gap), top_base_z ],
+              [ +(top_side_wall_x + side_x_gap), top_top_z  ]);
+}
+module BottomMainElevation(){
+  difference(){
+    rectfromto([ -total_side_wall_x, bottom_base_z        ],
+              [ +total_side_wall_x, bottom_wall_top_z    ]);
+
+    TopElevationForCutout();
+  }
 }
+module Bottom(){ ////toplevel
+  difference(){
+    union(){
+      linextr_y_xz(total_y_min, front_y_max)
+       BottomMainElevation();
+    }
+
+    linextr_y_xz(total_y_min + side_wall_th,
+                front_y_max - side_wall_th)
+      rectfromto([ -board_w/2, bottom_base_z + bottom_floor_th ],
+                [ +board_w/2, 20         ]);
 
-Top();
+    linextr_y_xz(total_y_min - 1,
+                total_y_min + side_wall_th + 1){
+      translate([ 0, top_base_z ]){
+       hull(){
+         translate([ 0, -cable_dia/2 ])
+           circle(r = cable_dia/2, $fa = 10, $fs = 1);
+         square([ cable_dia, 0.1 ], center=true);
+       }
+      }
+    }
+  }
+}
+
+module CoverMainElevation(){
+  difference(){
+    rectfromto([ -total_side_wall_x, cover_wall_bot_z        ],
+              [ +total_side_wall_x, cover_top_z    ]);
+
+    TopElevationForCutout();
+  }
+}
+module Cover(){ ////toplevel
+  linextr_y_xz(main_y_min, front_y_max)
+    CoverMainElevation();
+}
+
+module BottomDemo(){ ////toplevel
+  translate([0, 0, -0.25]) Bottom();
+  %Top();
+  translate([0, 0, +0.25]) Cover();
+}