adafruit-powerboost-500.scad

   1 // -*- C -*-
   2
   3 include <nutbox.scad>
   4
   5 psu_sz  = [ 21.7, 36.0 ] + [ 0.25, 0.25 ];
   6
   7 psu_th = 1.70 + 0.25;
   8 psu_th_for_clamp = 1.50;
   9
  10 psu_hole_pos = [ 2.05, // from back edge of psu_sz[0]
  11                  0.55 * 0.5 * 25.4, // from centreline
  12                  ];
  13 psu_hole_dia = 2.5 - 0.3;
  14 psu_baffle_gap = 1.0 + 0.5;
  15 psu_baffle_cnr_y = 7.45; // from connector end
  16 psu_baffle_th = [ 0.8, 3.5 ];
  17 psu_connector_z = 2.9 + 0.1;
  18 psu_connector_z_overlap = 0.15;
  19 psu_connector_depth = 6.25;
  20 psu_connector_w = 8.0 + 0.5;
  21 psu_usb_protr = 0.6;
  22 psu_usbend_led_x = 4.5;
  23 psu_innerend_led_depth = 10;
  24
  25 psu_clamp_th = 4.0 + 0.75;
  26 psu_clamp_w = 8.0;
  27 psu_clamp_gap = 0.4;
  28
  29 psu_board_clamp_ovlp = 4.5;
  30 psu_board_support_wall = 2;
  31 psu_board_nutbox = nutbox_data_M3;
  32
  33 // ----- calculated -----
  34
  35 psu_usbend_led_depth = psu_baffle_cnr_y*2 - psu_usbend_led_x;
  36
  37 psu_z = NutBox_h_base(psu_board_nutbox);
  38 psu_z_down = psu_z + 0.1;
  39
  40
  41 module PsuBoardRepresentation(){
  42   linear_extrude(height= psu_th)
  43     square(center=true, [psu_sz[0],psu_sz[1]]);
  44 }
  45
  46 module PsuRepresentation(){
  47   PsuBoardRepresentation();
  48   translate([0, -psu_sz[1]/2, -psu_connector_z])
  49     linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
  50     rectfromto([ -psu_connector_w/2, -10 ],
  51                [ +psu_connector_w/2, psu_connector_depth ]);
  52 }
  53
  54 module AtPsuMountCorner(mx,my){
  55   mirror([mx,0,0])
  56     mirror([0,my,0])
  57       translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
  58                 -1 * [0,0, psu_z_down])
  59         children();
  60 }
  61
  62 module PsuMountCornerExtrude(mx,my, plus_z=board_support_z){
  63   AtPsuMountCorner(mx,my){
  64     linear_extrude(height= psu_z_down + plus_z, convexity=10) {
  65       children();
  66     }
  67   }
  68 }
  69
  70 module PsuLedBafflePlan(){
  71   baffle_tr = [0, psu_baffle_cnr_y]
  72     + 0.5 * [psu_baffle_th[1], psu_baffle_th[0]];
  73   translate([0, -psu_sz[1]/2]) {
  74     mirror([1,0,0]) {
  75       rectfromto([-psu_baffle_th[1]/2, 0],
  76                  baffle_tr);
  77       rectfromto([-psu_sz[0]/2 - psu_board_support_wall *2,
  78                   baffle_tr[1] - psu_baffle_th[0]],
  79                  baffle_tr);
  80     }
  81   }
  82 }
  83
  84 module PsuLedWindowsPlan(){
  85   difference(){
  86     union(){
  87       AtPsuMountCorner(1,0) {
  88         rectfromto([ -(psu_board_support_wall + 0.1),
  89                      +psu_usbend_led_x ],
  90                    [ psu_sz[0]/2,
  91                      +psu_usbend_led_depth ]);
  92       }
  93       AtPsuMountCorner(0,0) {
  94         sz = psu_baffle_cnr_y - psu_board_support_wall - psu_baffle_th[0];
  95         translate([0, psu_baffle_cnr_y])
  96           rectfromto([ -(psu_board_support_wall + 0.1),
  97                        -sz/2 ],
  98                      [ psu_sz[0]/2,
  99                        +sz/2 ]);
 100       }
 101       AtPsuMountCorner(0,1){
 102         rectfromto([0,0],
 103                    [psu_sz[0]/2 - psu_hole_pos[1] - psu_hole_dia/2,
 104                      psu_innerend_led_depth]);
 105       }
 106     }
 107     PsuLedBafflePlan();
 108     translate([0, -psu_sz[1]/2])
 109       square(center=true, [psu_baffle_th[1], psu_sz[1]]);;
 110   }
 111 }
 112
 113 module PsuMountPositiveMain(){
 114   for (mx=[0,1]) {
 115     for (my=[0,1]) {
 116       PsuMountCornerExtrude(mx,my){
 117         rectfromto(-[1,1]*psu_board_support_wall,
 118                    +[1,1]*board_support_ovlp);
 119       }
 120     }
 121     // mount above at plug end
 122     PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
 123       rectfromto(-[1,1]*psu_board_support_wall,
 124                  [board_support_ovlp,
 125                   board_support_ovlp_ceil]);
 126     }
 127   }
 128   translate([0,0, -psu_z_down])
 129     linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
 130       PsuLedBafflePlan();
 131 }
 132
 133 module PsuMountNegative(){
 134   axis = [0, -psu_sz[1]/2, psu_th];
 135   PsuRepresentation();
 136   translate(axis)
 137     rotate([atan(2 * board_support_z / psu_sz[1]),
 138             0,0])
 139     translate(-axis)
 140     PsuBoardRepresentation();
 141 }
 142
 143 module PsuMountPositive(){
 144   difference(){
 145     PsuMountPositiveMain();
 146     PsuMountNegative();
 147     intersection(){
 148       hull(){
 149         PsuBoardRepresentation();
 150         translate([0,0,5]) PsuBoardRepresentation();
 151       }
 152       translate([-20,0,-20]) cube(40);
 153     }
 154   }
 155   for (mx=[0,1]) {
 156     PsuMountCornerExtrude(mx,1){
 157       translate([psu_sz[0]/2 - psu_hole_pos[1],
 158                  psu_hole_pos[0]]
 159                 + board_gap * [1,1] )
 160         circle(r= psu_hole_dia/2);
 161     }
 162   }
 163   translate([0, psu_sz[1]/2 + psu_board_nutbox[0]/2, 0])
 164     rotate([0,0,180])
 165     NutBox(psu_board_nutbox, psu_z_down);
 166 }
 167
 168 module PsuClamp(){ ////toplevel
 169   rotate([180,0,0]) difference(){
 170     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
 171       difference(){
 172         hull(){
 173           circle(r = fix_sz/2);
 174           translate([ -psu_board_nutbox[0]/2, 0])
 175             square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
 176         }
 177         circle(r = psu_board_nutbox[0]/2);
 178       }
 179     }
 180     translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
 181       translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
 182         mirror([1,0])
 183         translate([0,-20]) square(40);
 184     }
 185   }
 186 }