adafruit-powerboost-common.scad

   1 // -*- C -*-
   2
   3 include <nutbox.scad>
   4 include <utils.scad>
   5
   6 psu_sz  = psu_sz_nom + [ 0.11, 0.44 ] + [ 0.25, 0.25 ];
   7
   8 psu_hole_pos = [ 2.05, // from back edge of psu_sz[0]
   9                  0.55 * 0.5 * 25.4, // from centreline
  10                  ];
  11
  12 psu_th = 1.70 + 0.25;
  13 psu_th_for_clamp = 1.50;
  14
  15 psu_hole_dia = 2.5 - 0.3;
  16 psu_connector_z = 2.9 + 0.1;
  17 psu_connector_z_overlap = 0.15;
  18 psu_connector_depth = 6.25;
  19 psu_connector_w = 8.0 + 0.5;
  20 psu_usb_protr = 0.6;
  21
  22 psu_clamp_th = 4.0 + 0.75;
  23 psu_clamp_w = 8.0;
  24 psu_clamp_gap = 0.4;
  25
  26 psu_board_clamp_ovlp = 4.5;
  27 psu_board_nutbox = nutbox_data_M3;
  28
  29 psu_board_gap = 0.5;
  30 psu_board_support_wall = 2;
  31 psu_board_support_ovlp = 4.5;
  32 psu_board_support_ovlp_ceil = 2;
  33 psu_board_support_z = 2;
  34
  35 psu_baffle_gap = 1.0 + 0.5;
  36
  37 psu_y = +psu_sz[1]/2 + psu_usb_protr;
  38
  39 // ----- calculated -----
  40
  41 psu_z = NutBox_h_base(psu_board_nutbox);
  42 psu_z_down = psu_z + 0.1;
  43 psu_fix_sz = NutBox_outer_size(psu_board_nutbox);
  44 psu_board_nutbox_y = psu_sz[1]/2 + psu_board_nutbox[0]/2;
  45
  46 module PsuBoardRepresentation(){
  47   linear_extrude(height= psu_th)
  48     square(center=true, [psu_sz[0],psu_sz[1]]);
  49 }
  50
  51 module PsuRepresentation(){
  52   PsuBoardRepresentation();
  53   translate([0, -psu_sz[1]/2, -psu_connector_z])
  54     linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
  55     rectfromto([ -psu_connector_w/2, -10 ],
  56                [ +psu_connector_w/2, psu_connector_depth ]);
  57 }
  58
  59 module AtPsuMountCorner(mx,my){
  60   mirror([mx,0,0])
  61     mirror([0,my,0])
  62       translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
  63                 -1 * [0,0, psu_z_down])
  64         children();
  65 }
  66
  67 module PsuMountCornerExtrude(mx,my, plus_z=psu_board_support_z){
  68   AtPsuMountCorner(mx,my){
  69     linear_extrude(height= psu_z_down + plus_z, convexity=10) {
  70       children();
  71     }
  72   }
  73 }
  74
  75 module PsuMountPositiveMain(){
  76   for (mx=[0,1]) {
  77     for (my=[0,1]) {
  78       PsuMountCornerExtrude(mx,my){
  79         rectfromto(-[1,1]*psu_board_support_wall,
  80                    +[1,1]*psu_board_support_ovlp);
  81       }
  82     }
  83     // mount above at plug end
  84     PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
  85       rectfromto(-[1,1]*psu_board_support_wall,
  86                  [psu_board_support_ovlp,
  87                   psu_board_support_ovlp_ceil]);
  88     }
  89   }
  90   translate([0,0, -psu_z_down])
  91     linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
  92       PsuLedBafflePlan();
  93 }
  94
  95 module PsuMountNegative(){
  96   axis = [0, -psu_sz[1]/2, psu_th];
  97   PsuRepresentation();
  98   translate(axis)
  99     rotate([atan(2 * psu_board_support_z / psu_sz[1]),
 100             0,0])
 101     translate(-axis)
 102     PsuBoardRepresentation();
 103 }
 104
 105 module PsuMountPositive(){
 106   difference(){
 107     intersection(){
 108       PsuMountPositiveMain();
 109       linextr_y_xz(-psu_y, psu_sz[1]*2) square(100, center=true);
 110     }
 111     PsuMountNegative();
 112     intersection(){
 113       hull(){
 114         PsuBoardRepresentation();
 115         translate([0,0,5]) PsuBoardRepresentation();
 116       }
 117       translate([-20,0,-20]) cube(40);
 118     }
 119   }
 120   for (mx=[0,1]) {
 121     PsuMountCornerExtrude(mx,1){
 122       translate([psu_sz[0]/2 - psu_hole_pos[1],
 123                  psu_hole_pos[0]]
 124                 + psu_board_gap * [1,1] )
 125         circle(r= psu_hole_dia/2);
 126     }
 127   }
 128   translate([0, psu_board_nutbox_y, 0])
 129     rotate([0,0,180])
 130     NutBox(psu_board_nutbox, psu_z_down);
 131 }
 132
 133 module PsuClamp(){ ////toplevel
 134   rotate([180,0,0]) difference(){
 135     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
 136       difference(){
 137         hull(){
 138           circle(r = psu_fix_sz/2);
 139           translate([ -psu_board_nutbox[0]/2, 0])
 140             square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
 141         }
 142         circle(r = psu_board_nutbox[0]/2);
 143       }
 144     }
 145     translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
 146       translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
 147         mirror([1,0])
 148         translate([0,-20]) square(40);
 149     }
 150   }
 151 }
 152
 153 module PsuLedWindowsPlan(){
 154   difference(){
 155     PsuLedWindowsPlanCore();
 156     PsuLedBafflePlan();
 157   }
 158 }
 159
 160 module PsuMountDemo(ceil = 2.5) { ////toplevel
 161   translate([0, psu_y, psu_z]) {
 162     difference(){
 163       PsuMountPositive();
 164       linextr(-20, 0.1)
 165         PsuLedWindowsPlan();
 166     }
 167     %PsuMountNegative();
 168     color("yellow") translate([0,0, -psu_z - ceil])
 169       linear_extrude(height=0.4, convexity=10)
 170       PsuLedWindowsPlan();
 171
 172     translate([0, psu_board_nutbox_y, 10])
 173       rotate([180,0,0])
 174       rotate([0,0,-90])
 175       PsuClamp();
 176   }
 177 }
 178
 179 module PsuMountTest(ceil = 2.5) { ////toplevel
 180   $fs = 0.1;
 181   $fa = 3;
 182   difference(){
 183     union(){
 184       translate([0, psu_y, psu_z])
 185         PsuMountPositive();
 186       difference(){
 187         linextr_x_yz(-(psu_sz[0]/2 + 5),
 188                      +(psu_sz[0]/2 + 5)){
 189           difference(){
 190             rectfromto([-ceil, -ceil], [psu_sz[1] + 10, psu_z + 10]);
 191             rectfromto([0,0], 400*[1,1]);
 192           }
 193         }
 194         translate([0, psu_y, psu_z]) {
 195           PsuMountNegative();
 196         }
 197       }
 198     }
 199     translate([0, psu_y, psu_z]) {
 200       linextr(-10, 0.1)
 201         PsuLedWindowsPlan();
 202     }
 203   }
 204 }