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 - 0.5;
  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 psu_usba_v_apart = 7.0;
  40 psu_usba_v_from_edge = 4.86;
  41 psu_usba_v_space_below = 1.5;
  42 psu_usba_v_space_w = 1.7;
  43 psu_usba_v_space_l = 3.0;
  44
  45 psu_test_ceil = 2.5;
  46
  47 // ----- calculated -----
  48
  49 psu_z = NutBox_h_base(psu_board_nutbox);
  50 psu_z_down = psu_z + 0.1;
  51 psu_fix_sz = NutBox_outer_size(psu_board_nutbox);
  52 psu_board_nutbox_y = psu_sz[1]/2 + psu_board_nutbox[0]/2;
  53
  54 psu_mount_outer_sz_x = psu_sz[0] + psu_board_support_wall * 2; // centred
  55 psu_mount_outer_sz_y = psu_y + max(psu_board_support_wall, // at psu_y
  56                                    psu_board_nutbox_y + psu_fix_sz/2);
  57
  58 module PsuBoardRepresentation(){
  59   linear_extrude(height= psu_th)
  60     square(center=true, [psu_sz[0],psu_sz[1]]);
  61 }
  62
  63 module PsuRepresentation(){
  64   PsuBoardRepresentation();
  65   translate([0, -psu_sz[1]/2, -psu_connector_z])
  66     linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
  67     rectfromto([ -psu_connector_w/2, -10 ],
  68                [ +psu_connector_w/2, psu_connector_depth ]);
  69 }
  70
  71 module AtPsuMountCorner(mx,my){
  72   mirror([mx,0,0])
  73     mirror([0,my,0])
  74       translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
  75                 -1 * [0,0, psu_z_down])
  76         children();
  77 }
  78
  79 module PsuMountCornerExtrude(mx,my, plus_z=psu_board_support_z){
  80   AtPsuMountCorner(mx,my){
  81     linear_extrude(height= psu_z_down + plus_z, convexity=10) {
  82       children();
  83     }
  84   }
  85 }
  86
  87 module PsuUsbAVSpacePlan(){
  88   for (x= [-1,+1] * psu_usba_v_apart/2) {
  89     translate([x, -psu_usba_v_from_edge ]) {
  90       hull(){
  91         for (y= [-1,+1] * 0.5 * (psu_usba_v_space_l - psu_usba_v_space_w)) {
  92           translate([0,y])
  93             circle(r= psu_usba_v_space_w);
  94         }
  95       }
  96     }
  97   }
  98 }
  99
 100 module PsuMountPositiveMain(){
 101   for (mx=[0,1]) {
 102     for (my=[0,1]) {
 103       PsuMountCornerExtrude(mx,my){
 104         rectfromto(-[1,1]*psu_board_support_wall,
 105                    +[1,1]*psu_board_support_ovlp);
 106       }
 107     }
 108     // mount above at plug end
 109     PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
 110       rectfromto(-[1,1]*psu_board_support_wall,
 111                  [psu_board_support_ovlp,
 112                   psu_board_support_ovlp_ceil]);
 113     }
 114   }
 115   translate([0,0, -psu_z_down])
 116     linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
 117       PsuLedBafflePlan();
 118 }
 119
 120 module PsuMountNegative(){
 121   axis = [0, -psu_sz[1]/2, psu_th];
 122   PsuRepresentation();
 123   translate(axis)
 124     rotate([atan(2 * psu_board_support_z / psu_sz[1]),
 125             0,0])
 126     translate(-axis)
 127     PsuBoardRepresentation();
 128 }
 129
 130 module PsuMountPositive(){
 131   difference(){
 132     intersection(){
 133       PsuMountPositiveMain();
 134       linextr_y_xz(-psu_y, psu_sz[1]*2) square(100, center=true);
 135     }
 136     PsuMountNegative();
 137     intersection(){
 138       hull(){
 139         PsuBoardRepresentation();
 140         translate([0,0,5]) PsuBoardRepresentation();
 141       }
 142       translate([-20,0,-20]) cube(40);
 143     }
 144   }
 145   for (mx=[0,1]) {
 146     PsuMountCornerExtrude(mx,1){
 147       translate([psu_sz[0]/2 - psu_hole_pos[1],
 148                  psu_hole_pos[0]]
 149                 + psu_board_gap * [1,1] )
 150         circle(r= psu_hole_dia/2);
 151     }
 152   }
 153   difference(){
 154     translate([0, psu_board_nutbox_y, 0])
 155       rotate([0,0,180])
 156       NutBox(psu_board_nutbox, psu_z_down);
 157     translate([0, psu_sz[1]/2, 0])
 158       linextr(-psu_usba_v_space_below, +10)
 159       PsuUsbAVSpacePlan();
 160   }
 161 }
 162
 163 module PsuClamp(){ ////toplevel
 164   rotate([180,0,0]) difference(){
 165     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
 166       difference(){
 167         hull(){
 168           circle(r = psu_fix_sz/2);
 169           translate([ -psu_board_nutbox[0]/2, 0])
 170             square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
 171         }
 172         circle(r = psu_board_nutbox[0]/2);
 173       }
 174     }
 175     translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
 176       translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
 177         mirror([1,0])
 178         translate([0,-20]) square(40);
 179     }
 180     linextr(-10,10) {
 181       rotate(-90)
 182         translate([0, -psu_board_nutbox[0]/2])
 183         PsuUsbAVSpacePlan();
 184     }
 185   }
 186 }
 187
 188 module PsuLedWindowsPlan(){
 189   difference(){
 190     PsuLedWindowsPlanCore();
 191     PsuLedBafflePlan();
 192   }
 193 }
 194
 195 module PsuMountWindowsNegative(ceil){
 196   linextr(-10, 0.1)
 197     PsuLedWindowsPlan();
 198   translate([0, 0, -psu_z - ceil])
 199     linextr(-1, psu_initial_layer_thick)
 200     offset(delta=psu_window_ledge + psu_multicolour_gap)
 201     PsuLedWindowsPlan();
 202 }
 203
 204 module PsuMountDemo() { ////toplevel
 205   ceil = psu_test_ceil;
 206
 207   translate([0, psu_y, psu_z]) {
 208     difference(){
 209       PsuMountPositive();
 210       linextr(-20, 0.1)
 211         PsuLedWindowsPlan();
 212     }
 213     %PsuMountNegative();
 214
 215     color("yellow") translate([0,0, -psu_z - ceil])
 216       linear_extrude(height=0.4, convexity=10)
 217       PsuLedWindowsPlan();
 218
 219     color("blue") translate([0,0, -psu_z - ceil])
 220       linear_extrude(height=0.4, convexity=10)
 221       PsuLedLegendsPlan();
 222
 223     translate([0, psu_board_nutbox_y, 10])
 224       rotate([180,0,0])
 225       rotate([0,0,-90])
 226       PsuClamp();
 227   }
 228 }
 229
 230 module PsuMountTest() { ////toplevel
 231   ceil = psu_test_ceil;
 232   $fs = 0.1;
 233   $fa = 3;
 234   difference(){
 235     union(){
 236       translate([0, psu_y, psu_z])
 237         PsuMountPositive();
 238       difference(){
 239
 240         // rectangular box with wall
 241         linextr_x_yz(-psu_mount_outer_sz_x/2,
 242                      +psu_mount_outer_sz_x/2) {
 243           difference(){
 244             rectfromto([0, -ceil],
 245                        [psu_mount_outer_sz_y, psu_z + 10]);
 246             rectfromto([ceil,0], 400*[1,1]);
 247           }
 248         }
 249
 250         translate([0, psu_y, psu_z]) {
 251           PsuMountNegative();
 252         }
 253
 254         translate([0, psu_y, -ceil]) {
 255           linextr(-1, psu_initial_layer_thick) {
 256             offset(delta=psu_multicolour_gap)
 257               PsuLedLegendsPlan();
 258           }
 259         }
 260       }
 261     }
 262     translate([0, psu_y, psu_z])
 263       PsuMountWindowsNegative(ceil);
 264   }
 265 }
 266
 267 psu_multicolour_gap = 0.075;
 268 psu_initial_layer_thick = 0.400;
 269 psu_initial_layer_width = 0.750;
 270 psu_window_ledge = 0.50; // each side
 271
 272 psu_frame_gap = 1.0;
 273
 274 module PsuMountLayerFrame(bl, tr, ix) {
 275   gap0 = [1,1] * (psu_frame_gap + psu_initial_layer_width*(ix+0));
 276   gap1 = [1,1] * (psu_frame_gap + psu_initial_layer_width*(ix+1));
 277   linextr(0, psu_initial_layer_thick) {
 278     difference(){
 279       rectfromto(bl-gap1, tr+gap1);
 280       rectfromto(bl-gap0, tr+gap0);
 281     }
 282   }
 283 }
 284
 285 module PsuMountTestFullLayerFrame(ix) {
 286   PsuMountLayerFrame([-0.5 * psu_mount_outer_sz_x, 0],
 287                      [+0.5 * psu_mount_outer_sz_x,
 288                       psu_mount_outer_sz_y],
 289                      ix);
 290 }
 291
 292 module PsuMountTestFullMain() { ////toplevel
 293   ceil = psu_test_ceil;
 294
 295   PsuMountTestFullLayerFrame(2);
 296
 297   difference(){
 298     translate([0,0, ceil])
 299       PsuMountTest();
 300   }
 301 }
 302
 303 module PsuMountTestFullOneLayer(ix) {
 304   PsuMountTestFullLayerFrame(ix);
 305   linextr(0, psu_initial_layer_thick) {
 306     translate([0, psu_y]) children();
 307   }
 308 }
 309
 310 module PsuMountTestFullText() { ////toplevel
 311   PsuMountTestFullOneLayer(0)
 312     PsuLedLegendsPlan();
 313 }
 314 module PsuMountTestFullWindows() { ////toplevel
 315   PsuMountTestFullOneLayer(1)
 316     offset(delta=psu_window_ledge)
 317     PsuLedWindowsPlan();
 318 }
 319
 320 module PsuMountTestFullDemo() { ////toplevel
 321   color("blue") PsuMountTestFullMain();
 322   color("yellow") PsuMountTestFullText();
 323   %PsuMountTestFullWindows();
 324 }