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
  44 module PsuBoardRepresentation(){
  45   linear_extrude(height= psu_th)
  46     square(center=true, [psu_sz[0],psu_sz[1]]);
  47 }
  48
  49 module PsuRepresentation(){
  50   PsuBoardRepresentation();
  51   translate([0, -psu_sz[1]/2, -psu_connector_z])
  52     linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
  53     rectfromto([ -psu_connector_w/2, -10 ],
  54                [ +psu_connector_w/2, psu_connector_depth ]);
  55 }
  56
  57 module AtPsuMountCorner(mx,my){
  58   mirror([mx,0,0])
  59     mirror([0,my,0])
  60       translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
  61                 -1 * [0,0, psu_z_down])
  62         children();
  63 }
  64
  65 module PsuMountCornerExtrude(mx,my, plus_z=psu_board_support_z){
  66   AtPsuMountCorner(mx,my){
  67     linear_extrude(height= psu_z_down + plus_z, convexity=10) {
  68       children();
  69     }
  70   }
  71 }
  72
  73 module PsuMountPositiveMain(){
  74   for (mx=[0,1]) {
  75     for (my=[0,1]) {
  76       PsuMountCornerExtrude(mx,my){
  77         rectfromto(-[1,1]*psu_board_support_wall,
  78                    +[1,1]*psu_board_support_ovlp);
  79       }
  80     }
  81     // mount above at plug end
  82     PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
  83       rectfromto(-[1,1]*psu_board_support_wall,
  84                  [psu_board_support_ovlp,
  85                   psu_board_support_ovlp_ceil]);
  86     }
  87   }
  88   translate([0,0, -psu_z_down])
  89     linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
  90       PsuLedBafflePlan();
  91 }
  92
  93 module PsuMountNegative(){
  94   axis = [0, -psu_sz[1]/2, psu_th];
  95   PsuRepresentation();
  96   translate(axis)
  97     rotate([atan(2 * psu_board_support_z / psu_sz[1]),
  98             0,0])
  99     translate(-axis)
 100     PsuBoardRepresentation();
 101 }
 102
 103 module PsuMountPositive(){
 104   difference(){
 105     intersection(){
 106       PsuMountPositiveMain();
 107       linextr_y_xz(-psu_y, psu_sz[1]*2) square(100, center=true);
 108     }
 109     PsuMountNegative();
 110     intersection(){
 111       hull(){
 112         PsuBoardRepresentation();
 113         translate([0,0,5]) PsuBoardRepresentation();
 114       }
 115       translate([-20,0,-20]) cube(40);
 116     }
 117   }
 118   for (mx=[0,1]) {
 119     PsuMountCornerExtrude(mx,1){
 120       translate([psu_sz[0]/2 - psu_hole_pos[1],
 121                  psu_hole_pos[0]]
 122                 + psu_board_gap * [1,1] )
 123         circle(r= psu_hole_dia/2);
 124     }
 125   }
 126   translate([0, psu_sz[1]/2 + psu_board_nutbox[0]/2, 0])
 127     rotate([0,0,180])
 128     NutBox(psu_board_nutbox, psu_z_down);
 129 }
 130
 131 module PsuClamp(){ ////toplevel
 132   rotate([180,0,0]) difference(){
 133     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
 134       difference(){
 135         hull(){
 136           circle(r = fix_sz/2);
 137           translate([ -psu_board_nutbox[0]/2, 0])
 138             square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
 139         }
 140         circle(r = psu_board_nutbox[0]/2);
 141       }
 142     }
 143     translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
 144       translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
 145         mirror([1,0])
 146         translate([0,-20]) square(40);
 147     }
 148   }
 149 }
 150
 151 module PsuLedWindowsPlan(){
 152   difference(){
 153     PsuLedWindowsPlanCore();
 154     PsuLedBafflePlan();
 155   }
 156 }
 157
 158 module PsuMountDemo(ceil = 2.5) { ////toplevel
 159   translate([0, psu_y, psu_z]) {
 160     difference(){
 161       PsuMountPositive();
 162       linextr(-20, 0.1)
 163         PsuLedWindowsPlan();
 164     }
 165     %PsuMountNegative();
 166     color("yellow") translate([0,0, -psu_z - ceil])
 167       linear_extrude(height=0.4, convexity=10)
 168       PsuLedWindowsPlan();
 169   }
 170 }
 171
 172 module PsuMountTest(ceil = 2.5) { ////toplevel
 173   difference(){
 174     union(){
 175       translate([0, psu_y, psu_z])
 176         PsuMountPositive();
 177       difference(){
 178         linextr_x_yz(-(psu_sz[0]/2 + 5),
 179                      +(psu_sz[0]/2 + 5)){
 180           difference(){
 181             rectfromto([-ceil, -ceil], [psu_sz[1] + 5, psu_z + 10]);
 182             rectfromto([0,0], 400*[1,1]);
 183           }
 184         }
 185         translate([0, psu_y, psu_z]) {
 186           PsuMountNegative();
 187         }
 188       }
 189     }
 190     translate([0, psu_y, psu_z]) {
 191       linextr(-10, 0.1)
 192         PsuLedWindowsPlan();
 193     }
 194   }
 195 }