adafruit-powerboost-common.scad

   1 // -*- C -*-
   2
   3 include <nutbox.scad>
   4
   5 psu_th = 1.70 + 0.25;
   6 psu_th_for_clamp = 1.50;
   7
   8 psu_hole_dia = 2.5 - 0.3;
   9 psu_connector_z = 2.9 + 0.1;
  10 psu_connector_z_overlap = 0.15;
  11 psu_connector_depth = 6.25;
  12 psu_connector_w = 8.0 + 0.5;
  13 psu_usb_protr = 0.6;
  14
  15 psu_clamp_th = 4.0 + 0.75;
  16 psu_clamp_w = 8.0;
  17 psu_clamp_gap = 0.4;
  18
  19 psu_board_clamp_ovlp = 4.5;
  20 psu_board_support_wall = 2;
  21 psu_board_nutbox = nutbox_data_M3;
  22
  23 psu_y = +psu_sz[1]/2 + psu_usb_protr;
  24
  25 // ----- calculated -----
  26
  27 psu_z = NutBox_h_base(psu_board_nutbox);
  28 psu_z_down = psu_z + 0.1;
  29
  30 module PsuBoardRepresentation(){
  31   linear_extrude(height= psu_th)
  32     square(center=true, [psu_sz[0],psu_sz[1]]);
  33 }
  34
  35 module PsuRepresentation(){
  36   PsuBoardRepresentation();
  37   translate([0, -psu_sz[1]/2, -psu_connector_z])
  38     linear_extrude(height= psu_connector_z + psu_connector_z_overlap)
  39     rectfromto([ -psu_connector_w/2, -10 ],
  40                [ +psu_connector_w/2, psu_connector_depth ]);
  41 }
  42
  43 module AtPsuMountCorner(mx,my){
  44   mirror([mx,0,0])
  45     mirror([0,my,0])
  46       translate(-0.5 * [psu_sz[0], psu_sz[1], 0]
  47                 -1 * [0,0, psu_z_down])
  48         children();
  49 }
  50
  51 module PsuMountCornerExtrude(mx,my, plus_z=board_support_z){
  52   AtPsuMountCorner(mx,my){
  53     linear_extrude(height= psu_z_down + plus_z, convexity=10) {
  54       children();
  55     }
  56   }
  57 }
  58
  59 module PsuMountPositiveMain(){
  60   for (mx=[0,1]) {
  61     for (my=[0,1]) {
  62       PsuMountCornerExtrude(mx,my){
  63         rectfromto(-[1,1]*psu_board_support_wall,
  64                    +[1,1]*board_support_ovlp);
  65       }
  66     }
  67     // mount above at plug end
  68     PsuMountCornerExtrude(mx,0, psu_th + psu_board_support_wall){
  69       rectfromto(-[1,1]*psu_board_support_wall,
  70                  [board_support_ovlp,
  71                   board_support_ovlp_ceil]);
  72     }
  73   }
  74   translate([0,0, -psu_z_down])
  75     linear_extrude(psu_z_down - psu_baffle_gap, convexity=10)
  76       PsuLedBafflePlan();
  77 }
  78
  79 module PsuMountNegative(){
  80   axis = [0, -psu_sz[1]/2, psu_th];
  81   PsuRepresentation();
  82   translate(axis)
  83     rotate([atan(2 * board_support_z / psu_sz[1]),
  84             0,0])
  85     translate(-axis)
  86     PsuBoardRepresentation();
  87 }
  88
  89 module PsuMountPositive(){
  90   difference(){
  91     intersection(){
  92       PsuMountPositiveMain();
  93       linextr_y_xz(-psu_y, psu_sz[1]*2) square(100, center=true);
  94     }
  95     PsuMountNegative();
  96     intersection(){
  97       hull(){
  98         PsuBoardRepresentation();
  99         translate([0,0,5]) PsuBoardRepresentation();
 100       }
 101       translate([-20,0,-20]) cube(40);
 102     }
 103   }
 104   for (mx=[0,1]) {
 105     PsuMountCornerExtrude(mx,1){
 106       translate([psu_sz[0]/2 - psu_hole_pos[1],
 107                  psu_hole_pos[0]]
 108                 + board_gap * [1,1] )
 109         circle(r= psu_hole_dia/2);
 110     }
 111   }
 112   translate([0, psu_sz[1]/2 + psu_board_nutbox[0]/2, 0])
 113     rotate([0,0,180])
 114     NutBox(psu_board_nutbox, psu_z_down);
 115 }
 116
 117 module PsuClamp(){ ////toplevel
 118   rotate([180,0,0]) difference(){
 119     linear_extrude(height=psu_clamp_th + psu_th_for_clamp, convexity=5) {
 120       difference(){
 121         hull(){
 122           circle(r = fix_sz/2);
 123           translate([ -psu_board_nutbox[0]/2, 0])
 124             square(center=true, [ psu_board_clamp_ovlp*2, psu_clamp_w ]);
 125         }
 126         circle(r = psu_board_nutbox[0]/2);
 127       }
 128     }
 129     translate([0,0,-1]) linear_extrude(height=psu_th_for_clamp+1) {
 130       translate([ -psu_board_nutbox[0]/2 + psu_clamp_gap, 0 ])
 131         mirror([1,0])
 132         translate([0,-20]) square(40);
 133     }
 134   }
 135 }
 136
 137 module PsuLedWindowsPlan(){
 138   difference(){
 139     PsuLedWindowsPlanCore();
 140     PsuLedBafflePlan();
 141   }
 142 }
 143
 144 module PsuMountDemo(ceil = 2.5) { ////toplevel
 145   translate([0, psu_y, psu_z]) {
 146     PsuMountPositive();
 147     %PsuMountNegative();
 148     color("yellow") translate([0,0, -psu_z - ceil])
 149       linear_extrude(height=0.4, convexity=10)
 150       PsuLedWindowsPlan();
 151   }
 152 }