comment and simplify enclosure

1 files changed, 119 insertions, 41 deletions

diff --git a/enclosure/enclosure.scad b/enclosure/enclosure.scad
index 01eddd2..79837cb 100644
--- a/enclosure/enclosure.scad
+++ b/enclosure/enclosure.scad
@@ -5,109 +5,181 @@
   * top, big hole for the screen and small holes for air
 
   * board, holds the board and the switch / button / usb / sd holes on
-    the sides; the co2 sensor probably goes here as well
+    the sides; the co2 sensor goes here as well
 
   * bottom, for battery and pm sensor
  */
 
 use <threads-scad/threads.scad>
 
+// all measurements are in mm
+
+// thickness of bottom / top / side walls
 WALL_THICKNESS=1;
 
+/* [Screws] */
+// diameter of the screws; I'm using M4 screws
 SCREW_DIAM=4;
+// extra space between screws and box edges
 SCREW_PAD=0;
-
+// length of the bolt's stem, avoids half-empty holes in the bottom
 BOLT_STEM_Z=24.7;
 
+/* [Particle sensor] */
+// width (connector side - inlet side)
 PM_X=40.8;
+// height
 PM_Y=40.8;
+// depth
 PM_Z=12.5;
+// height of the window for the connector
 PM_CONN_Y=15.8;
-PM_CONN_Z=4;
+// depth of the window for the connector, from the top of the sensor
 PM_CONN_DEPTH=7.7;
 
+/* [Battery] */
+// width (longest dimension)
 BATT_X=55;
+// height
 BATT_Y=33.5;
+// depth (shortest dimension)
 BATT_Z=10.8;
 
+/* [CO2 sensor] */
+// width (connector side - other side)
 CO_X=28.5;
+// height
 CO_Y=24.1;
+// depth
 CO_Z=8;
+// height of the window for the connector
 CO_CONN_Y=10;
-
+// diameter of top holes to let air into the CO2 sensor
 CO_HOLE_DIAM=2;
-CO_HOLE_DIST=CO_HOLE_DIAM + 2; // distance between hole centres
+// distance between hole centres
+CO_HOLE_DIST=4;
 
-BOT_CABLE_WELL_X=15; // just some space for the battery & pm cables
-MID_CABLE_WELL_X=5;  // just some space between co2 & board
+/* [Cable wells] */
+// width of the space for the battery & pm cables
+BOT_CABLE_WELL_X=15;
+// width of the space between CO2 sensor & main board
+MID_CABLE_WELL_X=5;
 
-BOTTOM_Z=WALL_THICKNESS + PM_Z;
-MIDDLE_Z=WALL_THICKNESS + CO_Z;
-
-DISPLAY_WIN_X=51;
-DISPLAY_WIN_Y=26;
-DISPLAY_X_OFF=2.5;
-DISPLAY_Y_OFF=6.1;
-
-//PITCH=0.254; don't really care
+/* [Main board] */
+// width (longest dimension)
 BOARD_X=66.5;
+// height
 BOARD_Y=36.8;
+// distance between display face and bottom of PCB
 BOARD_SINK=2.2;
-BOARD_PAD=0;
-
-BOARD_PIN_OFF_X=2.35; BOARD_PIN_DIST_X=61.43;
-BOARD_PIN_OFF_Y=2.15; BOARD_PIN_DIST_Y=32.5;
-
+// width offset of left mounting hole
+BOARD_PIN_OFF_X=2.35;
+// width distance between left and right mounting hole
+BOARD_PIN_DIST_X=61.43;
+// height offset of bottom mounting hole
+BOARD_PIN_OFF_Y=2.15;
+// height distance between bottom and top mounting hole
+BOARD_PIN_DIST_Y=32.5;
+// diameter of support pillars
 BOARD_SUPPORT_DIAM=3;
+// diameter of mounting holes
 BOARD_SUPPORT_PIN_DIAM=2;
 
-USB_MICRO_B_X=12;
-USB_MICRO_B_Z=5.5;
+/* [Display] */
+// width (longest dimension)
+DISPLAY_WIN_X=51;
+// height
+DISPLAY_WIN_Y=26;
+// width offset of view window
+DISPLAY_X_OFF=2.5;
+// height offset of view window
+DISPLAY_Y_OFF=6.1;
 
-USB_MICRO_B_SINK=2;
+/* [USB hole] */
+// width
+USB_MICRO_B_X=12;
+// depth
+USB_MICRO_B_Z=4.75;
+// width distance between left edge of board to middle of USB socket
 USB_MICRO_B_OFF_X=42.7;
 
+/* [SD space] */
+// width (bit wider than the middle dimension of the SD card)
 SD_X=12.5;
+// height (how much the card protrudes from the PCB)
 SD_Y=9.5;
-SD_Z=1;
-SD_SINK=3;
+// depth (distance between bottom of PCB and bottom of card)
+SD_Z=3.5;
+// width distance between left edge of board to middle of SD card
 SD_OFF_X=54;
 
+/* [On/Off switch hole] */
+// width
 SWITCH_X=9;
+// height (how much the switch protrudes)
 SWITCH_Y=2;
+// depth (distance between bottom of PCB and bottom of switch)
 SWITCH_Z=4;
-SWITCH_SINK=SWITCH_Z/2;
+// width distance between left edge of board to middle of switch
 SWITCH_OFF_X=42.5;
 
+/* [Reset button hole] */
+// width
 RESET_X=2.5;
+// depth (distance between bottom of PCB and bottom of hole)
 RESET_Z=2;
-RESET_SINK=1;
+// width distance between left edge of board to middle of button
 RESET_OFF_X=51;
 
+/* [Other button] */
+// width
 BUTTON_X=5;
-BUTTON_Z=3;
-BUTTON_SINK=1;
+// depth (distance between bottom of PCB and bottom of hole)
+BUTTON_Z=2.5;
+// width distance between left edge of board to middle of button
 BUTTON_OFF_X=58;
 
-TOP_Z=2;
-
-PILLAR_Y=WALL_THICKNESS*2;
+module __Customizer_Limit__ () {}
+// we use SWITCH_Y to offset the PCB from the edge, so the height of
+// the pillars that partially cover the switch+button holes has to be
+// the same
+PILLAR_Y=SWITCH_Y;
+// fudge factor: the pillars need to be a bit thinner than the holes
+// they go into
 PILLAR_SHRINK=0.05;
 
+// top layer is 2 walls thick, just because
+TOP_Z=WALL_THICKNESS*2;
+// middle layer needs to hold the CO2 sensor on a wall; the PCB is much thinner
+MIDDLE_Z=WALL_THICKNESS + CO_Z;
+// bottom layers needs to hold the PM sensor and the battery
+BOTTOM_Z=WALL_THICKNESS + max(PM_Z,BATT_Z);
+
+// width of the whole thing: 2 walls, plus wider of the middle & bottom layers
 TOTAL_X=2*WALL_THICKNESS + max(
                                PM_X + BOT_CABLE_WELL_X + BATT_X,
                                CO_X + MID_CABLE_WELL_X + BOARD_X
                                );
+// height of the whole thing: 2 walls, plus highest of the middle & bottom layers
 TOTAL_Y=2*(WALL_THICKNESS + SCREW_DIAM + SCREW_PAD) + max(PM_Y,CO_Y,BOARD_Y,BATT_Y);
 
+// nearly all objects are centered in X&Y, and most are sitting on Z=0
+
+// just like a centered cube, but sitting at Z=0
 module box(v) {
   translate([0,0,v[2]/2]) cube(v,center=true);
 }
 
+/* SCREWS */
+
 module screw_hole() {
   cylinder(h=200,d=SCREW_DIAM,center=true,$fs=0.1);
 }
 
+// this is nearly copied from threads.scad: its ScrewHole subtracts
+// the hole from its children, I need a thing that I can subtract
+// multiple times from a single object, threads.scad doesn't expose
+// that
 module myScrew(outer_diam, height, position=[0,0,0], rotation=[0,0,0], pitch=0, tooth_angle=30, tolerance=0.4, tooth_height=0) {
   extra_height = 0.001 * height;
 
@@ -160,6 +232,8 @@ module screw_holes_threaded() {
   place_screw_holes() screw_hole_threaded();
 }
 
+/* all the various modules */
+
 module pm_sensor() {
   box([PM_X,PM_Y,PM_Z]);
 }
@@ -198,7 +272,7 @@ module middle_cable_well() {
 }
 
 module board_well() {
-  cube([ BOARD_X+BOARD_PAD, BOARD_Y+BOARD_PAD, 200], center=true);
+  cube([ BOARD_X, BOARD_Y, 200], center=true);
 }
 
 module board_support() {
@@ -235,16 +309,16 @@ module board_supports() {
 }
 
 module usb_well() {
-  translate([0,0,-USB_MICRO_B_SINK-USB_MICRO_B_Z/2]) box([USB_MICRO_B_X, 30, 30]);
+  translate([0,0,-USB_MICRO_B_Z]) box([USB_MICRO_B_X, 30, 30]);
 }
 
 module sd_well() {
   EXTRA=10;
-  translate([0,SD_Y/2-EXTRA/2,-SD_SINK-SD_Z/2]) box([SD_X, SD_Y+EXTRA, 30]);
+  translate([0,SD_Y/2-EXTRA/2,-SD_Z]) box([SD_X, SD_Y+EXTRA, 30]);
 }
 
 module switch_well() {
-  translate([0,0,-SWITCH_SINK-SWITCH_Z/2]) box([SWITCH_X, 30, 30]);
+  translate([0,0,-SWITCH_Z]) box([SWITCH_X, 30, 30]);
 }
 
 module switch_pillar() {
@@ -254,7 +328,7 @@ module switch_pillar() {
 }
 
 module reset_well() {
-  translate([0,0,-RESET_SINK-RESET_Z/2]) box([RESET_X, 30, 30]);
+  translate([0,0,-RESET_Z]) box([RESET_X, 30, 30]);
 }
 
 module reset_pillar() {
@@ -264,7 +338,7 @@ module reset_pillar() {
 }
 
 module button_well() {
-  translate([0,0,-BUTTON_SINK-BUTTON_Z/2]) box([BUTTON_X, 30, 30]);
+  translate([0,0,-BUTTON_Z]) box([BUTTON_X, 30, 30]);
 }
 
 module button_pillar() {
@@ -273,8 +347,8 @@ module button_pillar() {
     cube([BUTTON_X-PILLAR_SHRINK, PILLAR_Y, H], center=true);
 }
 
-// these will have matching pillars for the top piece, filling them
-// down to the right depth; top piece will be printed upside-down
+// these have matching outside_pillars for the top piece, filling them
+// down to the right depth; top piece needs to be printed upside-down
 module outside_wells() {
   translate([-BOARD_X/2,0,0]) {
     translate([0,BOARD_Y/2,0]) {
@@ -303,6 +377,8 @@ module display_hole() {
   cube([DISPLAY_WIN_X, DISPLAY_WIN_Y, 30], center=true);
 }
 
+/* The Layers */
+
 module bottom() {
   PM_X_OFF=(TOTAL_X - PM_X)/2;
 
@@ -368,6 +444,8 @@ module top() {
   }
 }
 
+/* render! */
+
 translate([0, TOTAL_Y * 1.2, 0]) bottom();
 //translate([0, 0, -BOTTOM_Z-2]) bottom();