in-progress openscad enclosure

1 files changed, 175 insertions, 15 deletions

diff --git a/enclosure/enclosure.scad b/enclosure/enclosure.scad
index e260376..f9498cb 100644
--- a/enclosure/enclosure.scad
+++ b/enclosure/enclosure.scad
@@ -10,6 +10,33 @@
   * bottom, for battery and pm sensor
  */
 
+WALL_THICKNESS=2;
+
+SCREW_DIAM=4;
+SCREW_PAD=1;
+
+PM_X=40.8;
+PM_Y=40.8;
+PM_Z=12.3;
+PM_CONN_Y=15.8;
+PM_CONN_Z=4;
+PM_CONN_DEPTH=7.7;
+
+BATT_X=55;
+BATT_Y=34;
+BATT_Z=11;
+
+CO_X=24;
+CO_Y=28;
+CO_Z=8;
+CO_CONN_Y=10;
+
+BOT_CABLE_WELL_X=25; // just some space for the battery & pm cables
+CABLE_HOLE_DIAM=10;
+
+BOTTOM_Z=WALL_THICKNESS + PM_Z;
+MIDDLE_Z=WALL_THICKNESS + CO_Z;
+
 DISPLAY_WIN_X=51;
 DISPLAY_WIN_Y=26;
 DISPLAY_OFF_X=16;
@@ -18,18 +45,160 @@ DISPLAY_OFF_Y=7;
 //PITCH=0.254; don't really care
 BOARD_X=66.5;
 BOARD_Y=36.8;
-BOARD_PIN_D=1.9;
+BOARD_SINK=2.1;
+
 BOARD_PIN_OFF_X=2.5; BOARD_PIN_DIST_X=61;
 BOARD_PIN_OFF_Y=2.5; BOARD_PIN_DIST_Y=32.5;
 
+BOARD_SUPPORT_DIAM=3;
+BOARD_SUPPORT_PIN_DIAM=1.9;
+
 BOARD_OFF_X=3;
 BOARD_OFF_Y=3;
 
 TOP_LAYER_Z=10;
 
-TOTAL_X=100;
-TOTAL_Y=40;
-TOTAL_Z=30;
+TOTAL_X=2*WALL_THICKNESS + max(
+                               PM_X + BOT_CABLE_WELL_X + BATT_X,
+                               CO_X + BOARD_X
+                               );
+TOTAL_Y=2*(WALL_THICKNESS*2 + SCREW_DIAM + SCREW_PAD) + PM_Y; // max(pm_y,...)
+
+module box(v) {
+  translate([0,0,v[2]/2]) cube(v,center=true);
+}
+
+module screw_hole() {
+  cylinder(h=200,d=SCREW_DIAM,center=true,$fs=0.1);
+}
+
+module screw_holes() {
+  OFF=WALL_THICKNESS + SCREW_DIAM/2 + SCREW_PAD;
+
+  translate([
+             TOTAL_X/2 - OFF,
+             TOTAL_Y/2 - OFF,
+             0]) screw_hole();
+
+  translate([
+             -(TOTAL_X/2 - OFF),
+             TOTAL_Y/2 - OFF,
+             0]) screw_hole();
+
+  translate([
+             TOTAL_X/2 - OFF,
+             -(TOTAL_Y/2 - OFF),
+             0]) screw_hole();
+
+  translate([
+             -(TOTAL_X/2 - OFF),
+             -(TOTAL_Y/2 - OFF),
+             0]) screw_hole();
+             
+}
+
+module pm_sensor() {
+  box([PM_X,PM_Y,PM_Z]);
+}
+
+module bottom_cable_well() {
+  box([BOT_CABLE_WELL_X,PM_CONN_Y,PM_CONN_DEPTH]);
+}
+
+module battery() {
+  box([BATT_X,BATT_Y,BATT_Z]);
+}
+
+module cable_hole() {
+  cylinder(h=200,d=CABLE_HOLE_DIAM,center=true,$fs=0.1);
+}
+
+module co_sensor() {
+  box([CO_X,CO_Y,CO_Z]);
+}
+
+module middle_cable_well() {
+  box([
+       TOTAL_X - CO_X/2,
+       CO_CONN_Y,
+       CO_Z,
+       ]);
+}
+
+module board_well() {
+  box([ BOARD_X, BOARD_Y, CO_Z]);
+}
+
+module board_support() {
+  HEIGHT=MIDDLE_Z - WALL_THICKNESS - BOARD_SINK;
+  translate([0,0,HEIGHT/2]) union() {
+    cylinder(
+             h=HEIGHT,
+             d=BOARD_SUPPORT_DIAM,
+             center=true,$fs=0.1
+             );
+
+    translate([BOARD_SUPPORT_DIAM*0.75,BOARD_SUPPORT_DIAM*0.25,0])
+      cube([BOARD_SUPPORT_DIAM*1.5,BOARD_SUPPORT_DIAM*1.5,HEIGHT],center=true);
+    translate([BOARD_SUPPORT_DIAM*0.25,BOARD_SUPPORT_DIAM*0.75,0])
+      cube([BOARD_SUPPORT_DIAM*1.5,BOARD_SUPPORT_DIAM*1.5,HEIGHT],center=true);
+
+    translate([0,0,BOARD_SINK/2]) cylinder(
+             h=HEIGHT+BOARD_SINK,
+             d=BOARD_SUPPORT_PIN_DIAM,
+             center=true,$fs=0.1
+             );
+  }
+}
+
+module board_supports() {
+  translate([ -BOARD_X/2 + BOARD_PIN_OFF_X, -BOARD_Y/2 + BOARD_PIN_OFF_Y,0]) {
+    translate([ 0, 0, 0]) rotate([0,0,180]) board_support();
+    translate([ BOARD_PIN_DIST_X, 0, 0]) rotate([0,0,-90]) board_support();
+    translate([ 0, BOARD_PIN_DIST_Y, 0]) rotate([0,0,90]) board_support();
+    translate([ BOARD_PIN_DIST_X, BOARD_PIN_DIST_Y, 0]) board_support();
+  }
+}
+
+module bottom() {
+  PM_X_OFF=(TOTAL_X - PM_X)/2;
+
+  CABLE_X_OFF= PM_X_OFF - PM_X/2 - BOT_CABLE_WELL_X/2; // touching the PM pocket
+  CABLE_Y_OFF=-PM_Y/2 + PM_CONN_Y/2;
+  CABLE_Z_OFF=BOTTOM_Z - PM_CONN_DEPTH;
+
+  BATT_X_OFF=CABLE_X_OFF - BOT_CABLE_WELL_X/2 - BATT_X/2;
+  BATT_Z_OFF=BOTTOM_Z - BATT_Z;
+
+  difference() {
+    box([TOTAL_X, TOTAL_Y, BOTTOM_Z]);
+    screw_holes();
+    translate([PM_X_OFF, 0, WALL_THICKNESS]) pm_sensor();
+    translate([CABLE_X_OFF, CABLE_Y_OFF, CABLE_Z_OFF]) bottom_cable_well();
+    translate([BATT_X_OFF, 0, BATT_Z_OFF]) battery();
+  }
+}
+
+module middle() {
+  CABLE_HOLE_X_OFF= TOTAL_X/2 - PM_X - BOT_CABLE_WELL_X/2;
+
+  CO_X_OFF=(TOTAL_X - CO_X)/2 - WALL_THICKNESS;
+  CO_Z_OFF=MIDDLE_Z - CO_Z;
+
+  BOARD_Z_OFF=MIDDLE_Z - BOARD_SINK;
+
+  union() {
+    difference() {
+      box([TOTAL_X, TOTAL_Y, MIDDLE_Z]);
+      screw_holes();
+      translate([CABLE_HOLE_X_OFF, 0, 0]) cable_hole();
+      translate([CO_X_OFF, 0, CO_Z_OFF]) co_sensor();
+      translate([0, 0, CO_Z_OFF]) middle_cable_well();
+      translate([0,0, CO_Z_OFF]) board_well();
+    }
+    translate([0,0, CO_Z_OFF]) board_supports();
+  }
+}
 
 module top() {
   difference() {
@@ -37,18 +206,9 @@ module top() {
     translate([BOARD_OFF_X, BOARD_OFF_Y, 0]) union() {
       translate([DISPLAY_OFF_X, DISPLAY_OFF_Y, -1])
         cube([DISPLAY_WIN_X, DISPLAY_WIN_Y, TOP_LAYER_Z*2]);
-
-      // alignment pins
-      translate([BOARD_PIN_OFF_X, BOARD_PIN_OFF_Y, -1])
-        cylinder(d=BOARD_PIN_D,h=TOP_LAYER_Z/2);
-      translate([BOARD_PIN_OFF_X+BOARD_PIN_DIST_X, BOARD_PIN_OFF_Y, -1])
-        cylinder(d=BOARD_PIN_D,h=TOP_LAYER_Z/2);
-      translate([BOARD_PIN_OFF_X, BOARD_PIN_OFF_Y+BOARD_PIN_DIST_Y, -1])
-        cylinder(d=BOARD_PIN_D,h=TOP_LAYER_Z/2);
-      translate([BOARD_PIN_OFF_X+BOARD_PIN_DIST_X, BOARD_PIN_OFF_Y+BOARD_PIN_DIST_Y, -1])
-        cylinder(d=BOARD_PIN_D,h=TOP_LAYER_Z/2);
     }
   }
 }
 
-top();
+//translate([0, TOTAL_Y * 1.2, 0]) bottom();
+middle();