/*
  a box divided on layers, 4 long screws at the corners to keep it
  together, alignment pins between layers

  * 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

  * bottom, for battery and pm sensor
 */

WALL_THICKNESS=2;

SCREW_DIAM=4;
SCREW_PAD=0;

PM_X=40.8;
PM_Y=40.8;
PM_Z=12.5;
PM_CONN_Y=15.8;
PM_CONN_Z=4;
PM_CONN_DEPTH=7.7;

BATT_X=55;
BATT_Y=33.5;
BATT_Z=10.8;

CO_X=28.5;
CO_Y=24.1;
CO_Z=8;
CO_CONN_Y=10;

CO_HOLE_DIAM=2;
CO_HOLE_DIST=CO_HOLE_DIAM + 2; // distance between hole centres

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_HOLE_DIAM=12.5;

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
BOARD_X=66.5;
BOARD_Y=36.8;
BOARD_SINK=2.2;
BOARD_PAD=2;

BOARD_PIN_OFF_X=2.35; BOARD_PIN_DIST_X=61.43;
BOARD_PIN_OFF_Y=2.15; BOARD_PIN_DIST_Y=32.5;

BOARD_SUPPORT_DIAM=3;
BOARD_SUPPORT_PIN_DIAM=2;

USB_MICRO_B_X=12;
USB_MICRO_B_Z=5.5;

USB_MICRO_B_SINK=2;
USB_MICRO_B_OFF_X=42.7;

SD_X=12.5;
SD_Y=9.5;
SD_Z=1;
SD_SINK=3;
SD_OFF_X=54;

SWITCH_X=9;
SWITCH_Z=4;
SWITCH_SINK=SWITCH_Z/2;
SWITCH_OFF_X=42.5;

RESET_X=2;
RESET_Z=2;
RESET_SINK=1;
RESET_OFF_X=51.5;

BUTTON_X=5;
BUTTON_Z=3;
BUTTON_SINK=1;
BUTTON_OFF_X=58;

TOP_Z=2;

TOTAL_X=2*WALL_THICKNESS + max(
                               PM_X + BOT_CABLE_WELL_X + BATT_X,
                               CO_X + MID_CABLE_WELL_X + BOARD_X
                               );
TOTAL_Y=2*(WALL_THICKNESS + SCREW_DIAM + SCREW_PAD) + max(PM_Y,CO_Y,BOARD_Y,BATT_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 co_hole() {
  cylinder(h=200,d=CO_HOLE_DIAM,center=true,$fs=0.2);
}

module co_holes() {
  translate([-CO_X/2,-CO_Y/2,0])
    for(
        x=[CO_HOLE_DIAM:CO_HOLE_DIST:CO_X],
          y=[CO_HOLE_DIAM:CO_HOLE_DIST:CO_Y]
        )
      translate([x,y,0]) co_hole();
}

module middle_cable_well() {
  box([
       20, // doesn't matter, wells at both sides are much wider
       CO_CONN_Y,
       CO_Z,
       ]);
}

module board_well() {
  box([ BOARD_X+BOARD_PAD, BOARD_Y+BOARD_PAD, CO_Z]);
}

module board_support() {
  HEIGHT=MIDDLE_Z - WALL_THICKNESS - BOARD_SINK;
  EXTRA=BOARD_SUPPORT_DIAM*2;

  translate([0,0,HEIGHT/2]) union() {
    cylinder(
             h=HEIGHT,
             d=BOARD_SUPPORT_DIAM,
             center=true,$fs=0.1
             );

    translate([EXTRA/2, EXTRA/2 - BOARD_SUPPORT_DIAM/2, 0])
      cube([EXTRA,EXTRA,HEIGHT],center=true);
    translate([EXTRA/2 - BOARD_SUPPORT_DIAM/2, EXTRA/2, 0])
      cube([EXTRA,EXTRA,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 usb_well() {
  translate([0,0,-USB_MICRO_B_SINK-USB_MICRO_B_Z/2]) box([USB_MICRO_B_X, 30, 30]);
}

module sd_well() {
  translate([0,SD_Y/2,-SD_SINK-SD_Z/2]) box([SD_X, SD_Y, 30]);
}

module switch_well() {
  translate([0,0,-SWITCH_SINK-SWITCH_Z/2]) box([SWITCH_X, 30, 30]);
}

module reset_well() {
  translate([0,0,-RESET_SINK-RESET_Z/2]) box([RESET_X, 30, 30]);
}

module button_well() {
  translate([0,0,-BUTTON_SINK-BUTTON_Z/2]) box([BUTTON_X, 30, 30]);
}

// these will have matching pillars for the top piece, filling them
// down to the right depth; top piece will be printed upside-down
module outside_wells() {
  translate([-BOARD_X/2,0,0]) {
    translate([0,BOARD_Y/2,0]) {
        translate([USB_MICRO_B_OFF_X, 0,0]) usb_well();
        translate([SD_OFF_X, 0,0]) sd_well(); // not actually facing outside
    };
    translate([0,-BOARD_Y/2,0]) {
        translate([SWITCH_OFF_X, 0,0]) switch_well();
        translate([RESET_OFF_X, 0,0]) reset_well();
        translate([BUTTON_OFF_X, 0,0]) button_well();
    };
  }
}

module display_hole() {
  cube([DISPLAY_WIN_X, DISPLAY_WIN_Y, 30], center=true);
}

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();
  }
}

// used by middle and top
BOARD_X_OFF= (TOTAL_X-BOARD_X)/2 - CO_X - MID_CABLE_WELL_X - WALL_THICKNESS;
BOARD_Y_OFF= (TOTAL_Y-BOARD_Y)/2 - SD_Y - WALL_THICKNESS;
CO_X_OFF=(TOTAL_X - CO_X)/2 - WALL_THICKNESS;

module middle() {
  CABLE_HOLE_X_OFF= TOTAL_X/2 - PM_X - BOT_CABLE_WELL_X/2;
  CABLE_HOLE_Y_OFF= -PM_Y/2 + PM_CONN_Y/2;

  CO_Z_OFF=MIDDLE_Z - CO_Z;

  CABLE_X_OFF= CO_X_OFF - CO_X/2 - MID_CABLE_WELL_X/2;

  BOARD_Z_OFF=MIDDLE_Z - BOARD_SINK;

  union() {
    difference() {
      box([TOTAL_X, TOTAL_Y, MIDDLE_Z]);
      screw_holes();
      translate([CABLE_HOLE_X_OFF, CABLE_HOLE_Y_OFF, 0]) cable_hole();
      translate([CO_X_OFF, 0, CO_Z_OFF]) co_sensor();
      translate([CABLE_X_OFF, 0, CO_Z_OFF]) middle_cable_well();
      translate([BOARD_X_OFF, BOARD_Y_OFF, 0]) {
        translate([0,0, CO_Z_OFF]) board_well();
        translate([0,0, BOARD_Z_OFF]) outside_wells();
      }
    }
    translate([BOARD_X_OFF, BOARD_Y_OFF, CO_Z_OFF]) board_supports();
  }
}

module top() {
  DISP_X_OFF=BOARD_X_OFF - (BOARD_X-DISPLAY_WIN_X)/2 + DISPLAY_X_OFF;
  DISP_Y_OFF=BOARD_Y_OFF - (BOARD_Y-DISPLAY_WIN_Y)/2 + DISPLAY_Y_OFF;

  difference() {
    box([TOTAL_X, TOTAL_Y, TOP_Z]);
    screw_holes();
    translate([CO_X_OFF, 0, 0]) co_holes();
    translate([DISP_X_OFF, DISP_Y_OFF, 0]) display_hole();
  }
}

translate([0, TOTAL_Y * 1.2, 0]) bottom();
//translate([0, 0, -BOTTOM_Z-2]) bottom();

middle();

translate([0, -TOTAL_Y * 1.2, 0]) top();
//translate([0, 0, +MIDDLE_Z+2]) top();