Add gaps to allow access to the voltage converter
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9c490a84a4
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74b7f1c6f7
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@ -27,51 +27,7 @@ converter_length = 22.25;
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converter_height = 5;
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module pill(length, bevel) {
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hull() {
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translate([0, 0, (-length / 2) + bevel]) sphere(r = bevel);
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translate([0, 0, (length / 2) - bevel]) sphere(r = bevel);
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}
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}
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module box_face(length, width, wall_thickness, bevel) {
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center_width = width - bevel * 2;
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center_length = length - bevel * 2;
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hull() {
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translate([-center_width / 2, -center_length / 2, 0])
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pill(wall_thickness, bevel);
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translate([center_width / 2, -center_length / 2, 0])
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pill(wall_thickness, bevel);
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translate([center_width / 2, center_length / 2, 0])
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pill(wall_thickness, bevel);
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translate([-center_width / 2, center_length / 2, 0])
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pill(wall_thickness, bevel);
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}
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}
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module channel(length, width, height) {
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union() {
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translate([0, 0, -height / 2 + wall_thickness / 2])
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box_face(length, width, wall_thickness, bevel);
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translate([-width / 2 + wall_thickness / 2, 0, 0]) rotate([0, 90, 0])
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box_face(length, height, wall_thickness, bevel);
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translate([width / 2 - wall_thickness / 2, 0, 0]) rotate([0, 90, 0])
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box_face(length, height, wall_thickness, bevel);
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}
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}
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module box(length, width, height) {
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union() {
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channel(length, width, height);
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translate([0, -length / 2 + wall_thickness / 2, 0]) rotate([90, 0, 0])
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box_face(height, width, wall_thickness, bevel);
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translate([0, length / 2 - wall_thickness / 2, 0]) rotate([90, 0, 0])
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box_face(height, width, wall_thickness, bevel);
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}
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}
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include <./common.scad>;
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// box(20, 10, 10);
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// color("blue", 0.5) cube([10, 20, 10], center = true);
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@ -122,6 +78,14 @@ module contact_box() {
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0])
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rotate([0, 90, 0])
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cylinder(h = cell_holder_width, r = wire_radius, center = true);
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color("green", 1) translate([-cell_holder_width / 2, 0, cell_holder_height / 2])
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rotate([0, 90, 0])
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cylinder(h = 5, r = contact_thickness / 2, center = true);
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color("green", 1) translate([cell_holder_width / 2, 0, cell_holder_height / 2])
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rotate([0, 90, 0])
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cylinder(h = 5, r = contact_thickness / 2, center = true);
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}
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}
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@ -140,35 +104,41 @@ module battery_slot() {
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}
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module converter_box() {
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box_width = wall_thickness * 2 + converter_height;
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box_length = wall_thickness * 2 + converter_height;
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box_width = cell_holder_width * 2 - wall_thickness;
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difference() {
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box(box_width, cell_holder_width * 2 - wall_thickness, cell_holder_height);
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box(box_length, box_width, cell_holder_height);
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translate([cell_holder_width - wire_radius, 0, 0])
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rotate([90, 0, 0])
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cylinder(h = box_width, r = wire_radius, center = true);
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cylinder(h = box_length, r = wire_radius, center = true);
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translate([cell_holder_width - wire_radius * 2, 0, 0])
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rotate([0, 90, 0])
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cylinder(h = wall_thickness + threshold, r = wire_radius, center = true);
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translate([-cell_holder_width + wire_radius, 0, 0])
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rotate([90, 0, 0])
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cylinder(h = box_width, r = wire_radius, center = true);
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cylinder(h = box_length, r = wire_radius, center = true);
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translate([-cell_holder_width + wire_radius * 2, 0, 0])
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rotate([0, 90, 0])
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cylinder(h = wall_thickness + threshold, r = wire_radius, center = true);
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translate([0, -box_width / 2, 0])
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translate([0, -box_length / 2, 0])
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rotate([0, 90, 0])
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cylinder(h = cell_holder_width * 2 + wall_thickness, r = wire_radius, center = true);
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translate([-cell_holder_width * .75, (-box_width + wall_thickness) / 2, 0])
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translate([-cell_holder_width * .75, (-box_length + wall_thickness) / 2, 0])
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rotate([90, 0, 0])
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cylinder(h = wall_thickness * 2, r = wire_radius, center = true);
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translate([cell_holder_width * .75, (-box_width + wall_thickness) / 2, 0])
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translate([cell_holder_width * .75, (-box_length + wall_thickness) / 2, 0])
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rotate([90, 0, 0])
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cylinder(h = wall_thickness * 2, r = wire_radius, center = true);
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color("red", 1) translate([-box_width / 4, -(converter_height + wall_thickness) / 2, cell_holder_height / 2])
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cube([5, wall_thickness + threshold * 2, cell_holder_height], center = true);
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color("red", 1) translate([box_width / 4, -(converter_height + wall_thickness) / 2, cell_holder_height / 2])
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cube([5, wall_thickness + threshold * 2, cell_holder_height], center = true);
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}
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}
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@ -176,7 +146,6 @@ module battery_case() {
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union() {
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translate([-cell_holder_width / 2, 0, 0]) battery_slot();
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translate([cell_holder_width / 2 - wall_thickness, 0, 0]) battery_slot();
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color("blue", 1)
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translate([-wall_thickness / 2,
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cell_holder_length / 2 + wall_thickness * 2 + battery_contact_flange_height + wall_thickness * 2 + wall_thickness / 2,
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0])
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@ -0,0 +1,47 @@
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module pill(length, bevel) {
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hull() {
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translate([0, 0, (-length / 2) + bevel]) sphere(r = bevel);
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translate([0, 0, (length / 2) - bevel]) sphere(r = bevel);
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}
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}
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module box_face(length, width, wall_thickness, bevel) {
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center_width = width - bevel * 2;
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center_length = length - bevel * 2;
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hull() {
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translate([-center_width / 2, -center_length / 2, 0])
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pill(wall_thickness, bevel);
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translate([center_width / 2, -center_length / 2, 0])
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pill(wall_thickness, bevel);
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translate([center_width / 2, center_length / 2, 0])
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pill(wall_thickness, bevel);
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translate([-center_width / 2, center_length / 2, 0])
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pill(wall_thickness, bevel);
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}
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}
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module channel(length, width, height) {
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union() {
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translate([0, 0, -height / 2 + wall_thickness / 2])
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box_face(length, width, wall_thickness, bevel);
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translate([-width / 2 + wall_thickness / 2, 0, 0]) rotate([0, 90, 0])
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box_face(length, height, wall_thickness, bevel);
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translate([width / 2 - wall_thickness / 2, 0, 0]) rotate([0, 90, 0])
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box_face(length, height, wall_thickness, bevel);
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}
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}
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module box(length, width, height) {
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union() {
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channel(length, width, height);
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translate([0, -length / 2 + wall_thickness / 2, 0]) rotate([90, 0, 0])
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box_face(height, width, wall_thickness, bevel);
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translate([0, length / 2 - wall_thickness / 2, 0]) rotate([90, 0, 0])
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box_face(height, width, wall_thickness, bevel);
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}
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}
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@ -1,174 +0,0 @@
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width = 65;
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length = 75;
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height = 16;
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wall_thickness = 2;
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guide_thickness = 1;
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power_width = 21;
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output_width = 37.5;
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half_wall_thickness = wall_thickness / 2;
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standoff_thickness = 10;
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hole_diameter = 3;
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// The radius of a nut in mm. However, based on my measurements, I'm not actually sure I have this right. The short height of a nut is 7.86mm. Derive from there.
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nut_radius = 8.5 * cos(30) / 2;
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nut_height = 2.69; // mm
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screw_radius = 2;
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handlebar_radius = 15;
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clasp_thickness = 4;
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clasp_width = 35;
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circular_face_count = 96;
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module hexagon(r, h) {
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pi = 3.1415926;
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polyhedron(
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points=[
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[r, 0, 0],
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[r * cos(60), r * sin(60), 0],
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[r * cos(120), r * sin(120), 0],
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[r * cos(180), r * sin(180), 0],
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[r * cos(240), r * sin(240), 0],
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[r * cos(300), r * sin(300), 0],
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[r, 0, h],
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[r * cos(60), r * sin(60), h],
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[r * cos(120), r * sin(120), h],
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[r * cos(180), r * sin(180), h],
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[r * cos(240), r * sin(240), h],
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[r * cos(300), r * sin(300), h],
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],
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faces=[
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[0, 1, 2, 3, 4, 5],
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[11, 10, 9, 8, 7, 6],
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[6, 7, 1, 0],
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[7, 8, 2, 1],
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[8, 9, 3, 2],
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[9, 10, 4, 3],
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[10, 11, 5, 4],
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[11, 6, 0, 5],
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]
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);
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}
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// Nut holders are blocks that have a hole drilled through them and a hexagonal-shaped cavity. The idea is to
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module nut_holder() {
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difference() {
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translate([-4.5, -4.5, -2]) cube([9, 9, 4]);
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union() {
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translate([0, 0, -1]) hexagon(nut_radius, 2);
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cylinder(h = 6, r = screw_radius, center = true, $fn = 24);
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}
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}
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}
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module screw_hole() {
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union() {
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translate([0, 0, 4]) cylinder(h = 2.1, r = screw_radius * 2, center = true, $fn = 24);
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cylinder(h = 6, r = screw_radius, center = true, $fn = 24);
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}
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}
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module base() {
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cube([width, length, wall_thickness]);
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}
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module face() {
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union() {
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cube([width, length, wall_thickness / 2]);
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translate([wall_thickness, wall_thickness, wall_thickness / 2]) cube([width-wall_thickness*2, length-wall_thickness*2, wall_thickness / 2]);
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translate([4.5 + wall_thickness, 4.5 + wall_thickness, 4]) nut_holder();
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translate([width - 4.5 - wall_thickness, 4.5 + wall_thickness, 4]) nut_holder();
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translate([width - 4.5 - wall_thickness, length - 4.5 - wall_thickness, 4]) nut_holder();
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translate([4.5 + wall_thickness, length - 4.5 - wall_thickness, 4]) nut_holder();
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}
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}
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module wall(length) {
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cube([length, height, wall_thickness]);
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}
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module power_wall() {
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difference() {
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wall(65);
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translate([9, 2, -.5]) cube([power_width, height, wall_thickness + 1]);
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}
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}
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module output_wall() {
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difference() {
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wall(65);
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translate([9, 2, -.5]) cube([output_width, height, wall_thickness + 1]);
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}
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}
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// Use hexagons as cutouts into which I can install a hex nut. This isn't quite right yet, but close.
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// hexagon(nut_radius, 1);
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// cube([standoff_thickness, standoff_thickness, 2]);
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/*
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difference() {
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union() {
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base();
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rotate([90, 0, 90]) wall(75);
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// translate([width - wall_thickness, 0, 0]) rotate([90, 0, 90]) wall(length);
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// rotate([90, 0, 0]) power_wall();
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// translate([0, length, 0]) rotate([90, 0, 0]) output_wall();
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// translate([wall_thickness,
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// wall_thickness,
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// wall_thickness]) standoff();
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// translate([width - wall_thickness - standoff_thickness,
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// wall_thickness,
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// wall_thickness]) standoff();
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// translate([wall_thickness,
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// length - wall_thickness - standoff_thickness,
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// wall_thickness]) standoff();
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// translate([width - wall_thickness - standoff_thickness,
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// length - wall_thickness - standoff_thickness,
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// wall_thickness]) standoff();
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}
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// translate([-half_wall_thickness, -wall_thickness - half_wall_thickness, height - half_wall_thickness]) cube([wall_thickness, length + wall_thickness * 2, wall_thickness]);
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// translate([width - half_wall_thickness, -wall_thickness - half_wall_thickness, height - half_wall_thickness]) cube([wall_thickness, length + wall_thickness * 2, wall_thickness]);
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// translate([-half_wall_thickness, -half_wall_thickness, height - half_wall_thickness]) rotate([0, 0, 270]) cube([wall_thickness, width + wall_thickness * 2, wall_thickness]);
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// translate([-half_wall_thickness, length + half_wall_thickness, height - half_wall_thickness]) rotate([0, 0, 270]) cube([wall_thickness, width + wall_thickness * 2, wall_thickness]);
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}
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*/
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module box() {
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difference() {
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union() {
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cube([width, length, wall_thickness * 2]);
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translate([0, 0, wall_thickness]) rotate([90, 0, 90]) wall(length);
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translate([width - wall_thickness, 0, wall_thickness]) rotate([90, 0, 90]) wall(length);
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translate([0, wall_thickness, wall_thickness]) rotate([90, 0, 0]) wall(width);
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translate([0, length, wall_thickness]) rotate([90, 0, 0]) wall(width);
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}
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translate([4.5 + wall_thickness, 4.5 + wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
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translate([width - 4.5 - wall_thickness, 4.5 + wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
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translate([width - 4.5 - wall_thickness, length - 4.5 - wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
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translate([4.5 + wall_thickness, length - 4.5 - wall_thickness, 4]) rotate([180, 0, 0]) screw_hole();
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}
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}
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module top_clasp() {
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difference() {
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union() {
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cylinder(h = clasp_width, r = handlebar_radius + clasp_thickness, center = true, $fn = circular_face_count);
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translate([0, 0, -clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count);
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translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count);
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translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count);
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translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count);
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translate([-handlebar_radius-5, -10, -clasp_width / 2 + 6]) cube([6, 20, clasp_width - 12]);
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}
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translate([-0.5, 0, 0]) cylinder(h = clasp_width+2, r = handlebar_radius + 1, center = true, $fn = circular_face_count);
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translate([-0.5, -handlebar_radius - 10, -clasp_width / 2 - 1]) cube([handlebar_radius + 10, handlebar_radius * 2 + 20, clasp_width + 2]);
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}
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}
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module body() {
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union() {
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box();
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// translate([width / 2, length / 2, -5 - handlebar_radius]) rotate([0, 90, 90]) top_clasp();
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}
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}
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body();
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// translate([width + 10, 0, 0]) face();
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