From 74b7f1c6f7d5f383f5194480bc6939aee5e95db3 Mon Sep 17 00:00:00 2001 From: Savanni D'Gerinel Date: Mon, 16 Sep 2024 21:35:12 -0400 Subject: [PATCH] Add gaps to allow access to the voltage converter --- bike-lights/case/battery_enclosure.scad | 75 +++------- bike-lights/case/common.scad | 47 +++++++ bike-lights/case/enclosure.scad | 174 ------------------------ 3 files changed, 69 insertions(+), 227 deletions(-) create mode 100644 bike-lights/case/common.scad delete mode 100644 bike-lights/case/enclosure.scad diff --git a/bike-lights/case/battery_enclosure.scad b/bike-lights/case/battery_enclosure.scad index 565f3cd..7ffd77d 100644 --- a/bike-lights/case/battery_enclosure.scad +++ b/bike-lights/case/battery_enclosure.scad @@ -27,51 +27,7 @@ converter_length = 22.25; converter_height = 5; -module pill(length, bevel) { - hull() { - translate([0, 0, (-length / 2) + bevel]) sphere(r = bevel); - translate([0, 0, (length / 2) - bevel]) sphere(r = bevel); - } -} - -module box_face(length, width, wall_thickness, bevel) { - center_width = width - bevel * 2; - center_length = length - bevel * 2; - - hull() { - translate([-center_width / 2, -center_length / 2, 0]) - pill(wall_thickness, bevel); - translate([center_width / 2, -center_length / 2, 0]) - pill(wall_thickness, bevel); - translate([center_width / 2, center_length / 2, 0]) - pill(wall_thickness, bevel); - translate([-center_width / 2, center_length / 2, 0]) - pill(wall_thickness, bevel); - } -} - -module channel(length, width, height) { - union() { - translate([0, 0, -height / 2 + wall_thickness / 2]) - box_face(length, width, wall_thickness, bevel); - translate([-width / 2 + wall_thickness / 2, 0, 0]) rotate([0, 90, 0]) - box_face(length, height, wall_thickness, bevel); - translate([width / 2 - wall_thickness / 2, 0, 0]) rotate([0, 90, 0]) - box_face(length, height, wall_thickness, bevel); - } -} - -module box(length, width, height) { - union() { - channel(length, width, height); - - translate([0, -length / 2 + wall_thickness / 2, 0]) rotate([90, 0, 0]) - box_face(height, width, wall_thickness, bevel); - - translate([0, length / 2 - wall_thickness / 2, 0]) rotate([90, 0, 0]) - box_face(height, width, wall_thickness, bevel); - } -} +include <./common.scad>; // box(20, 10, 10); // color("blue", 0.5) cube([10, 20, 10], center = true); @@ -122,6 +78,14 @@ module contact_box() { 0]) rotate([0, 90, 0]) cylinder(h = cell_holder_width, r = wire_radius, center = true); + + color("green", 1) translate([-cell_holder_width / 2, 0, cell_holder_height / 2]) + rotate([0, 90, 0]) + cylinder(h = 5, r = contact_thickness / 2, center = true); + + color("green", 1) translate([cell_holder_width / 2, 0, cell_holder_height / 2]) + rotate([0, 90, 0]) + cylinder(h = 5, r = contact_thickness / 2, center = true); } } @@ -140,35 +104,41 @@ module battery_slot() { } module converter_box() { - box_width = wall_thickness * 2 + converter_height; + box_length = wall_thickness * 2 + converter_height; + box_width = cell_holder_width * 2 - wall_thickness; difference() { - box(box_width, cell_holder_width * 2 - wall_thickness, cell_holder_height); + box(box_length, box_width, cell_holder_height); translate([cell_holder_width - wire_radius, 0, 0]) rotate([90, 0, 0]) - cylinder(h = box_width, r = wire_radius, center = true); + cylinder(h = box_length, r = wire_radius, center = true); translate([cell_holder_width - wire_radius * 2, 0, 0]) rotate([0, 90, 0]) cylinder(h = wall_thickness + threshold, r = wire_radius, center = true); translate([-cell_holder_width + wire_radius, 0, 0]) rotate([90, 0, 0]) - cylinder(h = box_width, r = wire_radius, center = true); + cylinder(h = box_length, r = wire_radius, center = true); translate([-cell_holder_width + wire_radius * 2, 0, 0]) rotate([0, 90, 0]) cylinder(h = wall_thickness + threshold, r = wire_radius, center = true); - translate([0, -box_width / 2, 0]) + translate([0, -box_length / 2, 0]) rotate([0, 90, 0]) cylinder(h = cell_holder_width * 2 + wall_thickness, r = wire_radius, center = true); - translate([-cell_holder_width * .75, (-box_width + wall_thickness) / 2, 0]) + translate([-cell_holder_width * .75, (-box_length + wall_thickness) / 2, 0]) rotate([90, 0, 0]) cylinder(h = wall_thickness * 2, r = wire_radius, center = true); - translate([cell_holder_width * .75, (-box_width + wall_thickness) / 2, 0]) + translate([cell_holder_width * .75, (-box_length + wall_thickness) / 2, 0]) rotate([90, 0, 0]) cylinder(h = wall_thickness * 2, r = wire_radius, center = true); + + color("red", 1) translate([-box_width / 4, -(converter_height + wall_thickness) / 2, cell_holder_height / 2]) + cube([5, wall_thickness + threshold * 2, cell_holder_height], center = true); + color("red", 1) translate([box_width / 4, -(converter_height + wall_thickness) / 2, cell_holder_height / 2]) + cube([5, wall_thickness + threshold * 2, cell_holder_height], center = true); } } @@ -176,7 +146,6 @@ module battery_case() { union() { translate([-cell_holder_width / 2, 0, 0]) battery_slot(); translate([cell_holder_width / 2 - wall_thickness, 0, 0]) battery_slot(); - color("blue", 1) translate([-wall_thickness / 2, cell_holder_length / 2 + wall_thickness * 2 + battery_contact_flange_height + wall_thickness * 2 + wall_thickness / 2, 0]) diff --git a/bike-lights/case/common.scad b/bike-lights/case/common.scad new file mode 100644 index 0000000..64bc628 --- /dev/null +++ b/bike-lights/case/common.scad @@ -0,0 +1,47 @@ +module pill(length, bevel) { + hull() { + translate([0, 0, (-length / 2) + bevel]) sphere(r = bevel); + translate([0, 0, (length / 2) - bevel]) sphere(r = bevel); + } +} + +module box_face(length, width, wall_thickness, bevel) { + center_width = width - bevel * 2; + center_length = length - bevel * 2; + + hull() { + translate([-center_width / 2, -center_length / 2, 0]) + pill(wall_thickness, bevel); + translate([center_width / 2, -center_length / 2, 0]) + pill(wall_thickness, bevel); + translate([center_width / 2, center_length / 2, 0]) + pill(wall_thickness, bevel); + translate([-center_width / 2, center_length / 2, 0]) + pill(wall_thickness, bevel); + } +} + +module channel(length, width, height) { + union() { + translate([0, 0, -height / 2 + wall_thickness / 2]) + box_face(length, width, wall_thickness, bevel); + translate([-width / 2 + wall_thickness / 2, 0, 0]) rotate([0, 90, 0]) + box_face(length, height, wall_thickness, bevel); + translate([width / 2 - wall_thickness / 2, 0, 0]) rotate([0, 90, 0]) + box_face(length, height, wall_thickness, bevel); + } +} + +module box(length, width, height) { + union() { + channel(length, width, height); + + translate([0, -length / 2 + wall_thickness / 2, 0]) rotate([90, 0, 0]) + box_face(height, width, wall_thickness, bevel); + + translate([0, length / 2 - wall_thickness / 2, 0]) rotate([90, 0, 0]) + box_face(height, width, wall_thickness, bevel); + } +} + + diff --git a/bike-lights/case/enclosure.scad b/bike-lights/case/enclosure.scad deleted file mode 100644 index 953253f..0000000 --- a/bike-lights/case/enclosure.scad +++ /dev/null @@ -1,174 +0,0 @@ -width = 65; -length = 75; -height = 16; -wall_thickness = 2; -guide_thickness = 1; -power_width = 21; -output_width = 37.5; -half_wall_thickness = wall_thickness / 2; -standoff_thickness = 10; -hole_diameter = 3; -// 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. -nut_radius = 8.5 * cos(30) / 2; -nut_height = 2.69; // mm -screw_radius = 2; -handlebar_radius = 15; -clasp_thickness = 4; -clasp_width = 35; -circular_face_count = 96; - -module hexagon(r, h) { - pi = 3.1415926; - polyhedron( - points=[ - [r, 0, 0], - [r * cos(60), r * sin(60), 0], - [r * cos(120), r * sin(120), 0], - [r * cos(180), r * sin(180), 0], - [r * cos(240), r * sin(240), 0], - [r * cos(300), r * sin(300), 0], - - [r, 0, h], - [r * cos(60), r * sin(60), h], - [r * cos(120), r * sin(120), h], - [r * cos(180), r * sin(180), h], - [r * cos(240), r * sin(240), h], - [r * cos(300), r * sin(300), h], - ], - faces=[ - [0, 1, 2, 3, 4, 5], - [11, 10, 9, 8, 7, 6], - [6, 7, 1, 0], - [7, 8, 2, 1], - [8, 9, 3, 2], - [9, 10, 4, 3], - [10, 11, 5, 4], - [11, 6, 0, 5], - ] - ); -} - -// Nut holders are blocks that have a hole drilled through them and a hexagonal-shaped cavity. The idea is to -module nut_holder() { - difference() { - translate([-4.5, -4.5, -2]) cube([9, 9, 4]); - union() { - translate([0, 0, -1]) hexagon(nut_radius, 2); - cylinder(h = 6, r = screw_radius, center = true, $fn = 24); - } - } -} - -module screw_hole() { - union() { - translate([0, 0, 4]) cylinder(h = 2.1, r = screw_radius * 2, center = true, $fn = 24); - cylinder(h = 6, r = screw_radius, center = true, $fn = 24); - } -} - -module base() { - cube([width, length, wall_thickness]); -} - -module face() { - union() { - cube([width, length, wall_thickness / 2]); - translate([wall_thickness, wall_thickness, wall_thickness / 2]) cube([width-wall_thickness*2, length-wall_thickness*2, wall_thickness / 2]); - translate([4.5 + wall_thickness, 4.5 + wall_thickness, 4]) nut_holder(); - translate([width - 4.5 - wall_thickness, 4.5 + wall_thickness, 4]) nut_holder(); - translate([width - 4.5 - wall_thickness, length - 4.5 - wall_thickness, 4]) nut_holder(); - translate([4.5 + wall_thickness, length - 4.5 - wall_thickness, 4]) nut_holder(); - } -} - -module wall(length) { - cube([length, height, wall_thickness]); -} - -module power_wall() { - difference() { - wall(65); - translate([9, 2, -.5]) cube([power_width, height, wall_thickness + 1]); - } -} - -module output_wall() { - difference() { - wall(65); - translate([9, 2, -.5]) cube([output_width, height, wall_thickness + 1]); - } -} - -// Use hexagons as cutouts into which I can install a hex nut. This isn't quite right yet, but close. -// hexagon(nut_radius, 1); - -// cube([standoff_thickness, standoff_thickness, 2]); - -/* -difference() { - union() { - base(); - rotate([90, 0, 90]) wall(75); - // translate([width - wall_thickness, 0, 0]) rotate([90, 0, 90]) wall(length); - // rotate([90, 0, 0]) power_wall(); - // translate([0, length, 0]) rotate([90, 0, 0]) output_wall(); - // translate([wall_thickness, - // wall_thickness, - // wall_thickness]) standoff(); - // translate([width - wall_thickness - standoff_thickness, - // wall_thickness, - // wall_thickness]) standoff(); - // translate([wall_thickness, - // length - wall_thickness - standoff_thickness, - // wall_thickness]) standoff(); - // translate([width - wall_thickness - standoff_thickness, - // length - wall_thickness - standoff_thickness, - // wall_thickness]) standoff(); - } - // translate([-half_wall_thickness, -wall_thickness - half_wall_thickness, height - half_wall_thickness]) cube([wall_thickness, length + wall_thickness * 2, wall_thickness]); - // translate([width - half_wall_thickness, -wall_thickness - half_wall_thickness, height - half_wall_thickness]) cube([wall_thickness, length + wall_thickness * 2, wall_thickness]); - // translate([-half_wall_thickness, -half_wall_thickness, height - half_wall_thickness]) rotate([0, 0, 270]) cube([wall_thickness, width + wall_thickness * 2, wall_thickness]); - // 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]); -} -*/ - -module box() { - difference() { - union() { - cube([width, length, wall_thickness * 2]); - translate([0, 0, wall_thickness]) rotate([90, 0, 90]) wall(length); - translate([width - wall_thickness, 0, wall_thickness]) rotate([90, 0, 90]) wall(length); - translate([0, wall_thickness, wall_thickness]) rotate([90, 0, 0]) wall(width); - translate([0, length, wall_thickness]) rotate([90, 0, 0]) wall(width); - } - translate([4.5 + wall_thickness, 4.5 + wall_thickness, 4]) rotate([180, 0, 0]) screw_hole(); - translate([width - 4.5 - wall_thickness, 4.5 + wall_thickness, 4]) rotate([180, 0, 0]) screw_hole(); - translate([width - 4.5 - wall_thickness, length - 4.5 - wall_thickness, 4]) rotate([180, 0, 0]) screw_hole(); - translate([4.5 + wall_thickness, length - 4.5 - wall_thickness, 4]) rotate([180, 0, 0]) screw_hole(); - } -} - -module top_clasp() { - difference() { - union() { - cylinder(h = clasp_width, r = handlebar_radius + clasp_thickness, center = true, $fn = circular_face_count); - translate([0, 0, -clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count); - translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count); - translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count); - translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1.5, center = true, $fn = circular_face_count); - translate([-handlebar_radius-5, -10, -clasp_width / 2 + 6]) cube([6, 20, clasp_width - 12]); - } - translate([-0.5, 0, 0]) cylinder(h = clasp_width+2, r = handlebar_radius + 1, center = true, $fn = circular_face_count); - translate([-0.5, -handlebar_radius - 10, -clasp_width / 2 - 1]) cube([handlebar_radius + 10, handlebar_radius * 2 + 20, clasp_width + 2]); - } -} - -module body() { - union() { - box(); - // translate([width / 2, length / 2, -5 - handlebar_radius]) rotate([0, 90, 90]) top_clasp(); - } -} - -body(); -// translate([width + 10, 0, 0]) face();