From d794b4872ff0e9897fc6647880721a697788814d Mon Sep 17 00:00:00 2001
From: Savanni D'Gerinel <savanni@luminescent-dreams.com>
Date: Fri, 13 Sep 2024 20:29:10 -0400
Subject: [PATCH] First draft of the battery enclosure.

---
 bike-lights/case/battery_enclosure.scad | 229 ++++++++++++++++++++++++
 1 file changed, 229 insertions(+)
 create mode 100644 bike-lights/case/battery_enclosure.scad

diff --git a/bike-lights/case/battery_enclosure.scad b/bike-lights/case/battery_enclosure.scad
new file mode 100644
index 0000000..0ba2753
--- /dev/null
+++ b/bike-lights/case/battery_enclosure.scad
@@ -0,0 +1,229 @@
+$fn = 50;
+threshold = 0.1;
+half_threshold = threshold / 2;
+
+wire_radius = 1;
+
+wall_thickness = 2;
+cutout_threshold = 1;
+
+battery_length = 71;
+battery_width = 18.75;
+
+cell_holder_length = battery_length + wall_thickness * 2;
+cell_holder_width = battery_width + wall_thickness * 2;
+cell_holder_height = battery_width + wall_thickness;
+
+battery_contact_thickness = .6;
+// battery_contact_thickness = 1;
+battery_contact_width = 11;
+battery_contact_length = 12.8;
+battery_contact_spring_height = 10.5;
+battery_contact_flange_height = 1.9;
+
+converter_width = 11.25;
+converter_length = 22.25;
+converter_height = 4.25;
+
+module box(length, width, height, wall_thickness) {
+    center_width = width - wall_thickness;
+    center_height = height - wall_thickness;
+    center_length = length - wall_thickness;
+
+    union() {
+        hull() {
+            translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+        }
+        hull() {
+            translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+        }
+        hull() {
+            translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+        }
+        hull() {
+            translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+        }
+        hull() {
+            translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+        }
+    }
+
+    /*
+    difference() {
+        cube([width,
+              length,
+              height],
+              center = true);
+        translate([0, 0, wall_thickness])
+            cube([width - wall_thickness * 2,
+                  length - wall_thickness * 2,
+                  height + threshold],
+                 center = true);
+    }
+    */
+}
+
+module channel(length, width, height, wall_thickness) {
+    center_width = width - wall_thickness;
+    center_height = height - wall_thickness;
+    center_length = length - wall_thickness;
+
+    union() {
+        hull() {
+            translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+        }
+        hull() {
+            translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
+        }
+        hull() {
+            translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+            translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
+        }
+    }
+
+    /*
+    difference() {
+        cube([width,
+              length,
+              height],
+              center = true);
+        translate([0, 0, wall_thickness])
+            cube([width - wall_thickness * 2,
+                  length + threshold,
+                  height + threshold],
+                 center = true);
+    }
+    */
+}
+
+module cell_cradle(length, width) {
+    translate([0, 0, -width / 4]) difference() {
+        cube([width + wall_thickness * 2,
+              wall_thickness,
+              width / 2],
+             center = true);
+        translate([0, 0, width / 2])
+            rotate([90, 0, 0])
+            cylinder(h = wall_thickness + cutout_threshold,
+                      r = width / 2,
+                      center = true);
+    }
+}
+
+module cell_box() {
+    union() {
+        channel(cell_holder_length, cell_holder_width, cell_holder_height, wall_thickness);
+        translate([0, -battery_length / 6, 0]) cell_cradle(cell_holder_length, battery_width);
+        translate([0, battery_length / 6, 0]) cell_cradle(cell_holder_length, battery_width);
+    }
+}
+
+
+module contact_box(width, contact_width, contact_height, contact_thickness) {
+    contact_thickness_ = contact_thickness * .75;
+    cutout_width = contact_width * .8;
+    box_width = width + wall_thickness * 2;
+    box_thickness = contact_thickness_ + wall_thickness * 2;
+    box_height = width + wall_thickness;
+
+    union() {
+        color("red", 1) cube([box_width,
+              box_thickness,
+              width + wall_thickness],
+              center = true);
+
+        translate([0,
+                   0,
+                   wall_thickness * 2])
+            cube([contact_width,
+                  contact_thickness_,
+                  contact_height + cutout_threshold],
+                 center = true);
+
+        /*
+        translate([box_width / 2 - (contact_width * .8) / 2,
+                   wall_thickness,
+                   box_height - contact_height])
+            cube([contact_width * .8,
+                  wall_thickness + contact_thickness_ + cutout_threshold,
+                  contact_height + cutout_threshold]);
+
+        translate([width / 2 + wall_thickness,
+                   0,
+                   width + wire_radius * 2])
+                   rotate([-90, 0, 0])
+                   cylinder(h=wall_thickness * 4, r=wire_radius, center = true);
+
+        rotate([0, 180, 0])
+            translate([-cutout_threshold / 2,
+                       box_thickness,
+                       width + wire_radius * 2])
+            cylinder(h = width + wall_thickness * 2 + cutout_threshold, r = 1, center = true);
+            */
+    }
+}
+
+module battery_slot(length, width) {
+    union() {
+        translate([width + wall_thickness * 2, wall_thickness, 0])
+            contact_box(battery_width,
+                        battery_contact_width,
+                        battery_contact_length,
+                        battery_contact_flange_height);
+        translate([0, wall_thickness, 0]) cell_box();
+        translate([0, wall_thickness + length, 0])
+            rotate([0, 0, 180])
+            contact_box(battery_width,
+                        battery_contact_width,
+                        battery_contact_length,
+                        battery_contact_flange_height);
+    }
+}
+
+module battery_case() {
+    union() {
+        battery_slot(battery_length, battery_width);
+        translate([battery_width + wall_thickness, 0, 0]) battery_slot(battery_length, battery_width);
+    }
+}
+
+battery_case();
+
+translate([-50, 0, 0])
+    contact_box(battery_width,
+                battery_contact_width,
+                battery_contact_length,
+                battery_contact_flange_height);
+
+/*
+rotate([0, 90, 0])
+    translate([0, 5, 0])
+    cylinder(h=battery_width + wall_thickness * 2 + cutout_threshold, r=1, center = true);
+
+translate([0, -5, 0])
+    rotate([0, 90, 0])
+    cylinder(h=battery_width + wall_thickness * 2 + cutout_threshold, r=1, center = true);
+*/