First draft of the battery enclosure.
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$fn = 50;
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threshold = 0.1;
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half_threshold = threshold / 2;
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wire_radius = 1;
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wall_thickness = 2;
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cutout_threshold = 1;
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battery_length = 71;
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battery_width = 18.75;
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cell_holder_length = battery_length + wall_thickness * 2;
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cell_holder_width = battery_width + wall_thickness * 2;
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cell_holder_height = battery_width + wall_thickness;
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battery_contact_thickness = .6;
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// battery_contact_thickness = 1;
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battery_contact_width = 11;
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battery_contact_length = 12.8;
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battery_contact_spring_height = 10.5;
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battery_contact_flange_height = 1.9;
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converter_width = 11.25;
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converter_length = 22.25;
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converter_height = 4.25;
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module box(length, width, height, wall_thickness) {
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center_width = width - wall_thickness;
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center_height = height - wall_thickness;
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center_length = length - wall_thickness;
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union() {
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hull() {
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translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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}
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hull() {
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translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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}
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hull() {
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translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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}
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hull() {
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translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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}
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hull() {
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translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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}
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}
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/*
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difference() {
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cube([width,
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length,
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height],
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center = true);
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translate([0, 0, wall_thickness])
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cube([width - wall_thickness * 2,
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length - wall_thickness * 2,
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height + threshold],
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center = true);
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}
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*/
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}
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module channel(length, width, height, wall_thickness) {
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center_width = width - wall_thickness;
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center_height = height - wall_thickness;
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center_length = length - wall_thickness;
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union() {
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hull() {
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translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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}
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hull() {
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translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, -center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, center_height / 2]) sphere(r = wall_thickness);
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}
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hull() {
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translate([-center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([-center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, -center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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translate([center_width / 2, center_length / 2, -center_height / 2]) sphere(r = wall_thickness);
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}
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}
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/*
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difference() {
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cube([width,
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length,
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height],
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center = true);
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translate([0, 0, wall_thickness])
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cube([width - wall_thickness * 2,
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length + threshold,
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height + threshold],
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center = true);
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}
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*/
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}
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module cell_cradle(length, width) {
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translate([0, 0, -width / 4]) difference() {
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cube([width + wall_thickness * 2,
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wall_thickness,
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width / 2],
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center = true);
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translate([0, 0, width / 2])
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rotate([90, 0, 0])
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cylinder(h = wall_thickness + cutout_threshold,
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r = width / 2,
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center = true);
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}
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}
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module cell_box() {
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union() {
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channel(cell_holder_length, cell_holder_width, cell_holder_height, wall_thickness);
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translate([0, -battery_length / 6, 0]) cell_cradle(cell_holder_length, battery_width);
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translate([0, battery_length / 6, 0]) cell_cradle(cell_holder_length, battery_width);
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}
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}
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module contact_box(width, contact_width, contact_height, contact_thickness) {
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contact_thickness_ = contact_thickness * .75;
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cutout_width = contact_width * .8;
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box_width = width + wall_thickness * 2;
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box_thickness = contact_thickness_ + wall_thickness * 2;
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box_height = width + wall_thickness;
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union() {
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color("red", 1) cube([box_width,
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box_thickness,
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width + wall_thickness],
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center = true);
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translate([0,
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0,
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wall_thickness * 2])
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cube([contact_width,
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contact_thickness_,
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contact_height + cutout_threshold],
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center = true);
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/*
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translate([box_width / 2 - (contact_width * .8) / 2,
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wall_thickness,
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box_height - contact_height])
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cube([contact_width * .8,
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wall_thickness + contact_thickness_ + cutout_threshold,
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contact_height + cutout_threshold]);
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translate([width / 2 + wall_thickness,
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0,
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width + wire_radius * 2])
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rotate([-90, 0, 0])
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cylinder(h=wall_thickness * 4, r=wire_radius, center = true);
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rotate([0, 180, 0])
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translate([-cutout_threshold / 2,
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box_thickness,
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width + wire_radius * 2])
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cylinder(h = width + wall_thickness * 2 + cutout_threshold, r = 1, center = true);
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*/
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}
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}
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module battery_slot(length, width) {
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union() {
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translate([width + wall_thickness * 2, wall_thickness, 0])
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contact_box(battery_width,
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battery_contact_width,
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battery_contact_length,
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battery_contact_flange_height);
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translate([0, wall_thickness, 0]) cell_box();
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translate([0, wall_thickness + length, 0])
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rotate([0, 0, 180])
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contact_box(battery_width,
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battery_contact_width,
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battery_contact_length,
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battery_contact_flange_height);
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}
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}
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module battery_case() {
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union() {
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battery_slot(battery_length, battery_width);
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translate([battery_width + wall_thickness, 0, 0]) battery_slot(battery_length, battery_width);
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}
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}
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battery_case();
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translate([-50, 0, 0])
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contact_box(battery_width,
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battery_contact_width,
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battery_contact_length,
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battery_contact_flange_height);
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/*
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rotate([0, 90, 0])
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translate([0, 5, 0])
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cylinder(h=battery_width + wall_thickness * 2 + cutout_threshold, r=1, center = true);
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translate([0, -5, 0])
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rotate([0, 90, 0])
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cylinder(h=battery_width + wall_thickness * 2 + cutout_threshold, r=1, center = true);
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*/
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