From e21016e0e048c8b4e81e4d60444c8da21ba066ed Mon Sep 17 00:00:00 2001
From: Savanni D'Gerinel <savanni@luminescent-dreams.com>
Date: Thu, 26 Sep 2024 22:15:30 -0400
Subject: [PATCH] Largely design the control panel case

---
 bike-lights/case/common.scad             | 64 +++++++++-------
 bike-lights/case/control_panel.scad      | 95 ++++++++++++++++++++++++
 bike-lights/case/control_panel_case.scad |  4 +
 bike-lights/case/control_panel_lid.scad  |  5 ++
 4 files changed, 141 insertions(+), 27 deletions(-)
 create mode 100644 bike-lights/case/control_panel.scad
 create mode 100644 bike-lights/case/control_panel_case.scad
 create mode 100644 bike-lights/case/control_panel_lid.scad

diff --git a/bike-lights/case/common.scad b/bike-lights/case/common.scad
index 64bc628..75ba697 100644
--- a/bike-lights/case/common.scad
+++ b/bike-lights/case/common.scad
@@ -5,43 +5,53 @@ module pill(length, bevel) {
     }
 }
 
-module box_face(length, width, wall_thickness, bevel) {
-    center_width = width - bevel * 2;
-    center_length = length - bevel * 2;
+module box_face(dimensions, bevel = 0) {
+    x = dimensions[0];
+    y = dimensions[1];
+    z = dimensions[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);
+    if (bevel > 0) {
+        translate([0, 0, z / 2])
+        hull() {
+            pill(z, bevel);
+            translate([x, 0, 0])
+                pill(z, bevel);
+            translate([x, y, 0])
+                pill(z, bevel);
+            translate([0, y, 0])
+                pill(z, bevel);
+        }
+    } else {
+        cube(dimensions);
     }
 }
 
-module channel(length, width, height) {
+module channel(length, width, height, bevel) {
     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);
+        box_face([length, width, wall_thickness], bevel);
+
+        translate([0, wall_thickness - bevel, bevel])
+            rotate([90, 0, 0])
+            box_face([length, height, wall_thickness], bevel);
+
+        translate([0, width + bevel, bevel])
+            rotate([90, 0, 0])
+            box_face([length, height, wall_thickness], bevel);
     }
 }
 
-module box(length, width, height) {
+module box(length, width, height, bevel = 0) {
     union() {
-        channel(length, width, height);
+        channel(length, width, height, bevel);
 
-        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);
+        translate([-bevel, 0, bevel])
+            rotate([90, 0, 0])
+            rotate([0, 90, 0])
+            box_face([width, height, wall_thickness], bevel);
+        translate([length - wall_thickness + bevel, 0, bevel])
+            rotate([90, 0, 0])
+            rotate([0, 90, 0])
+            box_face([width, height, wall_thickness], bevel);
     }
 }
 
-
diff --git a/bike-lights/case/control_panel.scad b/bike-lights/case/control_panel.scad
new file mode 100644
index 0000000..de323bc
--- /dev/null
+++ b/bike-lights/case/control_panel.scad
@@ -0,0 +1,95 @@
+$fn = 50;
+threshold = 0.1;
+
+board_length = 92;
+board_width = 72;
+board_height = 21.5;
+wall_thickness = 2;
+bevel = 0.5;
+
+hinge_radius = 2.5;
+
+case_width = board_width + wall_thickness * 2;
+case_length = board_length + wall_thickness * 2;
+case_height = board_height + wall_thickness;
+
+include <./common.scad>;
+
+module hinge(length) {
+    difference() {
+        union() {
+            cylinder(h = length, r = hinge_radius);
+            translate([0, -hinge_radius, 0])
+                cube([hinge_radius, hinge_radius * 2, length]);
+        }
+        translate([0, 0, -threshold / 2]) cylinder(h = length + threshold, r = 1);
+    }
+}
+
+module main_case() {
+    hinge_length = board_length / 4;
+    hinge_y_offset = board_width + wall_thickness + hinge_radius;
+    hinge_z_offset = board_height;
+
+    difference() {
+        union() {
+            box(case_length,
+                case_width,
+                case_height,
+                bevel);
+
+            translate([0, -hinge_radius - bevel + threshold, hinge_z_offset + bevel])
+                rotate([90, 0, 0])
+                rotate([0, 90, 0])
+                hinge(case_length / 4);
+
+            translate([case_length - hinge_length, -hinge_radius - bevel + threshold, hinge_z_offset + bevel])
+                rotate([90, 0, 0])
+                rotate([0, 90, 0])
+                hinge(case_length / 4);
+
+            translate([43, case_width, wall_thickness + 8])
+                rotate([90, 0, 0])
+                rotate([0, 180, 0])
+                linear_extrude(1)
+                text("lights", size = 3);
+
+            translate([67, case_width, wall_thickness + 8])
+                rotate([90, 0, 0])
+                rotate([0, 180, 0])
+                linear_extrude(1)
+                text("left", size = 3);
+
+            translate([55, case_width, wall_thickness + 8])
+                rotate([90, 0, 0])
+                rotate([0, 180, 0])
+                linear_extrude(1)
+                text("right", size = 3);
+        }
+
+        color("green", 1) translate([8.5 + wall_thickness, case_width - wall_thickness - threshold, wall_thickness])
+            cube([60, wall_thickness * 2, 7]);
+    }
+}
+
+module lid() {
+    lid_width = case_width + hinge_radius * 2 + wall_thickness;
+    union() {
+        difference() {
+            box_face([case_length,
+                      lid_width,
+                      wall_thickness],
+                     bevel);
+            translate([(case_length - 60) / 2, 14 + hinge_radius * 2, -threshold / 2])
+                cube([60, 16, wall_thickness + threshold]);
+        }
+
+        translate([case_length / 4 + 1, hinge_radius - 0.4, -hinge_radius])
+            rotate([180, 0, 0])
+            rotate([0, 90, 0]) hinge(case_length / 2 - 2);
+    }
+}
+
+// main_case();
+// color("red", 1) translate([0, 0, case_height + wall_thickness / 2]) lid();
+// color("red", 1) translate([0, 0, 40]) lid();
diff --git a/bike-lights/case/control_panel_case.scad b/bike-lights/case/control_panel_case.scad
new file mode 100644
index 0000000..9ba0bf7
--- /dev/null
+++ b/bike-lights/case/control_panel_case.scad
@@ -0,0 +1,4 @@
+
+include <./control_panel.scad>
+
+main_case();
diff --git a/bike-lights/case/control_panel_lid.scad b/bike-lights/case/control_panel_lid.scad
new file mode 100644
index 0000000..6824eca
--- /dev/null
+++ b/bike-lights/case/control_panel_lid.scad
@@ -0,0 +1,5 @@
+
+include <./control_panel.scad>
+
+lid();
+