add the slot to hold the power converter

bike-lights/bike/src/main.rs

@@ -17,7 +17,7 @@ use rp_pico::{
     entry,
     hal::{
         clocks::init_clocks_and_plls,
-        gpio::{FunctionSio, Pin, PinId, PullUp, SioInput},
+        gpio::{FunctionSio, Pin, PinId, PullDown, PullUp, SioInput, SioOutput},
         pac::{CorePeripherals, Peripherals},
         spi::{Enabled, Spi, SpiDevice, ValidSpiPinout},
         watchdog::Watchdog,
@@ -65,12 +65,16 @@ struct BikeUI<
     RightId: PinId,
     PreviousId: PinId,
     NextId: PinId,
+    BrakeId: PinId,
 > {
     spi: RefCell<Spi<Enabled, D, P, 8>>,
     left_blinker_button: DebouncedButton<LeftId>,
     right_blinker_button: DebouncedButton<RightId>,
     previous_animation_button: DebouncedButton<PreviousId>,
     next_animation_button: DebouncedButton<NextId>,
+    brake_sensor: Pin<BrakeId, FunctionSio<SioInput>, PullUp>,
+
+    brake_enabled: bool,
 }
 
 impl<
@@ -80,7 +84,8 @@ impl<
         RightId: PinId,
         PreviousId: PinId,
         NextId: PinId,
-    > BikeUI<D, P, LeftId, RightId, PreviousId, NextId>
+        BrakeId: PinId,
+    > BikeUI<D, P, LeftId, RightId, PreviousId, NextId, BrakeId>
 {
     fn new(
         spi: Spi<Enabled, D, P, 8>,
@@ -88,6 +93,7 @@ impl<
         right_blinker_button: Pin<RightId, FunctionSio<SioInput>, PullUp>,
         previous_animation_button: Pin<PreviousId, FunctionSio<SioInput>, PullUp>,
         next_animation_button: Pin<NextId, FunctionSio<SioInput>, PullUp>,
+        brake_sensor: Pin<BrakeId, FunctionSio<SioInput>, PullUp>,
     ) -> Self {
         Self {
             spi: RefCell::new(spi),
@@ -95,6 +101,9 @@ impl<
             right_blinker_button: DebouncedButton::new(right_blinker_button),
             previous_animation_button: DebouncedButton::new(previous_animation_button),
             next_animation_button: DebouncedButton::new(next_animation_button),
+            brake_sensor,
+
+            brake_enabled: false,
         }
     }
 }
@@ -106,10 +115,17 @@ impl<
         RightId: PinId,
         PreviousId: PinId,
         NextId: PinId,
-    > UI for BikeUI<D, P, LeftId, RightId, PreviousId, NextId>
+        BrakeId: PinId,
+    > UI for BikeUI<D, P, LeftId, RightId, PreviousId, NextId, BrakeId>
 {
     fn check_event(&mut self, current_time: Instant) -> Option<Event> {
-        if self.left_blinker_button.is_low(current_time) {
+        if self.brake_sensor.is_high().unwrap_or(true) && !self.brake_enabled {
+            self.brake_enabled = true;
+            Some(Event::Brake)
+        } else if self.brake_sensor.is_low().unwrap_or(false) && self.brake_enabled {
+            self.brake_enabled = false;
+            Some(Event::BrakeRelease)
+        } else if self.left_blinker_button.is_low(current_time) {
             self.left_blinker_button.set_debounce(current_time);
             Some(Event::LeftBlinker)
         } else if self.right_blinker_button.is_low(current_time) {
@@ -197,6 +213,9 @@ fn main() -> ! {
     let right_blinker_button = pins.gpio16.into_pull_up_input();
     let previous_animation_button = pins.gpio27.into_pull_up_input();
     let next_animation_button = pins.gpio26.into_pull_up_input();
+    let brake_sensor = pins.gpio18.into_pull_up_input();
+
+    let mut led_pin = pins.led.into_push_pull_output();
 
     let ui = BikeUI::new(
         spi,
@@ -204,11 +223,11 @@ fn main() -> ! {
         right_blinker_button,
         previous_animation_button,
         next_animation_button,
+        brake_sensor,
     );
 
     let mut app = App::new(Box::new(ui));
 
-    let mut led_pin = pins.led.into_push_pull_output();
     led_pin.set_high();
 
     let mut time = Instant::default();

bike-lights/case/battery_enclosure.scad

@@ -0,0 +1,189 @@
+$fn = 50;
+threshold = 0.1;
+half_threshold = threshold / 2;
+bevel = 0.5;
+
+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 = 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);
+    }
+}
+
+// box(20, 10, 10);
+// color("blue", 0.5) cube([10, 20, 10], center = true);
+
+module cell_cradle(width, height) {
+    difference() {
+        translate([0, 0, -height / 2]) cube([width,
+              wall_thickness,
+              height],
+             center = true);
+        color("red", 1) translate([0, 0, 0])
+            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);
+        translate([0, -battery_length / 6, wall_thickness]) cell_cradle(cell_holder_width, cell_holder_height / 2);
+        translate([0, battery_length / 6, wall_thickness]) cell_cradle(cell_holder_width, cell_holder_height / 2);
+    }
+}
+
+module contact_box() {
+    contact_thickness = battery_contact_flange_height * .75;
+    cutout_width = battery_contact_width * .8;
+    // box_thickness = contact_thickness_ + wall_thickness * 2;
+    // box_height = width + wall_thickness;
+
+    difference() {
+        box(wall_thickness * 2 + contact_thickness, cell_holder_width, cell_holder_height);
+        translate([0, contact_thickness, wall_thickness * 2])
+            cube([battery_contact_width,
+                  wall_thickness * 2,
+                  battery_contact_length + threshold],
+                 center = true);
+
+        color("red", 1) translate([0,
+                   -(wall_thickness + contact_thickness + threshold) / 2,
+                   cell_holder_height / 2])
+                   cube([5, wall_thickness + threshold * 2, cell_holder_height], center = true);
+
+        translate([0,
+                   -(wall_thickness + contact_thickness + threshold) / 2 - wire_radius,
+                   0])
+            rotate([0, 90, 0])
+            cylinder(h = cell_holder_width, r = wire_radius, center = true);
+    }
+}
+
+module battery_slot() {
+    difference() {
+        union() {
+            translate([0, -cell_holder_length / 2, 0]) contact_box();
+            translate([0, wall_thickness, 0]) cell_box();
+            translate([0, cell_holder_length / 2 + wall_thickness * 2, 0])
+                rotate([0, 0, 180])
+                contact_box();
+        }
+        translate([cell_holder_width / 2, 1, 0]) rotate([90, 0, 0]) cylinder(h = cell_holder_length + wall_thickness * 4 + battery_contact_flange_height * 2, r = wire_radius, center = true);
+        translate([-cell_holder_width / 2, 1, 0]) rotate([90, 0, 0]) cylinder(h = cell_holder_length + wall_thickness * 4 + battery_contact_flange_height * 2, r = wire_radius, center = true);
+    }
+}
+
+module converter_box() {
+    box_width = wall_thickness * 2 + converter_height;
+    difference() {
+        box(box_width, cell_holder_width * 2 - wall_thickness, cell_holder_height);
+
+        translate([cell_holder_width - wire_radius, 0, 0])
+            rotate([90, 0, 0])
+            cylinder(h = box_width, 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);
+        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])
+            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])
+            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])
+            rotate([90, 0, 0])
+            cylinder(h = wall_thickness * 2, r = wire_radius, center = true);
+    }
+}
+
+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])
+            converter_box();
+    }
+}
+
+
+battery_case();
+

bike-lights/case/enclosure.scad

@@ -0,0 +1,174 @@
+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();