bike-lights/case/battery_enclosure.scad

@@ -1,158 +0,0 @@
-$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;
-
-
-include <./common.scad>;
-
-// 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);
-
-        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);
-    }
-}
-
-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_length = wall_thickness * 2 + converter_height;
-    box_width = cell_holder_width * 2 - wall_thickness;
-    difference() {
-        box(box_length, box_width, cell_holder_height);
-
-        translate([cell_holder_width - wire_radius, 0, 0])
-            rotate([90, 0, 0])
-            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_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_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_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_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);
-    }
-}
-
-module battery_case() {
-    union() {
-        translate([-cell_holder_width / 2, 0, 0]) battery_slot();
-        translate([cell_holder_width / 2 - wall_thickness, 0, 0]) battery_slot();
-        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/common.scad

@@ -1,57 +0,0 @@
-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(dimensions, bevel = 0) {
-    x = dimensions[0];
-    y = dimensions[1];
-    z = dimensions[2];
-
-    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, bevel) {
-    union() {
-        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, bevel = 0) {
-    union() {
-        channel(length, width, height, 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);
-    }
-}
-

bike-lights/case/control_panel.scad

@@ -1,95 +0,0 @@
-$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();

bike-lights/case/control_panel_case.scad

@@ -1,4 +0,0 @@
-
-include <./control_panel.scad>
-
-main_case();

bike-lights/case/control_panel_lid.scad

@@ -1,5 +0,0 @@
-
-include <./control_panel.scad>
-
-lid();
-