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Design cases for the bike lighting project #250

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savanni merged 7 commits from bike-lights__case into main 2024-09-27 02:18:10 +00:00
Conversation 0 Commits 7 Files Changed 5 +69 -227
3 changed files with 69 additions and 227 deletions
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75
bike-lights/case/battery_enclosure.scad
View File

@ -27,51 +27,7 @@ converter_length = 22.25;
converter_height = 5; converter_height = 5;
module pill(length, bevel) { include <./common.scad>;
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); // box(20, 10, 10);
// color("blue", 0.5) cube([10, 20, 10], center = true); // color("blue", 0.5) cube([10, 20, 10], center = true);
@ -122,6 +78,14 @@ module contact_box() {
0]) 0])
rotate([0, 90, 0]) rotate([0, 90, 0])
cylinder(h = cell_holder_width, r = wire_radius, center = true); 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);
} }
} }
@ -140,35 +104,41 @@ module battery_slot() {
} }
module converter_box() { module converter_box() {
box_width = wall_thickness * 2 + converter_height; box_length = wall_thickness * 2 + converter_height;
box_width = cell_holder_width * 2 - wall_thickness;
difference() { difference() {
box(box_width, cell_holder_width * 2 - wall_thickness, cell_holder_height); box(box_length, box_width, cell_holder_height);
translate([cell_holder_width - wire_radius, 0, 0]) translate([cell_holder_width - wire_radius, 0, 0])
rotate([90, 0, 0]) rotate([90, 0, 0])
cylinder(h = box_width, r = wire_radius, center = true); cylinder(h = box_length, r = wire_radius, center = true);
translate([cell_holder_width - wire_radius * 2, 0, 0]) translate([cell_holder_width - wire_radius * 2, 0, 0])
rotate([0, 90, 0]) rotate([0, 90, 0])
cylinder(h = wall_thickness + threshold, r = wire_radius, center = true); cylinder(h = wall_thickness + threshold, r = wire_radius, center = true);
translate([-cell_holder_width + wire_radius, 0, 0]) translate([-cell_holder_width + wire_radius, 0, 0])
rotate([90, 0, 0]) rotate([90, 0, 0])
cylinder(h = box_width, r = wire_radius, center = true); cylinder(h = box_length, r = wire_radius, center = true);
translate([-cell_holder_width + wire_radius * 2, 0, 0]) translate([-cell_holder_width + wire_radius * 2, 0, 0])
rotate([0, 90, 0]) rotate([0, 90, 0])
cylinder(h = wall_thickness + threshold, r = wire_radius, center = true); cylinder(h = wall_thickness + threshold, r = wire_radius, center = true);
translate([0, -box_width / 2, 0]) translate([0, -box_length / 2, 0])
rotate([0, 90, 0]) rotate([0, 90, 0])
cylinder(h = cell_holder_width * 2 + wall_thickness, r = wire_radius, center = true); cylinder(h = cell_holder_width * 2 + wall_thickness, r = wire_radius, center = true);
translate([-cell_holder_width * .75, (-box_width + wall_thickness) / 2, 0]) translate([-cell_holder_width * .75, (-box_length + wall_thickness) / 2, 0])
rotate([90, 0, 0]) rotate([90, 0, 0])
cylinder(h = wall_thickness * 2, r = wire_radius, center = true); cylinder(h = wall_thickness * 2, r = wire_radius, center = true);
translate([cell_holder_width * .75, (-box_width + wall_thickness) / 2, 0]) translate([cell_holder_width * .75, (-box_length + wall_thickness) / 2, 0])
rotate([90, 0, 0]) rotate([90, 0, 0])
cylinder(h = wall_thickness * 2, r = wire_radius, center = true); 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);
} }
} }
@ -176,7 +146,6 @@ module battery_case() {
union() { union() {
translate([-cell_holder_width / 2, 0, 0]) battery_slot(); translate([-cell_holder_width / 2, 0, 0]) battery_slot();
translate([cell_holder_width / 2 - wall_thickness, 0, 0]) battery_slot(); translate([cell_holder_width / 2 - wall_thickness, 0, 0]) battery_slot();
color("blue", 1)
translate([-wall_thickness / 2, translate([-wall_thickness / 2,
cell_holder_length / 2 + wall_thickness * 2 + battery_contact_flange_height + wall_thickness * 2 + wall_thickness / 2, cell_holder_length / 2 + wall_thickness * 2 + battery_contact_flange_height + wall_thickness * 2 + wall_thickness / 2,
0]) 0])

47
bike-lights/case/common.scad Normal file
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@ -0,0 +1,47 @@
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);
}
}

174
bike-lights/case/enclosure.scad
View File

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