bike-lights/case/battery_enclosure.scad

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+$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

@@ -0,0 +1,57 @@
+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

@@ -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();

bike-lights/case/control_panel_case.scad

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

bike-lights/case/control_panel_lid.scad

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