monorepo/bike-lights/case/control_panel.scad

$fn = 50;
threshold = 0.1;

board_length = 92;
board_width = 72;
board_height = 21.5;
wall_thickness = 4;
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;

handlebar_radius = 15;
clasp_thickness = 4;
circular_face_count = 48;
clasp_width = 35;

include <./common.scad>;

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, center = true, $fn = circular_face_count);
            translate([0, 0, -clasp_width / 2 + 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
            translate([0, 0, clasp_width / 2]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, center = true, $fn = circular_face_count);
            translate([0, 0, clasp_width / 2 - 4]) cylinder(h = 1, r = handlebar_radius + clasp_thickness + 1, 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 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 base_case(length, width, height, bevel = 0) {
    difference() {
        union() {
            channel(length + wall_thickness / 2, width, height, bevel);

            translate([-bevel, 0, bevel])
                rotate([90, 0, 0])
                rotate([0, 90, 0])
                box_face([width, height, wall_thickness], bevel);

            // These are the sleds at the bottom of the case that should hold the lower of the two boards down
            color("blue") translate([0, wall_thickness - 2, wall_thickness + 4]) cube([length - 8, 4, wall_thickness / 2]);
            color("blue") translate([wall_thickness - 2, wall_thickness - 4, wall_thickness + 4]) cube([4, width, wall_thickness / 2]);
            color("blue") translate([length - 25, width - wall_thickness * 3 / 2, wall_thickness + 6]) cube([16, wall_thickness, wall_thickness / 2]);
        }

        // This makes an indent at the bottom to accomodate solder joins
        translate([wall_thickness + 2, wall_thickness + 2, wall_thickness / 2]) cube([length, width - wall_thickness * 2 - 4, wall_thickness / 2 + threshold]);

        // This creates a cutout that lets the power plug slide in better.
        translate([wall_thickness, width - wall_thickness, wall_thickness]) cube([length, 2, 6]);

        // These two put in the slots that should allow the fourth wall to be slotted into place.
        color("red") translate([length - 1, wall_thickness - 2, 4]) cube([2, 2, height]);
        color("red") translate([length - 1, width - wall_thickness, 4]) cube([2, 2, height]);
    }
}

module main_case() {
    hinge_length = board_length / 4;
    hinge_y_offset = board_width + wall_thickness + hinge_radius;
    hinge_z_offset = board_height;

    difference() {
        union() {
            base_case(case_length,
                case_width,
                case_height,
                bevel);

            translate([-bevel, 0, bevel])
                rotate([90, 0, 0])
                rotate([0, 90, 0])
                box_face([case_width, case_height, wall_thickness], 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);
            // translate([case_length / 2, case_width / 2, -20]) rotate([0, 90, 0]) top_clasp();
        }

        translate([case_length / 2, case_width / 2, -threshold]) hexagon(4.5, 6);

        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);
    }
}

module box_side() {
    box_side_slider(case_length, case_width, case_height);
}