Started working on mechanics rev 5.

cad/mechanics_rev4/housing/dimensions.scad

@@ -79,7 +79,7 @@ lid_t_b_y = lid_t_b_height + lid_t_b_overlap;
 // Screw holes
 drill_dia_m3 = 3.2;
 drill_thread_dia_m3 = 2.5;
-drill_depth_m3 = 6;
+drill_depth_m3 = 7;
 drill_sinking_dia1_m3 = 5.5;
 drill_sinking_dia2_m3 = 3;
 drill_sinking_height_m3 = 2; 
@@ -99,6 +99,7 @@ motherboard_mounting_x = motherboard_width - 2*5;
 motherboard_mounting_y = motherboard_height - 2*5;
 motherboard_mounting_d = 6;
 motherboard_mounting_h = 6;
+motherboard_mounting_drill_depth = 14;
 
 electronics_offset = 8;
 

cad/mechanics_rev4/housing/lid_f_b.scad

@@ -61,7 +61,7 @@ difference()
 		screw_sinkings(lid_f_b_holes_x, lid_f_b_holes_y, drill_sinking_dia1_m3, drill_sinking_dia2_m3, drill_sinking_height_m3);
 		// Cut out drill holes in mounting cylinders
 		translate([0, -electronics_offset, (housing_thickness - lids_depth/2 + motherboard_mounting_h/2 - 0.01)])
-                screw_holes(motherboard_mounting_x, motherboard_mounting_y, drill_thread_dia_m3, mounting*(motherboard_mounting_h + 1) ); 
+                screw_holes(motherboard_mounting_x, motherboard_mounting_y, drill_thread_dia_m3, mounting*(motherboard_mounting_drill_depth) ); 
 		// Logo 
 		// Can be turned off by setting logo to 0
 		translate([-47.5, 15, -lids_depth/2 - 0.01 + 3])

cad/mechanics_rev4/housing/main.scad

@@ -49,17 +49,17 @@ union()
 color(myColor1)
 {
 // Lid right
-translate([housing_outside_width/2 + close*20, 0, 0])
-rotate([0, 90, 0])
+*translate([housing_outside_width/2 + close*20, 0, 0])
+rotate([0, 0, 0])
 lid_l_r();
 
 // Lid left
-translate([-housing_outside_width/2 - close*20, 0, 0])
+*translate([-housing_outside_width/2 - close*20, 0, 0])
 rotate([0, 180, 0])
 lid_l_r();
 
 // Lid front
-translate([0, -housing_outside_depth/2 - close*20, 0])
+*translate([0, -housing_outside_depth/2 - close*20, 0])
 rotate([90, 0, 0])
 lid_f_b(1,0);
 

cad/mechanics_rev5/housing/box.scad

@@ -0,0 +1,97 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for the box without lids just to structure the code a bit better.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	20.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module to make a nice round box
+include <roundy.scad>
+use <roundy.scad>
+
+// Module for screw holes
+include <screw_holes.scad>
+use <screw_holes.scad>
+
+// Module for orings
+include <oring.scad>
+use <oring.scad>
+
+
+
+module box()
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+difference()
+{
+        // Main body
+        roundy(housing_outside_width, housing_outside_depth, housing_outside_height);
+        union()
+        {
+		// Cut out basic inner shape
+		cube([housing_inside_width, housing_inside_depth, housing_inside_height], center = true);
+                // Cut out all six sides
+                // Left and right
+                cube([housing_inside_width + 3*housing_thickness, lid_l_r_width, lid_l_r_height], center = true);
+                // Front and back
+                cube([lid_f_b_width, housing_inside_depth + 3*housing_thickness, lid_f_b_height], center = true);               	
+
+		// Cut deepenings for lids
+                // Left and right
+                for(x = [-1, 1])
+                translate([x*housing_outside_width/2 - x*lids_depth/2 + x*0.1, 0, 0])
+                rotate([0, 90, 0])
+                roundy(lid_l_r_x, lid_l_r_y, lids_depth + 0.2, center = true);
+                // Front and back
+                for(y = [-1, 1])
+                translate([0, y*housing_outside_depth/2 - y*lids_depth/2 + y*0.1, 0])
+                rotate([90, 0, 0])
+                cube([lid_f_b_x, lid_f_b_y, lids_depth + 0.2], center = true);
+                
+		// Screw holes
+                // Left and right
+                for(x = [-1, 1])
+                translate([x*housing_outside_width/2 - x*drill_depth_m3, 0, 0])
+                rotate([90, 0, 90])
+                screw_holes(lid_l_r_holes_x, lid_l_r_holes_y, drill_thread_dia_m3, 2*lids_depth);
+                // Front and back
+                for(y = [-1, 1])
+                translate([0, y*housing_outside_depth/2 - y*drill_depth_m3, 0])
+                rotate([90, 0, 0])
+                screw_holes(lid_f_b_holes_x, lid_f_b_holes_y, drill_thread_dia_m3, 2*lids_depth);
+               	
+		// O-rings	
+		// Left and right
+                for(x = [-1, 1])
+                translate([x*housing_outside_width/2 - x*lids_depth - x*oring_channel_depth/2, 0, 0])
+                rotate([90, 0, 90])
+                oring(oring_l_r_x, oring_l_r_y, oring_channel_width, oring_channel_depth);
+		// Front and back
+		for(y = [-1, 1])
+                translate([0, y*housing_outside_depth/2 - y*lids_depth - y*oring_channel_depth/2, 0])
+		rotate([90, 0, 0])
+		oring(oring_f_b_x, oring_f_b_y, oring_channel_width, oring_channel_depth);
+		
+		// Cut holes for battery holder
+		translate([battery_holder_pos_x, battery_holder_pos_y, 0.01 - (housing_inside_height + drill_depth_m3)/2])
+		cylinder(r = drill_thread_dia_m3/2, h = drill_depth_m3, center = true);
+		translate([battery_holder_pos_x - battery_holder_hole_dis_x, battery_holder_pos_y + battery_holder_hole_dis_y, 0.01 - (housing_inside_height + drill_depth_m3)/2])
+		cylinder(r = drill_thread_dia_m3/2, h = drill_depth_m3, center = true);
+		}
+}
+}

cad/mechanics_rev5/housing/box_female.scad

@@ -0,0 +1,58 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Female part of the box.
+//
+// Author:              Maximilian Stiefel
+// Last modification:   31.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module for raw box without any lids
+include <box.scad>
+use <box.scad>
+
+// Module for screw holes
+include <screw_holes.scad>
+use <screw_holes.scad>
+
+////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+
+// Set minimum angle of a fragment
+$fa = 0.5;
+// Set minimum size of a fragment
+$fs = 0.5;
+
+
+////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+color(myColor1)
+{
+translate([0, 0, housing_outside_height/2])
+//rotate([180, 0, 0])
+{
+difference()
+{
+	// Draw hole box
+	box();
+	union()
+	{
+	// Cut off half of it
+	translate([0, 0, housing_outside_height/4])
+	cube([housing_outside_width + 1, housing_outside_depth + 1, housing_outside_height/2 + 0.01], center = true);
+	
+	// Draw cylinders for mortise joint
+	translate([0, 0, -(mortise_joint_height + allowance2)/2])
+	screw_holes(housing_inside_width + housing_thickness/2, housing_inside_depth + housing_thickness/2, mortise_joint_dia + allowance1, mortise_joint_height + allowance2);
+	}
+}
+}
+}

cad/mechanics_rev5/housing/box_male.scad

@@ -0,0 +1,64 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Male part of the box.
+//
+// Author:              Maximilian Stiefel
+// Last modification:   31.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module for raw box without any lids
+include <box.scad>
+use <box.scad>
+
+// Module for screw holes
+include <screw_holes.scad>
+use <screw_holes.scad>
+
+////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+
+// Set minimum angle of a fragment
+$fa = 0.5;
+// Set minimum size of a fragment
+$fs = 0.5;
+
+
+////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+color(myColor1)
+{
+	translate([0, 0, housing_outside_height/2])
+	rotate([180, 0, 0])
+	union()
+	{
+		rotate([180, 0, 0])
+		{
+		// Draw cylinders for mortise joint
+		translate([0, 0, (mortise_joint_height - mortise_joint_cone_height)/2 - 0.01])
+		screw_holes(housing_inside_width + housing_thickness/2, housing_inside_depth + housing_thickness/2, mortise_joint_dia, mortise_joint_height - mortise_joint_cone_height);
+
+		// Draw cones
+		for(x=[-0.5,+0.5])
+		for(y=[-0.5,+0.5])
+		translate([x*(housing_inside_width + housing_thickness/2), y*(housing_inside_depth + housing_thickness/2), mortise_joint_height - mortise_joint_cone_height/2 - 0.01])
+		cylinder(r1 = (mortise_joint_dia)/2, r2 = 1, mortise_joint_cone_height, center = true);
+	}
+	difference()
+	{
+		// Draw hole box
+		box();
+		// Cut off half of it
+		translate([0, 0, -housing_outside_height/4])
+		cube([housing_outside_width + 1, housing_outside_depth + 1, housing_outside_height/2 + 0.01], center = true);
+	}
+	}
+}

cad/mechanics_rev5/housing/dimensions.scad

@@ -0,0 +1,132 @@
+/////////////////////////////////////////////////////////////////////////////////
+// File for all dimensions, so they can be changed globally.
+//
+// Author:              Maximilian Stiefel
+// Last modification:   07.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+// Allowance
+allowance15 = 15;
+allowance10 = 10;
+allowance5 = 5;
+allowance2 = 2;
+allowance1 = 1;
+allowance05 = 0.5;
+
+// Dimensions battery holder
+battery_holder_width = 53.5;
+battery_holder_depth = 50.5; 
+battery_holder_height = 13;
+
+// Dimensions motherboard
+motherboard_width = 80;
+motherboard_depth = 1.6;
+motherboard_height = 50;
+
+// Dimensions plugin boards
+pluginboard_width = 80;
+pluginboard_depth = 1.6;
+pluginboard_height = 50;
+
+// Dimensions magnet
+extra_space_magnet = 10;
+
+// Dimensions housing inside (cubic)
+housing_inside_width = motherboard_width + allowance15;
+housing_inside_depth = pluginboard_height + extra_space_magnet + allowance5;
+housing_inside_height = motherboard_height + battery_holder_height + allowance10;
+
+echo(housing_inside_width=housing_inside_width);
+echo(housing_inside_depth=housing_inside_depth);
+echo(housing_inside_height=housing_inside_height);
+
+// Dimensions housing 
+housing_thickness = 12; // Make it thick to avoid light comming through the walls
+housing_outside_width = housing_inside_width + 2*housing_thickness;
+housing_outside_depth = housing_inside_depth + 2*housing_thickness;
+housing_outside_height = housing_inside_height + 2*housing_thickness;
+
+echo(housing_outside_width=housing_outside_width);
+echo(housing_outside_depth=housing_outside_depth);
+echo(housing_outside_height=housing_outside_height);
+
+// Colors
+myColor1 = "DodgerBlue";
+myColor2 = "Maroon";
+
+// Lids dimensions
+lids_depth = housing_thickness/3;
+
+echo(lids_depth=lids_depth);
+ 
+lid_l_r_height = (3/4)*housing_inside_height;
+lid_l_r_width = (3/4)*housing_inside_depth;
+lid_l_r_overlap = (1.7)*housing_thickness; 
+lid_l_r_x = lid_l_r_height + lid_l_r_overlap;
+lid_l_r_y = lid_l_r_width + lid_l_r_overlap; 
+
+lid_f_b_width = housing_inside_width - 10;
+lid_f_b_height = housing_inside_height - 5;
+lid_f_b_overlap = (1.7)*housing_thickness;
+lid_f_b_x = lid_f_b_width + lid_f_b_overlap;
+lid_f_b_y = lid_f_b_height + lid_f_b_overlap; 
+
+lid_t_b_width = housing_inside_width;
+lid_t_b_height = housing_inside_depth;
+lid_t_b_overlap = (1.7)*housing_thickness;
+lid_t_b_x = lid_t_b_width + lid_t_b_overlap;
+lid_t_b_y = lid_t_b_height + lid_t_b_overlap; 
+
+// Screw holes
+drill_dia_m3 = 3.2;
+drill_thread_dia_m3 = 2.5;
+drill_depth_m3 = 7;
+drill_sinking_dia1_m3 = 5.5;
+drill_sinking_dia2_m3 = 3;
+drill_sinking_height_m3 = 2; 
+
+echo(drill_depth_m3=drill_depth_m3);
+
+lid_l_r_holes_x = lid_l_r_width + (6/10)*lid_l_r_overlap;
+lid_l_r_holes_y = lid_l_r_height + (6/10)*lid_l_r_overlap;
+
+lid_f_b_holes_x = lid_f_b_width + (6/10)*lid_f_b_overlap;
+lid_f_b_holes_y = lid_f_b_height + (6/10)*lid_f_b_overlap;
+
+lid_t_b_holes_x = lid_t_b_width + (6/10)*lid_t_b_overlap;
+lid_t_b_holes_y = lid_t_b_height + (6/10)*lid_t_b_overlap;
+
+motherboard_mounting_x = motherboard_width - 2*5;
+motherboard_mounting_y = motherboard_height - 2*5;
+motherboard_mounting_d = 6;
+motherboard_mounting_h = 6;
+motherboard_mounting_drill_depth = 14;
+
+electronics_offset = 8;
+
+// O-rings
+oring_channel_depth = 1.2;
+oring_channel_width = 2;
+
+oring_l_r_x = lid_l_r_width + 2*oring_channel_width + 6;
+oring_l_r_y = lid_l_r_height + 2*oring_channel_width + 6;
+
+oring_f_b_x = lid_f_b_width + 2*oring_channel_width + 6;
+oring_f_b_y = lid_f_b_height + 2*oring_channel_width + 6;
+
+oring_t_b_x = lid_t_b_width + 2*oring_channel_width + 6;
+oring_t_b_y = lid_t_b_height + 2*oring_channel_width + 6;
+
+// Mortise joint
+mortise_joint_height = 15;
+mortise_joint_dia = 7;
+mortise_joint_cone_height = 5;
+
+// Dimensions battery holder
+battery_holder_width = 53.5;
+battery_holder_depth = 50.5; 
+battery_holder_height = 13;
+battery_holder_hole_dis_x = 12.5;
+battery_holder_hole_dis_y = 36.5;
+battery_holder_pos_x = battery_holder_hole_dis_x/2;
+battery_holder_pos_y = -battery_holder_hole_dis_y/2;

cad/mechanics_rev5/housing/lid_f_b.scad

@@ -0,0 +1,79 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for the front and back lid.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	28.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module to make a nice round box
+include <roundy.scad>
+use <roundy.scad>
+
+// Module for screw holes
+include <screw_holes.scad>
+use <screw_holes.scad>
+
+// Module for screw holes
+include <screw_sinkings.scad>
+use <screw_sinkings.scad>
+
+
+module lid_f_b(logo, mounting)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+translate([0, 0, -lids_depth/2])
+rotate([180, 0, 0])
+difference()
+{
+	// Main body for the lid
+	union()
+	{
+		// Actual lid
+		cube([lid_f_b_x - allowance05, lid_f_b_y - allowance05, lids_depth], center = true);
+		translate([0, 0, housing_thickness/2 - 0.01])
+		cube([lid_f_b_width - allowance05, lid_f_b_height - allowance05, housing_thickness - lids_depth], center = true);
+		// Mounting cylinders
+		translate([0, -electronics_offset, (housing_thickness - lids_depth/2 + motherboard_mounting_h/2 - 0.01)])
+		screw_holes(motherboard_mounting_x, motherboard_mounting_y, motherboard_mounting_d, mounting*motherboard_mounting_h);
+	}
+
+	union()
+	{
+		// Cut out cylindric holes for screws to mount the lid on the housing
+		screw_holes(lid_f_b_holes_x, lid_f_b_holes_y, drill_dia_m3, 2*lids_depth);
+		// Cut out sinking holes
+		translate([0, 0, -lids_depth/2 + drill_sinking_height_m3/2 + 0.5])
+		screw_sinkings(lid_f_b_holes_x, lid_f_b_holes_y, drill_sinking_dia1_m3, drill_sinking_dia2_m3, drill_sinking_height_m3);
+		// Cut out drill holes in mounting cylinders
+		translate([0, -electronics_offset, (housing_thickness - lids_depth/2 + motherboard_mounting_h/2 - 0.01)])
+                screw_holes(motherboard_mounting_x, motherboard_mounting_y, drill_thread_dia_m3, mounting*(motherboard_mounting_drill_depth) ); 
+		// Logo 
+		// Can be turned off by setting logo to 0
+		translate([-30, 20, -lids_depth/2 - 0.01 + 3])
+		rotate([180, 0, 0])
+		linear_extrude(height = logo*3)
+		scale(1.5)
+		import("logo_taylored.dxf");
+		// Text
+		translate([-40, 35, -lids_depth/2 - 0.01 + 3])
+		rotate([180, 0, 0])
+		linear_extrude(height = logo*3)
+		text("UppSense", size = 12, font = "Liberation Sans:style=Bold");
+	}
+}
+}

cad/mechanics_rev5/housing/lid_l_r.scad

@@ -0,0 +1,62 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for the left and right lid.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	28.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module to make a nice round box
+include <roundy.scad>
+use <roundy.scad>
+
+// Module for screw holes
+include <screw_holes.scad>
+use <screw_holes.scad>
+
+// Module for screw holes
+include <screw_sinkings.scad>
+use <screw_sinkings.scad>
+
+
+module lid_l_r()
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+rotate([0, 90, 0])
+translate([0, 0, -lids_depth/2])
+rotate([180, 0, 0])
+difference()
+{
+	// Main body for the lid
+	union()
+	{
+		roundy(lid_l_r_x - allowance05, lid_l_r_y - allowance05, lids_depth);
+		translate([0, 0, housing_thickness/2 -0.01])
+		cube([lid_l_r_height - allowance05, lid_l_r_width - allowance05, housing_thickness - lids_depth], center = true);
+		echo(housing_thickness=housing_thickness);
+		echo(lids_depth=lids_depth);
+	}
+
+	union()
+	{
+		// Cut out cylindric holes
+		screw_holes(lid_l_r_holes_y, lid_l_r_holes_x, drill_dia_m3, 2*lids_depth);
+		translate([0, 0, -lids_depth/2 + drill_sinking_height_m3/2 + 0.5])
+		screw_sinkings(lid_l_r_holes_y, lid_l_r_holes_x, drill_sinking_dia1_m3, drill_sinking_dia2_m3, drill_sinking_height_m3);
+	}
+}
+}

cad/mechanics_rev5/housing/lid_t_b.scad

@@ -0,0 +1,59 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for the top and bottom lid.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	28.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module to make a nice round box
+include <roundy.scad>
+use <roundy.scad>
+
+// Module for screw holes
+include <screw_holes.scad>
+use <screw_holes.scad>
+
+// Module for screw holes
+include <screw_sinkings.scad>
+use <screw_sinkings.scad>
+
+
+module lid_t_b()
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+translate([0, 0, -lids_depth/2])
+rotate([180, 0, 0])
+difference()
+{
+	// Main body for the lid
+	union()
+	{
+		roundy(lid_t_b_x - allowance05, lid_t_b_y - allowance05, lids_depth);
+		translate([0, 0, housing_thickness/2 - 0.01])
+		cube([lid_t_b_width - allowance05, lid_t_b_height - allowance05, housing_thickness - lids_depth], center = true);
+	}
+
+	union()
+	{
+		// Cut out cylindric holes
+		screw_holes(lid_t_b_holes_x, lid_t_b_holes_y, drill_dia_m3, 2*lids_depth);
+		translate([0, 0, -lids_depth/2 + drill_sinking_height_m3/2 + 0.5])
+		screw_sinkings(lid_t_b_holes_x, lid_t_b_holes_y, drill_sinking_dia1_m3, drill_sinking_dia2_m3, drill_sinking_height_m3);
+	}
+}
+}

cad/mechanics_rev5/housing/main.scad

@@ -0,0 +1,78 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Main file to assemble everything.
+//
+// Author:              Maximilian Stiefel
+// Last modification:   20.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module for raw box without any lids
+include <box.scad>
+use <box.scad>
+
+// Module for raw box without any lids
+include <lid_l_r.scad>
+use <lid_l_r.scad>
+
+// Module for raw box without any lids
+include <lid_f_b.scad>
+use <lid_f_b.scad>
+
+// Module for raw box without any lids
+include <lid_t_b.scad>
+use <lid_t_b.scad>
+
+////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+// 0 = put lids, 1 = remove lids
+close = 0;
+// Set minimum angle of a fragment
+$fa = 0.5;
+// Set minimum size of a fragment
+$fs = 0.5;
+
+////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+//difference()
+//{
+union()
+{
+color(myColor1)
+{
+// Lid right
+translate([housing_outside_width/2 + close*20, 0, 0])
+rotate([0, 0, 0])
+lid_l_r();
+
+// Lid left
+translate([-housing_outside_width/2 - close*20, 0, 0])
+rotate([0, 180, 0])
+lid_l_r();
+
+// Lid front
+translate([0, -housing_outside_depth/2 - close*20, 0])
+rotate([90, 0, 0])
+lid_f_b(1,0);
+
+// Lid back
+translate([0, +housing_outside_depth/2 + close*20, 0])
+rotate([-90, 180, 0])
+!rotate([180, 0, 0])
+lid_f_b(1,1);
+
+color(myColor1, 0.8)
+box();
+}
+}
+//translate([-200, 0, 0])
+//cube([400,400,400], center=true);
+//}

cad/mechanics_rev5/housing/open_box.scad

@@ -0,0 +1,41 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for a open box with rounded edges.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	26.04.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+module open_box(width, length, height, thickness)
+{
+
+	/////////////////////////////////////////////////////////////////////////
+	// Vars
+	/////////////////////////////////////////////////////////////////////////
+	edge_rounding = 8;
+	compensation = 2*abs(edge_rounding-thickness);
+
+	/////////////////////////////////////////////////////////////////////////
+	// Action
+	/////////////////////////////////////////////////////////////////////////
+	translate([0, 0, 0]) difference(){		
+		// Hull 4 cylinders which are compensated against the thickness
+		// so the actual desired thickness/2 and edge rounding is always achieved.
+		hull(){
+			// x=0, y=0
+			translate([edge_rounding, edge_rounding, 0])
+				cylinder(r = edge_rounding, h = height + thickness);
+			// x=width, y=0
+			translate([width + edge_rounding - compensation, edge_rounding, 0])
+				cylinder(r = edge_rounding, h = height + thickness);
+			// x=0, y=length
+			translate([edge_rounding, length + edge_rounding - compensation,0])
+				cylinder(r = edge_rounding, h = height + thickness);
+			//x=width, y=length
+			translate([width + edge_rounding - compensation, length + edge_rounding - compensation,0])
+				cylinder(r = edge_rounding, h = height + thickness);
+		}
+
+		translate([thickness, thickness, thickness])
+			cube([width, length, height + 1]);
+	}
+}

cad/mechanics_rev5/housing/oring.scad

@@ -0,0 +1,31 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for oring deepnings.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	28.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Module to make a nice round box
+include <roundy.scad>
+use <roundy.scad>
+
+module oring(xdim, ydim, channel_width, channel_depth)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+difference()
+{
+	roundy(xdim, ydim, channel_depth + 0.1);
+	roundy(xdim - 2*channel_width, ydim - 2*channel_width, channel_depth + 0.15);
+}
+}

cad/mechanics_rev5/housing/roundy.scad

@@ -0,0 +1,30 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for a open box with rounded edges.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	26.04.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+module roundy(width, depth, height, center)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+edge_rounding = 5;
+transx = -width/2;
+transy = -depth/2;
+transz = -height/2;
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+// Hull 4 cylinders
+// The thickness of the cylinders (edge_rounding) is compensated	
+//translate([transx, transy, transz])
+hull(){
+	for(x=[-1, +1])
+	for(y=[-1, +1])
+		translate([x*width/2 + -x*edge_rounding, y*depth/2 + -y*edge_rounding, 0])
+		cylinder(r = edge_rounding, h = height, center =true);
+}
+}

cad/mechanics_rev5/housing/screw_holes.scad

@@ -0,0 +1,24 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for four holes along a rectangle for screw threads.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	09.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+module screw_holes(xdim, ydim, dia, depth)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+union(){
+	for(x=[-1, +1])
+	for(y=[-1, +1])
+		translate([x*xdim/2, y*ydim/2, 0])
+		cylinder(r = dia/2, h = depth, center =true);
+}
+}

cad/mechanics_rev5/housing/screw_sinkings.scad

@@ -0,0 +1,30 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for four sinking holes, that cone-shaped screw heads can sink in.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	09.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+module screw_sinkings(xdim, ydim, dia1, dia2, depth)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+union(){
+	for(x=[-1, +1])
+	for(y=[-1, +1])
+		translate([x*xdim/2, y*ydim/2, 0])
+		union()
+		{
+			translate([0, 0, -depth + 0.1])
+			cylinder(r = dia1/2, h = depth, center = true);
+			cylinder(r1 = dia1/2, r2 = dia2/2, h = depth, center = true);
+		}
+}
+
+}

cad/mechanics_rev5/pcb/dimensions.scad

@@ -0,0 +1,58 @@
+/////////////////////////////////////////////////////////////////////////////////
+// File for all dimensions, so they can be changed globally.
+//
+// Author:              Maximilian Stiefel
+// Last modification:   29.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+allowance03 = 0.3;
+allowance05 = 0.5;
+allowance1 = 1;
+
+// Glass dimensions
+glass_slide_height = 1;
+glass_slide_depth = 26 + allowance05;
+glass_slide_width = 76;
+
+// Holder dimensions
+window_size = 20;
+holder_height = 3 + glass_slide_height + allowance05;
+holder_depth = glass_slide_depth + allowance05 + 4;
+holder_width = 80; // Width of the PCB
+echo(holder_height=holder_height);
+holder_bottom_side_thickness = 2;
+
+// LED illuminator dimensions
+led_illuminator_thickness = 2; 
+led_illuminator_dia = 12.5 - led_illuminator_thickness;
+led_illuminator_height = 15;
+led_illuminator_leg1_pos_y = -6.25;
+led_illuminator_leg2_pos_y = 4;
+led_illuminator_leg2_pos_x = -4.75;
+led_illuminator_leg_dia = 2.2 - allowance05; 
+led_illuminator_leg_height = 4;
+led_pos_x = 18;
+led_pos_y = 13;
+led_illuminator_slot = 4;
+led_illuminator_angle = 35;
+
+// Screw dimensions
+drill_dia_m3 = 3.2;
+drill_depth = 7;
+drill_sinking_dia1_m3 = 5.5;
+drill_sinking_dia2_m3 = 3;
+drill_sinking_height_m3 = 2;
+
+// Leg dimensions
+leg_width = 4;
+leg_depth = 11;
+leg_height = led_illuminator_height;
+leg_inner_dia = 2.5;
+leg_pos_y = 13;
+leg_pos_x = 2.5;
+leg_distance = 6.5;
+leg_diff1 = leg_depth - leg_distance;
+//leg_drill_depth = 7;
+leg_drill_depth = leg_height + 1;
+
+myColor1 = "Grey";

cad/mechanics_rev5/pcb/glass_holder.scad

@@ -0,0 +1,51 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Glass slide holder to be mounted on the PCB. 
+//
+// Author:              Maximilian Stiefel
+// Last modification:   29.06.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Dimesnions
+include <screw_sinkings.scad>
+use <screw_sinkings.scad>
+
+/////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+module glass_holder()
+{
+	//translate([0, 0, holder_height/2 + leg_height -0.01])
+	difference()
+	{
+		// Main body
+		cube([holder_width, holder_depth, holder_height], center = true);
+		union()
+		{
+			// Cut glass slide out and make an entrance
+			translate([-2.5, 0, holder_bottom_side_thickness])
+			cube([glass_slide_width + allowance05 + 5, glass_slide_depth + allowance05, holder_height], center = true);
+			// Cut out a cylinder for the LED
+			translate([glass_slide_width/2 - led_pos_x, 0, 0])
+			cylinder(r = led_illuminator_dia/2, h = 20, center = true);
+			// Cut out a "window" where the receiver photodiode is sitting
+			translate([glass_slide_width/2 - led_pos_x, glass_slide_depth/2, 2])
+			cube([window_size, 10, 10], center = true);	
+			// Cut out holes for screws
+			translate([0, 0, -holder_bottom_side_thickness + 0.5])
+			rotate([180, 0, 0])
+			screw_sinkings(glass_slide_width - 2*leg_pos_x, 0, drill_sinking_dia1_m3, drill_sinking_dia2_m3, drill_sinking_height_m3);
+		}
+	}
+}

cad/mechanics_rev5/pcb/led_illuminator.scad

@@ -0,0 +1,47 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Illuminator for LED to keep the UV light away from the photodiode. 
+//
+// Author:              Maximilian Stiefel
+// Last modification:   29.06.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+/////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+module illuminator()
+{
+	difference()
+	{
+		union()
+		{
+			cylinder(r = led_illuminator_dia/2 + led_illuminator_thickness, h = led_illuminator_height + allowance03, center = true);
+			// The two legs	
+			translate([0, led_illuminator_leg1_pos_y, - (led_illuminator_height + led_illuminator_leg_height)/2 - 0.01 ])
+			cylinder(r = (led_illuminator_leg_dia)/2, h = led_illuminator_leg_height, center = true);
+			translate([led_illuminator_leg2_pos_x, led_illuminator_leg2_pos_y, - (led_illuminator_height + led_illuminator_leg_height)/2 - 0.01 ])
+			cylinder(r = (led_illuminator_leg_dia)/2, h = led_illuminator_leg_height, center = true);
+		}
+		union()
+		{
+			// Cut out inner cylinder
+			cylinder(r = led_illuminator_dia/2, led_illuminator_height + +allowance03 + 0.01, center = true);	
+			// Cut out slot
+			rotate([0, 0, led_illuminator_angle + 180])
+			translate([led_illuminator_dia/2, 0, -led_illuminator_height/2 - 0.01])
+			cube([led_illuminator_dia/2, led_illuminator_slot, led_illuminator_height], center = true);
+		}
+	}
+}
+

cad/mechanics_rev5/pcb/legs.scad

@@ -0,0 +1,43 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Legs for the glass slide holder. 
+//
+// Author:              Maximilian Stiefel
+// Last modification:   29.06.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+/////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+module legs()
+{
+	difference()
+	{
+	union()
+	{
+		// Leg
+		translate([0, - leg_depth/2 + leg_diff1/2, leg_height/2])
+		cube([leg_width, leg_depth, leg_height], center = true);
+	}
+	union()
+	{
+		// Drill holes
+		for(y = [0, 1])
+		translate([0, -y*leg_distance, -0.01])
+		cylinder(r = leg_inner_dia/2, h = leg_drill_depth);
+		
+	}
+}
+}
+

cad/mechanics_rev5/pcb/main.scad

@@ -0,0 +1,56 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Main file to bring everything together. 
+//
+// Author:              Maximilian Stiefel
+// Last modification:   29.06.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+/////////////////////////////////////////////////////////////////////////////////
+// Includes
+/////////////////////////////////////////////////////////////////////////////////
+
+// Dimesnions
+include <dimensions.scad>
+use <dimensions.scad>
+
+// Module for the glass holder
+include <glass_holder.scad>
+use <glass_holder.scad>
+
+// Module for the legs 
+include <legs.scad>
+use <legs.scad>
+
+// Module for the legs 
+include <led_illuminator.scad>
+use <led_illuminator.scad>
+
+/////////////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////////////
+$fa = 0.5; // minimum facet angle is now 0.5
+$fs = 0.5; // minimum facet size is now 0.5 mm
+
+/////////////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////////////
+color(myColor1)
+{
+	// Glass holder
+	translate([0, 0, holder_height/2 + leg_height -0.01])
+	!translate([0, 0, holder_height/2])	
+	glass_holder();
+	
+	// Legs
+	translate([glass_slide_width/2 - leg_pos_x, 0, 0])
+	legs();
+	
+	translate([-glass_slide_width/2 + leg_pos_x, 0, 0])
+	rotate([0, 0, 180])
+	legs();
+	
+	translate([glass_slide_width/2 - led_pos_x, 0, led_illuminator_height/2 + 0.01])	
+	//translate([0, 0, (led_illuminator_height + allowance03)/2])
+	//rotate([0, 180 ,0])
+	illuminator();
+}

cad/mechanics_rev5/pcb/screw_holes.scad

@@ -0,0 +1,24 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for four holes along a rectangle for screw threads.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	09.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+module screw_holes(xdim, ydim, dia, depth)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+union(){
+	for(x=[-1, +1])
+	for(y=[-1, +1])
+		translate([x*xdim/2, y*ydim/2, 0])
+		cylinder(r = dia/2, h = depth, center =true);
+}
+}

cad/mechanics_rev5/pcb/screw_sinkings.scad

@@ -0,0 +1,30 @@
+/////////////////////////////////////////////////////////////////////////////////
+// Module for four sinking holes, that cone-shaped screw heads can sink in.
+//
+// Author: 		Maximilian Stiefel
+// Last modification: 	09.07.2017
+/////////////////////////////////////////////////////////////////////////////////
+
+module screw_sinkings(xdim, ydim, dia1, dia2, depth)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+union(){
+	for(x=[-1, +1])
+	for(y=[-1, +1])
+		translate([x*xdim/2, y*ydim/2, 0])
+		union()
+		{
+			translate([0, 0, -depth + 0.1])
+			cylinder(r = dia1/2, h = depth, center = true);
+			cylinder(r1 = dia1/2, r2 = dia2/2, h = depth, center = true);
+		}
+}
+
+}

software/Basic_Blink/out/firmware/fwMeminfo.new

@@ -0,0 +1,10 @@
+   Section|                   Description| Start (hex)|   End (hex)|Used space
+------------------------------------------------------------------------------
+      data|        Initialized Data (RAM)|    3FFE8000|    3FFE8389|     905
+    rodata|           ReadOnly Data (RAM)|    3FFE8390|    3FFE8D6C|    2524
+       bss|      Uninitialized Data (RAM)|    3FFE8D70|    3FFEF160|   25584
+      text|            Cached Code (IRAM)|    40100000|    401063A8|   25512
+irom0_text|           Uncached Code (SPI)|    4020A000|    4023964C|  194124
+Total Used RAM : 29013
+Free RAM : 52907
+Free IRam : 7274

software/Basic_Blink/out/firmware/fwMeminfo.old

@@ -0,0 +1,10 @@
+   Section|                   Description| Start (hex)|   End (hex)|Used space
+------------------------------------------------------------------------------
+      data|        Initialized Data (RAM)|    3FFE8000|    3FFE8389|     905
+    rodata|           ReadOnly Data (RAM)|    3FFE8390|    3FFE8D50|    2496
+       bss|      Uninitialized Data (RAM)|    3FFE8D50|    3FFEF108|   25528
+      text|            Cached Code (IRAM)|    40100000|    401063A8|   25512
+irom0_text|           Uncached Code (SPI)|    4020A000|    40239584|  193924
+Total Used RAM : 28929
+Free RAM : 52991
+Free IRam : 7274