Housing finished. Final checks outstanding.

cad/mechanics_rev3/box.scad

@@ -56,32 +56,32 @@ difference()
                 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_height + lid_l_r_overlap, lid_l_r_width + lid_l_r_overlap, lids_depth + 0.2, center = true);
+                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_width + lid_f_b_overlap, lid_f_b_height + lid_f_b_overlap, lids_depth + 0.2], center = true);
+                cube([lid_f_b_x, lid_f_b_y, lids_depth + 0.2], center = true);
                 // Top and bottom
                 for(z = [-1, 1])
                 translate([0, 0, z*housing_outside_height/2 - z*lids_depth/2 + z*0.1])
-                roundy(lid_t_b_width + lid_t_b_overlap, lid_t_b_height + lid_t_b_overlap, lids_depth + 0.2);
+                roundy(lid_t_b_x, lid_t_b_y, lids_depth + 0.2);
 
                 // 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_dia_m3, 2*lids_depth);
+                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_dia_m3, 2*lids_depth);
+                screw_holes(lid_f_b_holes_x, lid_f_b_holes_y, drill_thread_dia_m3, 2*lids_depth);
                 // Top and bottom
                 for(z = [-1, 1])
                 translate([0, 0, z*housing_outside_height/2 - z*drill_depth_m3])
-                screw_holes(lid_t_b_holes_x, lid_t_b_holes_y, drill_dia_m3, 2*lids_depth);
+                screw_holes(lid_t_b_holes_x, lid_t_b_holes_y, drill_thread_dia_m3, 2*lids_depth);
 
 		// O-rings	
 		// Left and right

cad/mechanics_rev3/dimensions.scad

@@ -6,8 +6,11 @@
 /////////////////////////////////////////////////////////////////////////////////
 
 // Allowance
+allowance15 = 15;
+allowance10 = 10;
 allowance5 = 5;
 allowance1 = 1;
+allowance05 = 0.5;
 
 // Dimensions battery holder
 battery_holder_width = 53.5;
@@ -28,7 +31,7 @@ pluginboard_height = 50;
 extra_space_magnet = 10;
 
 // Dimensions housing inside (cubic)
-housing_inside_width = motherboard_width + allowance5;
+housing_inside_width = motherboard_width + allowance15;
 housing_inside_depth = pluginboard_height + extra_space_magnet + allowance5;
 housing_inside_height = motherboard_height + battery_holder_height + allowance5;
 
@@ -58,29 +61,44 @@ echo(lids_depth=lids_depth);
 lid_l_r_height = housing_inside_height/2;
 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 - 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 = 2.5;
+drill_dia_m3 = 3.2;
+drill_thread_dia_m3 = 2.5;
 drill_depth_m3 = 6;
+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_x = lid_l_r_width + (5/10)*lid_l_r_overlap;
-lid_l_r_holes_y = lid_l_r_height + (6/10)*lid_l_r_overlap;
+lid_l_r_holes_y = lid_l_r_height + (5/10)*lid_l_r_overlap;
 
-lid_f_b_holes_x = lid_f_b_width + (6/10)*lid_f_b_overlap;
+lid_f_b_holes_x = lid_f_b_width + (5/10)*lid_f_b_overlap;
-lid_f_b_holes_y = lid_f_b_height + (6/10)*lid_f_b_overlap;
+lid_f_b_holes_y = lid_f_b_height + (5/10)*lid_f_b_overlap;
 
-lid_t_b_holes_x = lid_t_b_width + (6/10)*lid_t_b_overlap;
+lid_t_b_holes_x = lid_t_b_width + (5/10)*lid_t_b_overlap;
-lid_t_b_holes_y = lid_t_b_height + (6/10)*lid_t_b_overlap;
+lid_t_b_holes_y = lid_t_b_height + (5/10)*lid_t_b_overlap;
+
+motherboard_mounting_x = motherboard_width - 5;
+motherboard_mounting_y = motherboard_height -5;
+motherboard_mounting_d = 6;
+motherboard_mounting_h = 6;
 
 // O-rings
 oring_channel_depth = 1.2;

cad/mechanics_rev3/lid_f_b.scad

@@ -0,0 +1,74 @@
+/////////////////////////////////////////////////////////////////////////////////
+// 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)
+{
+/////////////////////////////////////////////////////////////////////////
+// Vars
+/////////////////////////////////////////////////////////////////////////
+
+
+/////////////////////////////////////////////////////////////////////////
+// Action
+/////////////////////////////////////////////////////////////////////////
+translate([0, 0, -lids_depth/2])
+rotate([180, 0, 0])
+difference()
+{
+	// Main body for the lid
+	union()
+	{
+		// Logo 
+		// Can be turned off by setting logo to 0
+		translate([-47.5, 15, -lids_depth/2 + 0.01])
+		rotate([180, 0, 0])
+		linear_extrude(height = logo*1)
+		scale(0.95)
+		import("logo.dxf");
+		// 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, 0, (housing_thickness - lids_depth/2 + motherboard_mounting_h/2 - 0.01)])
+		screw_holes(motherboard_mounting_x, motherboard_mounting_y, motherboard_mounting_d, 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, 0, (housing_thickness - lids_depth/2 + motherboard_mounting_h/2 - 0.01)])
+                screw_holes(motherboard_mounting_x, motherboard_mounting_y, drill_thread_dia_m3, motherboard_mounting_h + 1); 
+	}
+}
+}

cad/mechanics_rev3/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_rev3/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_rev3/main.scad

@@ -17,9 +17,59 @@ use <dimensions.scad>
 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 = 1;
+
 ////////////////////////////////////////////////////////////////////////////////
 // Action
 /////////////////////////////////////////////////////////////////////////////////
 
 color(myColor1)
+{
+// Lid left
+translate([housing_outside_width/2 + close*20, 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);
+
+// Lid back
+translate([0, +housing_outside_depth/2 + close*20, 0])
+rotate([-90, 180, 0])
+lid_f_b(0);
+
+// Lid top 
+translate([0, 0, housing_outside_height/2 + close*20])
+lid_t_b();
+
+// Lid bottom
+translate([0, 0, -housing_outside_height/2 - close*20])
+rotate([180, 0, 0])
+lid_t_b();
+}
+
+color(myColor1, 0.8)
 box();
+

cad/mechanics_rev3/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);
+		}
+}
+
+}