sensibly rename lite case files

Author: gluap

src/LiteCase/buttonmount_cherry.scad renamed to src/LiteCase/HandlebarButton.scad

@@ -1,5 +1,18 @@
+use <../../lib/Round-Anything/polyround.scad>
+
+use <../Mounting/StandardMountAdapter.scad>
+
+
+corner_x = 24;
+boardcorner_x = 17;
+boardcorner_y = 23;
+square_x = 5;
+lite_l = 45;
+lite_w = 80 - 18;
+
+
 // 0,0,0: Mitte des Lite-PCB, auf der Seite mit dem OpenBIkeSensor logo, x: Richtung USB-Port, Z: Richtung Ultraschallsensoren
-$fn = 100;
+$fn = 120;
 
 Lite_PCB_x = 44;
 Lite_PCB_y = 29.2;
@@ -8,54 +21,183 @@ Lite_PCB_Dimensions = [Lite_PCB_x, Lite_PCB_y, Lite_PCB_z];
 
 Lite_ESP_socket_x = 38;
 Lite_ESP_socket_y = 2.54;
-Lite_ESP_socket_z = 9;
+Lite_ESP_socket_z = 9 + Lite_PCB_z + 1.8;
 Lite_ESP_socket_dimensions = [Lite_ESP_socket_x, Lite_ESP_socket_y, Lite_ESP_socket_z];
 
-Lite_transducer_position = [23.8, 0, 20.1];
-Lite_transducer_variance = 0.8;
+Lite_transducer_position = [23.8, 0, 20.6];
+Lite_transducer_variance = 1.2;
 Lite_transducer_diameter = 16 + Lite_transducer_variance;
 Lite_transducer_diameter_small = 12.5 + Lite_transducer_variance;
 
-
-
 Lite_ESP_position_x = 0;
 Lite_ESP_position_y = 0;
-Lite_ESP_position_z = - 15.2;
+Lite_ESP_position_z = - 16.2;
+
+Lite_ESP_dimensions = [53, 29, 4.8];
 
-Lite_USB_position_x = 0;
+Lite_USB_position_x = 55;
 Lite_USB_position_y = 0;
-Lite_USB_position_z = 0;
+Lite_USB_position_z = - 14.5;
+
+Lite_screwmount_top = 4;
+Lite_screwmount_bottom = 6;
+Lite_screwmount_height = Lite_screwmount_top + Lite_screwmount_bottom;
+
+Lite_USB = [Lite_USB_position_x, Lite_USB_position_y, Lite_USB_position_z];
 
 Lite_ESP_position = [Lite_ESP_position_x, Lite_ESP_position_y, Lite_ESP_position_z];
-module ESP() color("black")translate([25, 0, 0])cube([51.5, 28.5, 4.5], center = true);
-module Ultrasonic(i) {
-  color("blue") translate([23.9, i * 7.3, 17.99])cube([41.5, 1.4, 36], center = true);
-  #translate([23.9, 0, 16.99])cube([41.5, 19.5, 35], center = true);
 
-  translate(Lite_transducer_position - [0, 8 * i, 100])rotate([i * 90, 0, 0])cylinder(d2 = Lite_transducer_diameter, h = 8.5);
+sensor_x = - Lite_transducer_position[2] + .5;
+sensor_y = Lite_transducer_position[0];
+
+function angle_three_points_2d(pa, pb, pc) = asin(cross(pb - pa, pb - pc) / (norm(pb - pa) * norm(pb - pc)));
+
+module rounded_cube(x, y, z, r, r2, center = true) {
+  t = center ? - [x / 2, y / 2, z / 2]: [0, 0, 0];
+  translate(t)polyRoundExtrude([[0, 0, max(r, r2)], [0, y, max(r, r2)], [x, y, max(r, r2)], [x, 0, max(r, r2)]], z, r, r2);
+}
 
+module SidePolygon() {
+  corners = [
+      [square_x, - lite_w / 2, 9],
+    // chose radius so the corners match
+      [- corner_x, - 0, (corner_x - boardcorner_x) / (1 / sin(angle_three_points_2d([0, 0], [- corner_x, - 0], [square_x, lite_w / 2])) - 1)],
+      [square_x, lite_w / 2, 9],
+      [lite_l, lite_w / 2, 5],
+      [lite_l, - lite_w / 2, 5]
+    ];
+  translate([sensor_x, sensor_y])polygon(polyRound(corners, fn = 150));
+}
 
-  #translate(Lite_transducer_position - [0, 8 * i, 0])rotate([i * 90, 0, 0])cylinder(d = Lite_transducer_diameter_small, h = 40);
+module MidPolygon() {
+  corners = [[square_x, - lite_w / 2, 5], [- boardcorner_x, - boardcorner_y, 5], [- boardcorner_x, boardcorner_y, 5], [square_x, lite_w / 2, 5], [lite_l, lite_w / 2, 5], [lite_l, -
+  lite_w / 2, 5]];
+  translate([sensor_x, sensor_y]) polygon(polyRound(corners));
+}
+
+module LidCutter() {
+  translate([40, 0, Lite_ESP_position_z + 0.8])cube([120, 90, 0.1], center = true);
+}
+
+module Box() {
+  hull() {
+    for (i = [- 1, 1]) {
+      translate([0, 0, i * 9 - (i + 1) / 2])linear_extrude(1)MidPolygon();
+      translate([0, 0, i * 18 - (i + 1) / 2])linear_extrude(1)SidePolygon();
+    }
+  }
+}
+
+module ESP() {
+  difference() {
+    color("black")translate([24.6, 0, 0.2])cube(Lite_ESP_dimensions, center = true);
+    for (i = [- 1, 1])for (j = [- 1, 1]) {
+      translate([i * 24.6 + 22.6, j * 12.5 - 2.5, - 4.7])cube([4, 5, 5]);
+    }
+  }
+}
+
+module Ultrasonic(i, onlyboards = false, h = 30) {
+  translate([0, 0, - h / 2 + 34 / 2]) {
+    color("blue") translate([23.9, i * 7.3, 17.99])cube([42.5, 1.4, h], center = true);
+    hull() {
+      translate([Lite_transducer_position[0], 0, 14.99])cube([42.5, 21.5, h], center = true);
+      translate([Lite_transducer_position[0], 0, 16.99])cube([42.5, 16.5, h], center = true);
+      translate([Lite_transducer_position[0], 0, 10.99])cube([49.5, 18.5, h], center = true);
+    }
+    intersection() {
+      translate([0, 0, + h / 2 - 34 / 2])hull() {
+        translate(Lite_transducer_position - [0, 8 * i, 100])rotate([i * 90, 0, 0])cylinder(d1 = Lite_transducer_diameter + 12, d2 = Lite_transducer_diameter, h = 8.5);
+        translate(Lite_transducer_position - [0, 8 * i, 0])rotate([i * 90, 0, 0])cylinder(d1 = Lite_transducer_diameter + 12, d2 = Lite_transducer_diameter, h = 8.5);
+      }
+      color("blue") translate([23.9, i * 7, 17.99])cube([41.5, 60, h + 14], center = true);
+
+    }
+  }
+  translate(Lite_transducer_position - [0, 8 * i, 0])rotate([i * 90, 0, 0])cylinder(d = Lite_transducer_diameter_small, h = 40);
+}
+
+module USB_hole() {
+  translate(Lite_USB) {
+    translate([0, 0, - 2.25])
+      rounded_cube(45, 12.5, 8, 0, 0, center = true);
+    rounded_cube(45, 5, 12.5, 2.5, 0, center = true);
+  }
+}
+
+module Screwbump(size = 6, hole_diameter = 3.8, height = 6, bottom = true, toppart = 2.1, insert = 4) {
+  outer_polygon = [[size, 0, 0], [- size, 0, 0], [- size, size, size], [0, 3 * size, size], [size, size, size]];
+  difference() {
+    hull() {
+      translate([0, 0, 0])polyRoundExtrude(outer_polygon, 1, 0, 0);
+
+      translate([0, 0, height - 1])polyRoundExtrude(outer_polygon, 1, 0, 0);
+      if (bottom)translate([0, - 0.01, 1.3 * height])rotate([90, 0, 0])cylinder(d = size, h = 0.1);
+    }
+    translate([0, size, toppart])cylinder(d = insert, h = height - toppart);
+    translate([0, size, - .01])cylinder(d = hole_diameter, h = toppart);
+  }
 }
 
 
 module LiteElectronics(onlyboards = false) {
   // the rendered model from stls (not closed, only for preview)
-  translate([15, 0, 0])rotate([180, 00, 00])rotate([0, 0, 90])import("../../lib/OpenBikeSensor-Lite-PCB-0.1.2.stl");
+  //if (!$preview) translate([15, 0, 0])rotate([180, 00, 00])rotate([0, 0, 90])import("../../lib/OpenBikeSensor-Lite-PCB-0.1.2.stl");
 
   // board cube
   color("green")translate(- [0, Lite_PCB_y / 2, Lite_PCB_z])cube(Lite_PCB_Dimensions, center = false);
+  color("green")translate(- [0.2, Lite_PCB_y / 2 + 0.2, Lite_PCB_z + 14])cube(Lite_PCB_Dimensions + [0.4, 0.4, 14], center = false);
+
 
   // sockets for ESP
-  for (i = [- 1, 1]) color("darkgrey")translate([3.5, i * Lite_PCB_y / 2 - (i + 1) * Lite_ESP_socket_y / 2 - i * 0.45, - Lite_ESP_socket_dimensions[2] - Lite_PCB_Dimensions[2]])
+  for (i = [- 1, 1]) color("darkgrey")translate([3.5, i * Lite_PCB_y / 2 - (i + 1) * Lite_ESP_socket_y / 2 - i * 0.45, - Lite_ESP_socket_dimensions[2] + 1.8])
     cube(Lite_ESP_socket_dimensions);
 
-  #translate(Lite_ESP_position)ESP();
-
-  for (i = [- 1, 1])Ultrasonic(i);
+  translate(Lite_ESP_position)ESP();
+
+  // printability chamfers above ESP
+  hull() {
+    translate([24.6, 0, Lite_ESP_position_z - 2])cube([45, 29, 1], center = true);
+    translate([24.6, 0, Lite_ESP_position_z - 4.3])cube([45, 18.5, 5.01], center = true);
+  }
+  translate([0, 0, 0])hull() {
+    translate([24.6, 0, Lite_ESP_position_z - 2])cube([Lite_ESP_dimensions[0], 20, 0.5], center = true);
+    translate([25., 0, Lite_ESP_position_z - 4.3])cube([45, 18.5, 0.1], center = true);
+  }
+  for (i = [- 1, 1])Ultrasonic(i, onlyboards = onlyboards, h = 50);
+  USB_hole();
 }
-LiteElectronics();
+
 difference() {
-  //translate([12.5, - 18, 9])cube([23, 36, 28]);
-  for (i = [- 1, 1])Ultrasonic(i);
-}
+  union() {
+    translate([- 7, 0, Lite_ESP_position_z + 0.8 + 0.05 - Lite_screwmount_top])rotate([0, 0, 90])
+      Screwbump(size = 4, hole_diameter = 3.2, height = Lite_screwmount_height, bottom = true, toppart = Lite_screwmount_top);
+    translate([lite_w - 7.3, 12, Lite_ESP_position_z + 0.8 + 0.05 - Lite_screwmount_top])rotate([0, 0, - 90])
+      Screwbump(size = 4, hole_diameter = 3.2, height = Lite_screwmount_height, bottom = true, toppart = Lite_screwmount_top);
+    translate([lite_w - 7.3, - 12, Lite_ESP_position_z + 0.8 + 0.05 - Lite_screwmount_top])rotate([0, 0, - 90])
+      Screwbump(size = 4, hole_diameter = 3.2, height = Lite_screwmount_height, bottom = true, toppart = Lite_screwmount_top);
+    translate([23.8, - 3.5, - 17.9])rotate([180, 0, 90])StandardMountAdapter(screwholes = false, channels = false, twoholes = false);
+    difference() {
+      union() {
+        rotate([90, 90, 0])Box();
+        difference() {
+          translate(Lite_USB + [0, 0, - 3.5 - 1.6 + 1]) {
+            rounded_cube(28, 16.5, 6.5, 0, 1.5, center = true);
+
+            difference() {
+              #rounded_cube(30, 15, 6.5, 0, 1.5, center = true);
+              translate([8, - 20, - 5])cube([4, 60, 20]);
+            }
+          }
+          translate(Lite_USB + [10, 0, 0])cube([4, 20, 12.5], center = true);
+        }
+      }
+      hull()    translate([23.8, - 3.5, - 18])rotate([180, 0, 90])StandardMountAdapter(screwholes = false, channels = false);
+
+    }
+  }
+  LiteElectronics();
+  LidCutter();
+}
+
+if ($preview) translate([80, 0, 0])LiteElectronics();