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arprussarpruss
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getting closer
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‎mainbox.scad‎

Lines changed: 118 additions & 59 deletions
Original file line numberDiff line numberDiff line change
@@ -3,38 +3,41 @@ use <tubemesh.scad>;
33
use <certamenbutton.scad>;
44

55
// TODO:
6-
// speaker rails
76
// cut up
8-
// screw wells for screen
97
// screw wells for joining halves
108

11-
includeBoards = false;
9+
includeBoards = true;
1210
megaWidth = 53.34;
1311
megaLength = 101.6;
14-
megaPCBThickness = 1.66;
15-
megaHoles = [ //[ 50.8, 13.97 ],
16-
[ 50.8, 96.52 ]];
12+
megaHoles = [
13+
[ 2.54, 15.24 ],
14+
[ 50.8, 13.97 ],
15+
[ 2.54, 90.17 ],
16+
[ 50.8, 96.52 ]
17+
]; // from Kelly Egan's Arduino library
1718
/* [[x,z,width,height],...] */
19+
megaPCBThickness = 1.66;
1820
megaFrontCutouts = [ [7, megaPCBThickness, 12.23, 10.82],
1921
[ megaWidth-9.04-6.7, megaPCBThickness, 9.04, 11.08 ] ];
2022
cbWidth = 54.9;
2123
cbLength = 99.06; // between edges of RJ-45 breakout board
2224
cbPCBThickness = 1.7;
2325
cbFrontCutouts = [[5.88,5.45,15.15,11.56],[cbWidth-5.58-15.15,5.45,15.15,11.56]];
2426
cbBackCutouts = [[cbWidth-5.58-15.15,5.45,15.15,11.56]];
25-
cbHoles = [[4.04,cbLength-7.5]];
26-
maxPCBThickness = max(megaPCBThickness, cbPCBThickness);
27+
cbHoles = [[4.04,7.5],[cbWidth-4.04,7.5],[4.04,cbLength-7.5],[cbWidth-4.04,cbLength-7.5]];
28+
29+
pcbThickness = max(cbPCBThickness,megaPCBThickness);
30+
2731
mountExtra = 2;
2832

29-
boardDivider = 3;
30-
slideBackbone = 3;
3133
underPCBs = 5;
3234

35+
cutLine = underPCBs + 0.5*( cbFrontCutouts[0][1] + megaPCBThickness + max([for(c=megaFrontCutouts) c[3]]) );
36+
3337
fitTolerance = 0.4;
3438
cutoutTolerance = 1;
35-
bottomSlideWidth = 1.82;
36-
topSlideWidth = 1.75;
3739

40+
boardDivider = 2;
3841
sideWallThickness = 1.25;
3942
bottomThickness = 1.5;
4043
topThickness = 3.2; // match Certamen button
@@ -43,7 +46,7 @@ screenScrewHorizontalSpacing = 74.8;
4346
screenScrewVerticalSpacing = 31.2;
4447
screenWidth = 71.21;
4548
screenHeight = 24.04;
46-
// make sure screendepth fits well
49+
screenDepth = 7;
4750

4851
screenScrewWellDepth = 7.97;
4952
speakerDiameter = 39.2;
@@ -53,9 +56,12 @@ speakerMountThickness = 1.5;
5356
grilleSolidWidth = 2;
5457
grilleHoleWidth = 2.5;
5558

56-
corner = 9;
59+
corner = 9; // corner-boardDivider must allow room for the speaker
5760

58-
boxHeight = speakerDiameter+underPCBs+2+maxPCBThickness+topThickness+bottomThickness;
61+
pcbHolderThickness = 2;
62+
pcbHolderHeight = underPCBs+pcbThickness+2;
63+
64+
boxHeight = speakerDiameter+underPCBs+2+pcbThickness+topThickness+bottomThickness;
5965

6066
nudge = 0.001;
6167
insideWidth = boardDivider+4*fitTolerance+megaWidth+cbWidth;
@@ -72,13 +78,27 @@ modeX = 0.75*insideWidth;
7278
modeY = 0.75*insideLength;
7379

7480
cbX = fitTolerance;
81+
cbY = fitTolerance;
7582
megaX = 3*fitTolerance+cbWidth+boardDivider;
83+
megaY = fitTolerance;
7684
topZ = boxHeight-topThickness-bottomThickness;
7785
speakerDiameter1 = speakerDiameter + 2 * fitTolerance;
7886

87+
screwTolerance = 0.125;
88+
screwHoleSize = 2.6;
89+
screwHoleSize1 = screwHoleSize + 2*screwTolerance;
90+
screwPillarSize = 12;
91+
7992
speakerY = 0.5*insideLength;
8093
speakerX = boxWidth-corner-2*sideWallThickness;
81-
speakerZ = (topZ + maxPCBThickness+underPCBs)/2;
94+
speakerZ = speakerDiameter1/2;
95+
96+
ventHeight=18;
97+
ventWidth=insideWidth*0.75;
98+
ventSpacing=2;
99+
100+
ventX=insideWidth/2;
101+
ventZ=topZ-10;
82102

83103
module cutouts(cutouts, length, extra) {
84104
for (c=cutouts) {
@@ -105,13 +125,13 @@ module contents(visualize=true) {
105125
extraCutout = visualize?0:cutoutTolerance;
106126
color("blue") {
107127
translate( [megaX,fitTolerance,underPCBs] ) cube([megaWidth, megaLength, megaPCBThickness]);
108-
translate([megaX,fitTolerance+nudge-cutoutLength,underPCBs-nudge]) cutouts(megaFrontCutouts, cutoutLength,extraCutout);
128+
translate([megaX,fitTolerance-cutoutLength,underPCBs]) cutouts(megaFrontCutouts, cutoutLength,extraCutout);
109129
}
110130
color("red") {
111131
translate( [cbX,fitTolerance,underPCBs])
112132
cube([cbWidth, cbLength, cbPCBThickness]);
113-
translate([cbX,fitTolerance+nudge-cutoutLength,underPCBs-nudge]) cutouts(cbFrontCutouts, cutoutLength,extraCutout);
114-
translate([cbX,fitTolerance+cbLength-nudge,underPCBs-nudge]) cutouts(cbBackCutouts, cutoutLength,extraCutout);
133+
translate([cbX,fitTolerance-cutoutLength,underPCBs]) cutouts(cbFrontCutouts, cutoutLength,extraCutout);
134+
translate([cbX,fitTolerance+cbLength,underPCBs]) cutouts(cbBackCutouts, cutoutLength,extraCutout);
115135
}
116136
color([0,.4,0]) {
117137
translate([screenX-screenHeight/2-extraCutout,screenY-screenWidth/2-extraCutout,topZ-1]) cube([screenHeight+2*extraCutout,screenWidth+2*extraCutout,cutoutLength]);
@@ -125,67 +145,106 @@ module contents(visualize=true) {
125145
}
126146
}
127147

128-
mountHeight = underPCBs+maxPCBThickness+topSlideWidth+mountExtra;
129-
130148
module boardMounts() {
131-
module diagonalSlideLeft() {
132-
section1 = [ [0,0,0], [topSlideWidth,0,topSlideWidth], [topSlideWidth,0,topSlideWidth+mountExtra],[0,0,topSlideWidth+mountExtra] ];
133-
section2 = [for (v=section1) v+[0,insideLength,0]];
134-
135-
leftPointsAndFaces =
136-
pointsAndFaces([ section1, section2]);
137-
polyhedron(points=leftPointsAndFaces[0], faces=leftPointsAndFaces[1]);
138-
}
139-
140-
module diagonalSlideRight() {
141-
mirror([1,0,0]) diagonalSlideLeft();
142-
}
143-
144-
render(convexity=2)
149+
render(convexity=2) {
145150
intersection() {
146151
union() {
147-
translate([nudge-slideBackbone,0,0])
148-
cube([slideBackbone,insideLength,mountHeight]);
149-
translate([insideWidth-nudge,0,0])
150-
cube([slideBackbone,insideLength,mountHeight]);
151-
152-
cube([bottomSlideWidth, insideLength, underPCBs]);
153-
translate([2*fitTolerance+cbWidth-bottomSlideWidth,0,0])
154-
cube([bottomSlideWidth*2+boardDivider, insideLength, underPCBs]);
155-
translate([insideWidth-bottomSlideWidth, 0,0])
156-
cube([bottomSlideWidth+nudge, insideLength, underPCBs]);
157-
translate([2*fitTolerance+cbWidth-nudge,0,0])
158-
cube([boardDivider+2*nudge,insideLength,mountHeight]);
159-
translate([0,0,underPCBs+cbPCBThickness]) diagonalSlideLeft();
160-
translate([2*fitTolerance+cbWidth,0,underPCBs+cbPCBThickness]) diagonalSlideRight();
161-
translate([megaX-fitTolerance,0,underPCBs+megaPCBThickness]) diagonalSlideLeft();
162-
translate([megaX+fitTolerance+megaWidth,0,underPCBs+megaPCBThickness]) diagonalSlideRight();
163-
translate([0,insideLength-(megaLength-cbLength),0]) cube([2*fitTolerance+cbWidth, megaLength-cbLength, underPCBs+cbPCBThickness+topSlideWidth]);
164-
}
165-
box(inset=sideWallThickness+fitTolerance);
152+
translate([cbX-fitTolerance-pcbHolderThickness,0,0]) cube([pcbHolderThickness,insideLength,pcbHolderHeight]);
153+
translate([cbX+cbWidth+fitTolerance,0,0]) cube([pcbHolderThickness,insideLength,pcbHolderHeight]);
154+
translate([megaX+megaWidth+fitTolerance,0,0]) cube([pcbHolderThickness,insideLength,pcbHolderHeight]);
155+
translate([0,insideLength-(megaLength-cbLength),0]) cube([2*fitTolerance+cbWidth, megaLength-cbLength, pcbHolderHeight]);
156+
}
157+
box();
158+
}
159+
pcbScrews(megaX,megaY,megaHoles);
160+
pcbScrews(cbX,cbY,cbHoles);
161+
}
162+
}
163+
164+
module screwPillar(height, taper=true) {
165+
difference() {
166+
cylinder(d1=screwPillarSize, d2=taper ? screwHoleSize1+4 : screwPillarSize, h=height, $fn=16);
167+
cylinder(d=screwHoleSize1, h=height+nudge, $fn=16);
168+
}
169+
}
170+
171+
module pcbScrews(x,y,positions) {
172+
for(pos=positions) {
173+
translate([x+pos[0],y+pos[1],0]) screwPillar(underPCBs, taper=true);
166174
}
167175
}
168176

169177
module box(height=boxHeight,inset=0) {
170178
linear_extrude(height=height) translate([-corner-sideWallThickness+inset,-sideWallThickness+inset]) roundedSquare([boxWidth-2*inset, boxLength-2*inset], radius=corner-inset);
171179
}
172180

181+
module screenScrew(holeOnly=false) {
182+
pillarSize = screwHoleSize1+4;
183+
render(convexity=2)
184+
translate([0,0,topZ-(screenDepth-topThickness)-nudge])
185+
difference() {
186+
if (!holeOnly) cylinder(d=pillarSize, h=screenDepth, $fn=16);
187+
translate([0,0,-nudge]) cylinder(d=screwHoleSize1, h=screenDepth-1, $fn=16);
188+
}
189+
}
190+
191+
module screenScrews(holeOnly=false) {
192+
dx = screenScrewVerticalSpacing / 2;
193+
dy = screenScrewHorizontalSpacing / 2;
194+
195+
translate([screenX-dx,screenY-dy]) screenScrew(holeOnly=holeOnly);
196+
translate([screenX+dx,screenY-dy]) screenScrew(holeOnly=holeOnly);
197+
translate([screenX-dx,screenY+dy]) screenScrew(holeOnly=holeOnly);
198+
translate([screenX+dx,screenY+dy]) screenScrew(holeOnly=holeOnly);
199+
}
200+
173201
module shell() {
174202
render(convexity=6)
175203
difference() {
176-
translate([0,0,-bottomThickness]) box();
204+
translate([0,0,-bottomThickness+nudge]) box();
177205
box(height=boxHeight-bottomThickness-topThickness,inset=sideWallThickness);
178206
contents(visualize=false);
207+
screenScrews(holeOnly=true);
208+
translate([0,-sideWallThickness-nudge,0]) vent();
209+
translate([0,insideLength-nudge,0]) vent();
179210
}
180211
}
181212

182-
module bottom() {
213+
module speakerMount() {
214+
height = nudge+topZ-speakerZ+10;
215+
module strip() {
216+
cube([speakerMountXStickout+speakerMountThickness,speakerMountThickness,height]);
217+
translate([speakerMountXStickout,0,0])
218+
cube([speakerMountThickness,speakerMountYStickout+speakerMountThickness,height]);
219+
}
220+
translate([speakerX+nudge,speakerY,0])
221+
rotate([0,0,180]) {
222+
translate([0,0,topZ-height]) {
223+
translate([0,-speakerDiameter1/2-speakerMountThickness,0]) strip();
224+
translate([0,speakerDiameter1/2+speakerMountThickness,0]) mirror(v=[0,1,0]) strip();
225+
}
226+
topHolderHeight = (topZ-speakerZ)-speakerDiameter1/2;
227+
translate([0,-5, topZ-topHolderHeight])
228+
cube([speakerMountXStickout, 10, topHolderHeight+nudge]);
229+
}
230+
}
231+
232+
module vent() {
233+
translate([ventX-ventWidth/2,-nudge,ventZ-ventHeight/2])
234+
for (x=[0:2*ventSpacing:ventWidth]) {
235+
translate([x,0,0])
236+
cube([ventSpacing,2*nudge+sideWallThickness,ventHeight]);
237+
}
238+
}
239+
240+
241+
module inside() {
183242
boardMounts();
243+
screenScrews();
184244
%shell();
185245
if (includeBoards) contents(visualize=true);
186246
}
187247

188248
%shell();
189-
bottom();
190-
191-
// todo: screws; front empty, back full
249+
inside();
250+
speakerMount();

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