Having a few TCRT5000 proximity sensors lying around, I used one for the Color Mixer so folks could just wave a finger to flip the LED colors, rather than pound relentlessly on the top plate:
The stem fits into a slot made with a 3/8 inch end mill:
You move the cutter by the length of the sensor (10.0 mm will work) to make the slot. In practical terms, drill a hole at the midpoint, insert the cutter, then move ±5.0 mm from the center:
A bead of epoxy around the stem on the bottom of the panel should hold it in place forevermore.
The rectangular inner hole came out a tight push fit for the TCRT5000 sensor, so I didn’t bother gluing it in place and, surprisingly, it survived the day unscathed!
The OpenSCAD source code as a GitHub Gist:
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| // TCRT5000 Proximity switch sensor mount | |
| // Ed Nisley KE4ZNU - October 2016 | |
| Layout = "Build"; // Show Build | |
| //- Extrusion parameters must match reality! | |
| ThreadThick = 0.25; | |
| ThreadWidth = 0.40; | |
| HoleWindage = 0.2; | |
| Protrusion = 0.1; // make holes end cleanly | |
| inch = 25.4; | |
| function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit); | |
| //---------------------- | |
| // Dimensions | |
| Sensor = [5.9,10.0,7.0]; | |
| SensorHoleCutter = 3/8 * inch; | |
| echo(str("Cutter dia: ",SensorHoleCutter," mm")); | |
| echo(str("Cutter motion: ",Sensor[1]," mm")); | |
| PanelThick = 5.0; | |
| StemLength = PanelThick + 6*ThreadThick; | |
| FlangeThick = 3 * ThreadThick; | |
| //---------------------- | |
| // Flange model | |
| module ProxFlange() { | |
| difference() { | |
| union() { | |
| linear_extrude(height=FlangeThick) | |
| hull() | |
| for (i=[-1,1], j=[-1,1]) | |
| translate([i*Sensor[0],j*Sensor[1]]) | |
| circle(r=Sensor[0]/2,$fn=8*4); | |
| translate([0,0,-StemLength]) | |
| linear_extrude(height=StemLength) | |
| hull() | |
| for (j=[-1,1]) | |
| translate([0,j*Sensor[1]/2]) | |
| circle(d=SensorHoleCutter,$fn=8*4); | |
| } | |
| translate([0,0,-Protrusion]) | |
| cube(Sensor + [HoleWindage,HoleWindage,2*(PanelThick + Protrusion)],center=true); | |
| } | |
| } | |
| //---------------------- | |
| // Build it | |
| if (Layout == "Show") | |
| ProxFlange(); | |
| if (Layout == "Build") | |
| translate([0,0,FlangeThick]) | |
| rotate([180,0,0]) | |
| ProxFlange(); | |
The Smell of Molten Projects in the Morning 