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// Test support frame for proto boards |
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// Ed Nisley KE4ZNU – Jan 2017 |
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// June 2017 – Add side-mount bracket, inserts into bottom |
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// 2017-11 – Selectable board sizes, chassis mounting holes |
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/* [Options] */ |
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PCBSelect = "ArdUno"; // ["20×80","40×60","30×70","50×70","70×90","80×120","ArdDuemil","ArdMega","ArdPro","ArdUno","ProtoneerCNC"] |
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Layout = "Frame"; // [Frame, Bracket] |
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ClampFlange = true; // external flange |
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Mounts = true; // frame to chassis screw holes |
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Channel = false; // wiring channel cutout |
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WasherRecess = false; // cutout around screw head |
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/* [Extrusion parameters] */ |
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ThreadThick = 0.25; // [0.15, 0.20, 0.25] |
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ThreadWidth = 0.40; |
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function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit); |
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/* [Hidden] */ |
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Protrusion = 0.1; |
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HoleWindage = 0.2; |
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inch = 25.4; |
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Tap4_40 = 0.089 * inch; |
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Clear4_40 = 0.110 * inch; |
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Head4_40 = 0.211 * inch; |
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Head4_40Thick = 0.065 * inch; |
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Nut4_40Dia = 0.228 * inch; |
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Nut4_40Thick = 0.086 * inch; |
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Washer4_40OD = 0.270 * inch; |
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Washer4_40ID = 0.123 * inch; |
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Tap6_32 = 0.106 * inch; |
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Clear6_32 = 0.166 * inch; |
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Head6_32 = 0.251 * inch; |
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Head6_32Thick = 0.097 * inch; |
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Nut6_32Dia = 0.312 * inch; |
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Nut6_32Thick = 0.109 * inch; |
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Washer6_32OD = 0.361 * inch; |
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Washer6_32ID = 0.156 * inch; |
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ID = 0; |
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OD = 1; |
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LENGTH = 2; |
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//- PCB sizes |
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// the list must contain all the selection names as above |
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//* [Hidden] */ |
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PCB_NAME = 0; |
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PCB_DIMENSION = 1; |
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PCBSizes = [ |
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["40×60",[40,60,1.6]], |
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["30×70",[30,70,1.6]], |
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["50×70",[50,70,1.6]], |
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["20×80",[20,80,1.6]], |
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["70×90",[70,90,1.6]], |
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["80×120",[80,120,1.6]], |
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["ArdDuemil",[69,84,1.6]], |
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["ArdMega",[102,53.5,1.6]], |
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["ArdPro",[53,53.5,1.6]], |
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["ArdUno",[69,53.1,1.6]], |
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["ProtoneerCNC",[69,53.1,1.6]], |
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]; |
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PCBIndex = search([PCBSelect],PCBSizes)[0]; |
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PCBSize = PCBSizes[PCBIndex][PCB_DIMENSION]; |
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//echo(str("PCB Size Table: ",PCBSizes)); |
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//echo(str("PCB Select: ",PCBSelect)); |
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//echo(str("PCB Index: ",PCBIndex)); |
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echo(str("PCB Size: ",PCBSize)); |
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/* [Sizes] */ |
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WallThick = 4.0; // basic frame structure |
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FrameHeight = 10.0; |
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/* [Hidden] */ |
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Insert = [3.9,4.6,5.8]; |
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PCBShelf = 1.0; // width of support rim under PCB |
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Clearance = 1*[ThreadWidth,ThreadWidth,0]; // around PCB on all sides |
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ScrewOffset = ThreadWidth + Insert[OD]/2; // beyond PCB edges |
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echo(str("Screw offset: ",ScrewOffset)); |
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/* [Screw Selectors] */ |
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// ij selectors for PCB clamp screw holes: -1/0/1 = left/center/right , bottom/center/top |
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ScrewSites = [ |
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// [-1,1],[1,1],[1,-1],[-1,-1], // corners |
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// [-1,0],[1,0],[0,1],[0,-1] // middles |
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[-1,1],[-1,-1],[1,0] // Arduinos |
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]; |
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// ij selectors for frame mounting holes |
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MountSites = [ |
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[0,-1],[0,1], |
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// [-1,0],[1,0] |
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]; |
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function ScrewAngle(ij) = (ij[0]*ij[1]) ? ij[0]*ij[1]*15 : ((!ij[1]) ? 30 : 0); // align screw sides |
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OAHeight = FrameHeight + Clearance[2] + PCBSize[2]; // total frame height |
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echo(str("OAH: ",OAHeight)); |
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BossOD = 2*Washer4_40OD; // make bosses oversized for washers |
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FlangeExtension = 4.0 + Washer6_32OD/2 – WallThick; // beyond frame structure |
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FlangeThick = IntegerMultiple(2.0,ThreadThick); // plate under frame |
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Flange = PCBSize |
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+ 2*[ScrewOffset,ScrewOffset,0] |
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+ [BossOD,BossOD,0] |
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+ [2*FlangeExtension,2*FlangeExtension,(FlangeThick – PCBSize[2])] |
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; |
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FlangeRadius = BossOD/4; |
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echo(str("Flange: ",Flange)); |
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NumSides = 4*5; |
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WireChannel = [Flange[0],15.0,3.0 + PCBSize[2]]; // ad-hoc wiring cutout |
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WireChannelOffset = [ |
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Flange[0]/2,0,(FrameHeight + PCBSize[2] – WireChannel[2]/2) |
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]; |
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//- Adjust hole diameter to make the size come out right |
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module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes |
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Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2); |
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FiiDia = Dia / cos(180/Sides); |
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cylinder(r=(FiiDia + HoleWindage)/2,h=Height,$fn=Sides); |
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} |
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//- Build things |
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if (Layout == "Frame") |
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difference() { |
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union() { // body block |
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translate([0,0,OAHeight/2]) |
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cube(PCBSize + Clearance + [2*WallThick,2*WallThick,FrameHeight],center=true); |
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for (ij = ScrewSites) // screw bosses |
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if (ij[0] != 0 || ij[1] != 0) |
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translate([ij[0]*(PCBSize[0]/2 + ScrewOffset), |
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ij[1]*(PCBSize[1]/2 + ScrewOffset), |
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0]) |
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cylinder(d=BossOD,h=OAHeight,$fn=NumSides); |
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if (ClampFlange) // flange for work holder & mounting screw holes |
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linear_extrude(height=Flange[2]) |
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hull() |
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for (i=[-1,1], j=[-1,1]) { |
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translate([i*(Flange[0]/2 – FlangeRadius),j*(Flange[1]/2 – FlangeRadius)]) |
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circle(r=FlangeRadius,$fn=NumSides); // convenient rounding size |
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} |
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} |
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for (ij = ScrewSites) { // screw position indeies |
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if (ij[0] != 0 || ij[1] != 0) { |
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translate([ij[0]*(PCBSize[0]/2 + ScrewOffset), |
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ij[1]*(PCBSize[1]/2 + ScrewOffset), |
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-Protrusion]) |
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rotate(ScrewAngle(ij)) |
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PolyCyl(Clear4_40,(OAHeight + 2*Protrusion),6); // screw clearance holes |
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translate([ij[0]*(PCBSize[0]/2 + ScrewOffset), |
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ij[1]*(PCBSize[1]/2 + ScrewOffset), |
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-Protrusion]) |
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rotate(ScrewAngle(ij)) |
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PolyCyl(Insert[OD],OAHeight – PCBSize[2] – 3*ThreadThick + Protrusion,6); // inserts |
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if (WasherRecess) |
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translate([ij[0]*(PCBSize[0]/2 + ScrewOffset), |
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ij[1]*(PCBSize[1]/2 + ScrewOffset), |
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OAHeight – PCBSize[2]]) |
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PolyCyl(1.2*Washer4_40OD,(PCBSize[2] + Protrusion),NumSides); // optional washer recess |
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} |
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} |
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if (Mounts) |
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for (ij = MountSites) |
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translate([ij[0]*(Flange[0]/2 – Washer6_32OD/2),ij[1]*(Flange[1]/2 – Washer6_32OD/2),-Protrusion]) |
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rotate(ScrewAngle(ij)) |
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PolyCyl(Clear6_32,(Flange[2] + 2*Protrusion),6); |
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translate([0,0,OAHeight/2]) // through hole below PCB |
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cube(PCBSize – 2*[PCBShelf,PCBShelf,0] + [0,0,2*OAHeight],center=true); |
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translate([0,0,(OAHeight – (PCBSize[2] + Clearance[2])/2 + Protrusion/2)]) // PCB pocket on top |
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cube(PCBSize + Clearance + [0,0,Protrusion],center=true); |
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if (Channel) |
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translate(WireChannelOffset) // opening for wires from bottom side |
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cube(WireChannel + [0,0,Protrusion],center=true); |
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} |
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// Add-on bracket to hold smaller PCB upright at edge |
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PCB2Insert = [3.0,4.9,4.1]; |
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PCB2OC = 45.0; |
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if (Layout == "Bracket") |
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difference() { |
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hull() // frame body block |
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for (i=[-1,1]) // bosses around screws |
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translate([i*(PCBSize[0]/2 + ScrewOffset),0,0]) |
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cylinder(r=Washer4_40OD,h=OAHeight,$fn=NumSides); |
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for (i=[-1,1]) // frame screw holes |
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translate([i*(PCBSize[0]/2 + ScrewOffset),0,-Protrusion]) |
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rotate(i*180/(2*6)) |
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PolyCyl(Clear4_40,(OAHeight + 2*Protrusion),6); |
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for (i=[-1,1]) // PCB insert holes |
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translate([i*PCB2OC/2,(Washer4_40OD + Protrusion),OAHeight/2]) |
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rotate([90,0,0]) |
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cylinder(d=PCB2Insert[OD],h=2*(Washer4_40OD + Protrusion),$fn=6); |
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} |
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The Smell of Molten Projects in the Morning 