The Smell of Molten Projects in the Morning
Ed Nisley's Blog: Shop notes, electronics, firmware, machinery, 3D printing, laser cuttery, and curiosities. Contents: 100% human thinking, 0% AI slop.
Mechanical widgetry
The folks at the Long Island LUG asked me to give my DIY 3D Printing & the Makerbot Thing-O-Matic presentation, which will happen 11 October at 8 pm. Details & directions at lilug.org.
Should you happen to be in the area that evening, drop in and pick up a tchotchke!
That little Lenovo Q150 doesn’t include an optical drive and, mostly, I don’t need one, but sometimes it’s handy to boot from a CD. I picked up a used DVD burner that also fits my Dell E1405 laptop (should I need a spare) and a tiny USB laptop drive case from the usual eBay sources for a grand total of $17 delivered.
The drive had a mounting bracket on the back that obviously had to come off, because the bracket screws snuggled right in among the USB adapter electronics:
In fact, that flat tab with a hole would have clunked up against the back of the case and prevented it from sliding all the way in, but the screws also foiled Plan B: flip the bracket around so the tab goes under the drive where it couldn’t get lost if I needed it again.
So now the bracket & screws live in a little bag in the Box o’ USB Stuff.
The DVD drive works fine with just a single USB cable, although the case came with a power-only USB cable, so the latter also lives in the bag with the bracket. Maybe I’ll need it in the unlikely event I actually burn a DVD in that drive?
While cranking out some Tux Cookie Cutters, I varied the Reversal settings to see what effect they’d have on a single object with a smooth perimeter. I’d previously settled on 25 rpm for 125 ms with no early action, so this series tests three different times with early action turned on.
Position 1, where the perimeter threads join. Yes, I have Jitter activated and cranked up to something like 10, but it obviously has no effect on this object:
Position 2, where the nozzle enters from the outside to start a new thread. The snot hanging off the end makes for an ugly wad:
Position 3, another nozzle entry point:
Early Reversal action simply doesn’t work well. With retraction times sufficient to prevent drooling, stopping the extruder before the end of the thread produces unacceptable gaps and starting it before reaching the thread produces hanging snots when the nozzle passes over an existing wall.
Shorter retraction times produce strands all over the object, because the extruder still contains pressurized plastic and drools.
I’d previously discovered, although I didn’t write up, that unbalanced Reversal times didn’t provide any benefit: inhale and exhale times must be essentially equal to prevent either starving the first part of each thread or serious drooling. So there’s really only one degree of freedom: the total volume of plastic = rpm x duration.
Perhaps having separate early action times would help: adjust the shutdown and startup delay times independently of the total Reversal inhale/exhale time. Right now, those delays are simply the inhale/exhale times, evidently assuming clean cutoffs and startups, which obviously isn’t the case.
And, alas, the Reversal Threshold bug remains unfixed, so you (well, I) can’t tell Reversal to not operate across short motions like the end of one thread and the not-quite-adjacent start of the next.
In the process of adapting my HT GPS interface to a Wouxun KG-UV3D radio, I printed some trial-fit pieces that consistently came out a little short. A bit of division showed that the larger pieces tended to be small in the X & Y axes by about 0.5%. This makes no difference for most 3D printed objects, but in this case the pieces must match up precisely with the radio’s existing battery interface layout. Half a percent matters a lot across a 75 mm part.
The advice found with most calibration pieces seems to boil down to fudging the printer’s steps/mm setting to make the answer come out right. The default Thing-O-Matic calibration (in machines/thingomatic.xml, wherever that’s hidden in your installation) looks like this:
<axis id="x" length="106" maxfeedrate="6000" homingfeedrate="2500" stepspermm="47.069852" endstops="min"/> <!-- Pulley dia: 10.82mm / 1/8 step = 1/(10.82 * pi / 1600) --> <axis id="y" length="120" maxfeedrate="6000" homingfeedrate="2500" stepspermm="47.069852" endstops="min"/> <!-- Pulley dia: 10.82mm / 1/8 step = 1/(10.82 * pi / 1600) -->
You will, of course, have twiddled the maxfeedrate, homingfeedrate, and maybe even the comments to make the answers work on your machine.
Nophead slapped me upside the head when I made the same mistake that produced the stock stepspermm values: the pulley moves the belt by a fixed number of teeth on each revolution, so you just multiply by the belt tooth pitch to find the distance per revolution. Divide that into the number of (micro)steps per revolution and you get the exact stepspermm value. The stock MBI pulleys have 17 teeth and the belt has a 2 mm tooth pitch, so:
47.05882 step/mm = 1600 step / (17 * 2 mm)
That differs from the stock value by not very much at all:
0.999766 = 47.05882 / 47.069852
Given that these steppers aren’t losing steps (don’t start with me, you know how I get), I’m quite confident that the X and Y stages move by exactly the commanded distance every time.
The printer uses a heated build plate and the first layer is 0.33 mm, give-or-take about 0.05 mm, and the objects come out with essentially straight vertical walls. However, the walls aren’t quite perfect, tending to be a bit larger where they contact the plate, and I finally asked the obvious question (abs plastic shrinkage), which produces, among many other hits, that useful table.
The money quote is that ABS shrinks just about exactly 0.5% as it cools. That’s modulo the starting temperature, the molding process, and so forth and so on, but it’s a pretty nice match.
Therefore, fudging the printer’s scale isn’t appropriate, because that affects everything you might do with it. Such as, for example, the initial homing sequence, which depends on fairly precise locations that must match up with reality and have no shrinkage problems whatsoever.
Skeinforge’s Scale plugin applies a factor to the object, so that’s (probably) a more appropriate location for this adjustment. The myriad SF settings get broken down by Craft (extrusion, milling, whatever) and material (ABS, PLA, whatever), so if you can keep all that straight, then you can apply the appropriate Scale for each process and material.
The Scale doc may seem a tad sparse, but the plugin does have separate settings for the XY plane and the Z height. The latter (probably) doesn’t need scaling, because the nozzle height sets the actual extrusion level; the top layer or two will stretch to make the vertical size come out right as the object cools while it’s a-building.
I’ll toss a 1.005 scale factor into the XY mix and see what horrors that unleashes by way of unintended consequences.
More on the radio interface & suchlike in a while…
Having twice failed to make music-wire springs work, I rummaged around in the Big Box o’ Small Springs with more diligence and unearthed a pair of coil compression springs that exactly match the pin ferrule OD. Twiddling the solid model produced this longer & flatter version with in-line springs and cylindrical plugs holding them in place:
A closeup of the pin arrangement, which now looks very clean and easy to build:
The OpenSCAD code will print out a quartet of plugs (pick the best two), but having thought of that too late, I turned a pair from a random acrylic rod:
I did remember to solder the wires before assembling the pins this time…
Because the pins now index on their shoulder with the springs at partial extension, I set the drills into the pin vice vise [Update: One can probably be arrested for pin vice] to produce depths displayed by the OpenSCAD program before reaming out the printed holes:
ECHO: "Depth to taper end: 24.72" ECHO: " ferrule end: 15.62" ECHO: " plug end: 4.62"
Then glue the pin plugs into the holder and the flat lid atop the case to capture the battery, clamping everything to the corner of the Sherline’s countertop:
And it Just Worked: nice travel between the limits, smooth operation, it’s the way I should have done it from the beginning*. You knew that all along, right?
Here are the three NB-5L Battery Holder versions, all snuggled up together. The longer and flatter coil-spring version sits on the right:
Now I can take some data…
The OpenSCAD source code:
// Holder for Canon NB-5L Li-Ion battery
// Ed Nisley KE4ZNU August 2011
include </home/ed/Thing-O-Matic/lib/MCAD/units.scad>
include </home/ed/Thing-O-Matic/lib/MCAD/boxes.scad>
include </home/ed/Thing-O-Matic/Useful Sizes.scad>
// Layout options
Layout = "Build"; // Case Lid Plugs Show Build Fit
//- Extrusion parameters - must match reality!
// Print with +2 shells and 3 solid layers
ThreadThick = 0.33;
ThreadWidth = 2.0 * ThreadThick;
HoleWindage = 0.2;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1; // make holes end cleanly
BuildOffset = 3.0; // clearance for build layout
//- Battery dimensions - rationalized from several samples
// Coordinate origin at battery corner by contact plates on bottom surface
BatteryLength = 45.25;
BatteryWidth = 32.17;
BatteryThick = 7.85;
ContactWidth = 2.10;
ContactLength = 4.10;
ContactRecess = 0.85;
ContactOC = 3.18; // center-to-center across contact face
ContactOffset = 4.45; // offset from battery edge
ContactHeight = 3.05; // offset from battery bottom plane
AlignThick = 2.2; // alignment recesses on contact face
AlignDepth = 2.0; // into face
AlignWidth1 = 0.7; // across face at contacts
AlignWidth2 = 2.8; // ... other edge
//- Pin dimensions
PinTipDia = 1.6;
PinTipLength = 10.0;
PinTaperLength = 2.3;
PinShaftDia = 2.4;
PinShaftLength = 6.8;
PinFerruleDia = 3.1;
PinFerruleLength = 2.0;
PinLength = PinTipLength + PinTaperLength + PinShaftLength + PinFerruleLength;
ExtendRelax = 1.5 + ContactRecess; // pin extension when no battery is present
ExtendOvertravel = 1.0; // ... beyond engaged position
//- Spring dimensions
SpringDia = 3.1; // coil OD
SpringMax = 9.3;
SpringLength = SpringMax - 0.3; // slightly compressed
SpringMin = 4.5;
SpringPlugDia = 5.0; // plug retaining the spring
SpringPlugLength = IntegerMultiple(4.0,ThreadWidth);
SpringPlugSides = 12;
SpringTravel = ExtendRelax + ExtendOvertravel;
//- Holder dimensions
GuideRadius = ThreadWidth; // friction fit ridges
GuideOffset = 10;
WallThick = 4*ThreadWidth; // holder sidewalls
BaseThick = 6*ThreadThick; // bottom of holder to bottom of battery
TopThick = 4*ThreadThick; // top of battery to top of holder
ThumbRadius = 10.0; // thumb opening at end of battery
CornerRadius = 3*ThreadThick; // nice corner rounding
CaseLength = SpringPlugLength + SpringLength + PinLength - ExtendRelax
+ BatteryLength + GuideRadius + WallThick;
CaseWidth = 2*WallThick + 2*GuideRadius + BatteryWidth;
CaseThick = BaseThick + BatteryThick + TopThick;
//- XY origin at front left battery corner, Z on platform below that
CaseLengthOffset = -(SpringPlugLength + SpringLength + PinLength - ExtendRelax);
CaseWidthOffset = -(WallThick + GuideRadius);
CaseThickOffset = BaseThick;
LidLength = ExtendRelax - CaseLengthOffset;
echo(str("Depth to taper end: ",
(SpringPlugLength + SpringLength + PinFerruleLength + PinShaftLength + PinTaperLength)));
echo(str(" ferrule end: ",
(SpringPlugLength + SpringLength + PinFerruleLength)));
echo(str(" plug end: ",SpringPlugLength));
//----------------------
// Useful routines
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(r=(FixDia + HoleWindage)/2,
h=Height,
$fn=Sides);
}
module ShowPegGrid(Space = 10.0,Size = 1.0) {
Range = floor(50 / Space);
for (x=[-Range:Range])
for (y=[-Range:Range])
translate([x*Space,y*Space,Size/2])
%cube(Size,center=true);
}
//-------------------
//-- Guides for tighter friction fit
module Guides() {
translate([GuideOffset,-GuideRadius,CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([GuideOffset,(BatteryWidth + GuideRadius),CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength - GuideOffset),-GuideRadius,CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength - GuideOffset),(BatteryWidth + GuideRadius),CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength + GuideRadius),GuideOffset/2,CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength + GuideRadius),(BatteryWidth - GuideOffset/2),CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
}
//-- Contact pins (holes therefore)
module PinShape() {
union() {
cylinder(r=(PinTipDia + HoleWindage)/2,h=(PinTipLength + Protrusion),$fn=6);
translate([0,0,PinTipLength])
cylinder(r=(PinShaftDia + HoleWindage)/2,
h=(PinTaperLength + PinShaftLength + Protrusion),$fn=6);
translate([0,0,(PinLength - PinFerruleLength)])
cylinder(r=(PinFerruleDia + HoleWindage)/2,
h=(PinFerruleLength + Protrusion),$fn=6);
translate([0,0,(PinLength)])
cylinder(r=(SpringDia + HoleWindage)/2,
h=(SpringLength + Protrusion),$fn=6);
translate([0,0,(PinLength + SpringLength)])
cylinder(r=(SpringPlugDia + HoleWindage)/2,h=(SpringPlugLength + Protrusion),$fn=SpringPlugSides);
translate([0,0,(PinLength + SpringLength + SpringPlugLength)])
cylinder(r=(SpringPlugDia + HoleWindage)/2,h=2*SpringPlugLength,$fn=SpringPlugSides); // extend hole
}
}
module PinAssembly() {
translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) {
rotate([0,270,0]) {
PinShape(); // pins
translate([0,(2*ContactOC),0])
PinShape();
}
}
}
//-- Case with origin at battery corner
module Case() {
difference() {
union() {
difference() {
translate([(CaseLength/2 + CaseLengthOffset),
(CaseWidth/2 + CaseWidthOffset),
(CaseThick/2)])
roundedBox([CaseLength,CaseWidth,CaseThick],CornerRadius); // basic case shape
translate([-ExtendOvertravel,-GuideRadius,CaseThickOffset])
cube([(BatteryLength + GuideRadius + ExtendOvertravel),
(BatteryWidth + 2* GuideRadius),
(BatteryThick + Protrusion)]); // battery space
}
Guides();
translate([-ExtendOvertravel,-GuideRadius,BaseThick])
cube([(AlignDepth + ExtendOvertravel),
(AlignWidth1 + GuideRadius),
AlignThick]); // alignment blocks
translate([-ExtendOvertravel,
(BatteryWidth - AlignWidth2),
BaseThick])
cube([(AlignDepth + ExtendOvertravel),
(AlignWidth2 + GuideRadius),
AlignThick]);
}
translate([(-ExtendOvertravel),
(CaseWidthOffset - Protrusion),
(CaseThickOffset + BatteryThick)])
cube([CaseLength,
(CaseWidth + 2*Protrusion),
(TopThick + Protrusion)]); // battery access
translate([(CaseLengthOffset - Protrusion),
(CaseWidthOffset - Protrusion),
(CaseThickOffset + BatteryThick)])
cube([(CaseLength + 2*Protrusion),
(CaseWidth + 2*Protrusion),
(TopThick + Protrusion)]); // battery insertion allowance
translate([(BatteryLength - Protrusion),
(CaseWidth/2 + CaseWidthOffset),
(CaseThickOffset + ThumbRadius)])
rotate([90,0,0])
rotate([0,90,0])
cylinder(r=ThumbRadius,
h=(WallThick + GuideRadius + 2*Protrusion),
$fn=22); // remove thumb notch
PinAssembly();
}
}
module Lid() {
difference() {
translate([0,0,(CaseThick/2 - BaseThick - BatteryThick)])
roundedBox([LidLength,
CaseWidth,CaseThick],CornerRadius);
translate([0,0,-(CaseThick/2)])
cube([(LidLength + 2*Protrusion),
(CaseWidth + 2*Protrusion),
(CaseThick)],center=true);
}
}
module PlugShape() {
difference() {
cylinder(r=SpringPlugDia/2,h=SpringPlugLength,$fn=SpringPlugSides);
translate([0,0,-Protrusion])
PolyCyl(PinShaftDia,(SpringPlugLength + 2*Protrusion),SpringPlugSides/2);
}
}
module Plugs() {
translate([0,ContactOC,0])
PlugShape();
translate([0,-ContactOC,0])
PlugShape();
}
//-------------------
// Build it!
ShowPegGrid();
if (Layout == "Case")
Case();
if (Layout == "Lid")
Lid();
if (Layout == "Plugs")
Plugs();
if (Layout == "Show") { // reveal pin assembly
difference() {
Case();
translate([(CaseLengthOffset - Protrusion),
(CaseWidthOffset - Protrusion + WallThick + ContactOffset + ContactOC),
(BaseThick + ContactHeight)])
cube([(-CaseLengthOffset + Protrusion),
(CaseWidth + 2*Protrusion),
CaseThick + BaseThick - ContactHeight + Protrusion]);
translate([(CaseLengthOffset - Protrusion),
(CaseWidthOffset - Protrusion),
-Protrusion])
cube([(-CaseLengthOffset + Protrusion),
(WallThick + GuideRadius + ContactOffset + Protrusion),
CaseThick]);
}
translate([ExtendRelax,ContactOffset,(CaseThickOffset + ContactHeight)]) { // pins
rotate([0,270,0]) {
%PinShape();
// translate([0,(2*ContactOC),0])
// %PinShape();
}
}
translate([CaseLengthOffset,ContactOffset,(CaseThickOffset + ContactHeight)])
rotate([0,90,0])
PlugShape();
}
if (Layout == "Build") {
translate([-(CaseLength/2 + CaseLengthOffset),-(CaseWidthOffset - BuildOffset),0])
Case();
translate([0,(CaseLengthOffset/2 - BuildOffset),0])
rotate([0,0,90])
Lid();
translate([CaseLengthOffset - SpringPlugDia,-CaseWidth/2,0])
Plugs();
translate([(CaseLengthOffset + SpringPlugDia),-CaseWidth/2,0]) // extra set of plugs
Plugs();
}
if (Layout == "Fit") {
Case();
translate([(-LidLength/2 + ExtendRelax),
(CaseWidth/2 + CaseWidthOffset),
(BaseThick + BatteryThick)])
Lid();
translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) { // pins
rotate([0,270,0]) {
%PinShape();
translate([0,(2*ContactOC),0])
%PinShape();
}
}
translate([CaseLengthOffset,
(ContactOffset + ContactOC),
(CaseThickOffset + ContactHeight)])
rotate([0,90,0])
Plugs();
}
(*) Modulo, of course, simply buying a $5 charger from eBay and gutting it. What’s the fun in that?
So there we were, on our way to the Dutchess County Fair when I noticed the Check Engine light glowing beyond my right hand on the dashboard. We decided to not stop at the fair, drove through Rhinebeck, and returned home without turning the engine off.
The last time that light came on, my Shop Assistant and I were on our way to Cabin Fever in York PA one Friday afternoon in mid-January. The Mass Air Flow Sensor had just failed, rendering the car un-driveable: the engine ran so poorly we barely got off I-81 to drift into a parking lot. Although the local Toyota dealer was just across the road, I replaced that sensor on Monday morning in the Autozone parking lot, half a mile down the road, at 19 °F in a stiff wind with inadequate tools; said Toyota dealer being useless like tits on a bull during the entire weekend.
After the obligatory research, I put the van up on jack stands, crawled underneath, and discovered that the Bank 1 Oxygen Sensor lies behind & below the transverse-and-rotated engine, directly above and front of the chassis cross-support strut, where it cannot be seen or touched from any position. That’s why there are no pictures: there was no room for a camera and nothing to see.
I had to buy a 3/8 inch breaker bar, as the sensor position lacked clearance for a socket wrench, a U-joint, a T-handle, or a step-down adapter from my 1/2 breaker bar behind the special 22 mm Oxygen Sensor Socket. I eventually got the sensor loose and unscrewed it one painful eighth of a turn at a time, with the exhaust pipe preventing a full 1/4 turn, removing and reseating the breaker bar with my fingertips for every single one of those increments.
I deleted all over Toyota’s censored for quite some time thereafter…
It’s been a couple of weeks, the Check Engine light remains off, and I hereby declare victory.
After that failure, I thought maybe making the spring guide pocket a bit wider and seating the spring wire in a solid plug would work. A tweak to the OpenSCAD script produced this, along with slightly larger locating ribs around the battery compartment:
A closer look at the plug spring assembly:
The hole is now slightly larger, distinct from the side of the pocket, and the partition between the pocket and plug (although something of a formality) seats the plug during assembly. The plug started out at 3 mm in diameter, as I intended to try ramming a heated wire into a length of filament. That worked, mmmm, somewhat poorly, so I drilled a hole in a length of filament:
Unfortunately, that whole bodge didn’t work any better than the spring in the first pass at a holder, so I gave up and cast the springs in epoxy. The OpenSCAD code produces a 5 mm diameter hole that should provide a larger epoxy plate with better grip than the 3 mm holes in this picture, but it probably won’t make much difference:
The alert reader will note a complete faceplant: yeah, I forgot to solder the wires into the pins before blobbing the springs in place. Fortunately, the epoxy cures slowly enough that I could:
I hate it when that happens…
With springs & wires properly in place and the epoxy cured overnight, the pins had considerably better springiness and free motion than before, although they didn’t have quite the range of travel I wanted. I think the spring wire bent slightly on the first push, as the pins never came quite as far out after that.
So this was a qualified success, but not a solid win. Time for round three…
The OpenSCAD source code:
// Holder for Canon NB-5L Li-Ion battery
// Ed Nisley KE4ZNU August 2011
include </home/ed/Thing-O-Matic/lib/MCAD/units.scad>
include </home/ed/Thing-O-Matic/lib/MCAD/boxes.scad>
include </home/ed/Thing-O-Matic/Useful Sizes.scad>
// Layout options
Layout = "Show"; // Case Lid Show Build Fit
//- Extrusion parameters - must match reality!
// Print with +2 shells and 3 solid layers
ThreadThick = 0.33;
ThreadWidth = 2.0 * ThreadThick;
HoleWindage = 0.2;
function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
Protrusion = 0.1; // make holes end cleanly
BuildOffset = 3.0; // clearance for build layout
//- Battery dimensions - rationalized from several samples
// Coordinate origin at battery corner by contact plates on bottom surface
BatteryLength = 45.25;
BatteryWidth = 32.17;
BatteryThick = 7.85;
ContactWidth = 2.10;
ContactLength = 4.10;
ContactRecess = 0.85;
ContactOC = 3.18; // center-to-center across contact face
ContactOffset = 4.45; // offset from battery edge
ContactHeight = 3.05; // offset from battery bottom plane
AlignThick = 2.2; // alignment recesses on contact face
AlignDepth = 2.0; // into face
AlignWidth1 = 0.7; // across face at contacts
AlignWidth2 = 2.8; // ... other edge
//- Pin dimensions
PinTipDia = 1.6;
PinTipLength = 10.0;
PinTaperLength = 2.3;
PinShaftDia = 2.4;
PinShaftLength = 6.8;
PinFerruleDia = 3.0;
PinFerruleLength = 2.0;
PinLength = PinTipLength + PinTaperLength + PinShaftLength + PinFerruleLength;
PinHoleOffset = 13.9; // tip to spring hole
ExtendRelax = 1.5 + ContactRecess; // pin extension when no battery is present
ExtendOvertravel = 1.0; // ... beyond engaged position
//- Holder dimensions
GuideRadius = ThreadWidth; // friction fit ridges
GuideOffset = 10;
WallThick = 4*ThreadWidth; // holder sidewalls
BaseThick = IntegerMultiple(6.0,ThreadThick); // bottom of holder to bottom of battery
TopThick = 6*ThreadThick; // top of battery to top of holder
ThumbRadius = 10.0; // thumb opening at end of battery
CornerRadius = 3*ThreadThick; // nice corner rounding
CaseLength = 2*WallThick + PinLength - ExtendRelax + ExtendOvertravel + BatteryLength + GuideRadius;
CaseWidth = 2*WallThick + 2*GuideRadius + BatteryWidth;
CaseThick = BaseThick + BatteryThick + TopThick;
//- XY origin at front left battery corner, Z on platform below that
CaseLengthOffset = -(WallThick + PinLength - ExtendRelax + ExtendOvertravel);
CaseWidthOffset = -(WallThick + GuideRadius);
CaseThickOffset = BaseThick;
LidLength = ExtendRelax - CaseLengthOffset;
//- Spring dimensions
SpringPlugDia = 5.0; // epoxy plug holding spring wire
SpringPlugLength = IntegerMultiple(1.5,ThreadThick);
SpringDia = 0.024 * inch; // music wire spring
SpringTravel = ExtendRelax + ExtendOvertravel;
SpringLength = BaseThick + ContactHeight - SpringPlugLength - 2*ThreadThick;
echo(str("Spring wire from end: ",WallThick + PinLength - PinHoleOffset));
echo(str(" from side: ",WallThick + GuideRadius + ContactOffset));
echo(str("Pin spacing on centers: ",ContactOC));
//----------------------
// Useful routines
module PolyCyl(Dia,Height,ForceSides=0) { // based on nophead's polyholes
Sides = (ForceSides != 0) ? ForceSides : (ceil(Dia) + 2);
FixDia = Dia / cos(180/Sides);
cylinder(r=(FixDia + HoleWindage)/2,
h=Height,
$fn=Sides);
}
module ShowPegGrid(Space = 10.0,Size = 1.0) {
Range = floor(50 / Space);
for (x=[-Range:Range])
for (y=[-Range:Range])
translate([x*Space,y*Space,Size/2])
%cube(Size,center=true);
}
//-------------------
//-- Guides for tighter friction fit
module Guides() {
translate([GuideOffset,-GuideRadius,CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([GuideOffset,(BatteryWidth + GuideRadius),CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength - GuideOffset),-GuideRadius,CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength - GuideOffset),(BatteryWidth + GuideRadius),CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength + GuideRadius),GuideOffset/2,CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
translate([(BatteryLength + GuideRadius),(BatteryWidth - GuideOffset/2),CaseThickOffset])
PolyCyl(2*GuideRadius,(BatteryThick - Protrusion),4);
}
//-- Contact pins (holes therefore)
module PinShape() {
PolyPin = false;
union() {
if (PolyPin)
PolyCyl(PinTipDia,(PinTipLength + Protrusion));
else
cylinder(r=(PinTipDia + HoleWindage)/2,h=(PinTipLength + Protrusion),$fn=6);
translate([0,0,PinTipLength])
if (PolyPin)
PolyCyl(PinShaftDia,(PinTaperLength + PinShaftLength + Protrusion));
else
cylinder(r=(PinShaftDia + HoleWindage)/2,
h=(PinTaperLength + PinShaftLength + Protrusion),$fn=6);
translate([0,0,(PinLength - PinFerruleLength)])
if (PolyPin)
PolyCyl(PinFerruleDia,(PinFerruleLength + Protrusion));
else
cylinder(r=(PinFerruleDia + HoleWindage)/2,
h=(PinFerruleLength + Protrusion),$fn=6);
translate([0,0,PinLength])
if (PolyPin)
PolyCyl(PinFerruleDia,PinLength); // very long holes to punch case
else
cylinder(r=(PinFerruleDia + HoleWindage)/2,h=PinLength,$fn=6);
}
}
module PinAssembly() {
translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) {
rotate([0,270,0]) {
PinShape(); // pins
translate([0,(2*ContactOC),0])
PinShape();
}
}
translate([-(PinHoleOffset - ExtendRelax + SpringTravel/2 - SpringDia/2 - HoleWindage/2),
ContactOffset,
(CaseThickOffset + ContactHeight - SpringLength/2 - Protrusion)]) {
cube([(SpringTravel + SpringDia/2 + HoleWindage),
PinShaftDia,
(SpringLength + 2*Protrusion)],
center=true); // spring deflection pocket
translate([0,(2*ContactOC),0])
cube([(SpringTravel + SpringDia/2 + HoleWindage),
PinShaftDia,
(SpringLength + 2*Protrusion)],
center=true);
}
translate([-(PinHoleOffset - ExtendRelax),
ContactOffset,
(-Protrusion/2)]) {
PolyCyl(SpringDia,(BaseThick + ContactHeight + Protrusion),4); // spring wire
PolyCyl(SpringPlugDia,(SpringPlugLength + Protrusion)); // wire holder
translate([0,(2*ContactOC),0]) {
PolyCyl(SpringDia,(BaseThick + ContactHeight + Protrusion),4);
PolyCyl(SpringPlugDia,(SpringPlugLength + Protrusion));
}
}
}
//-- Case with origin at battery corner
module Case() {
difference() {
union() {
difference() {
translate([(CaseLength/2 + CaseLengthOffset),
(CaseWidth/2 + CaseWidthOffset),
(CaseThick/2)])
roundedBox([CaseLength,CaseWidth,CaseThick],CornerRadius); // basic case shape
translate([-ExtendOvertravel,-GuideRadius,CaseThickOffset])
cube([(BatteryLength + GuideRadius + ExtendOvertravel),
(BatteryWidth + 2* GuideRadius),
(BatteryThick + Protrusion)]); // battery space
}
Guides();
translate([-ExtendOvertravel,-GuideRadius,BaseThick])
cube([(AlignDepth + ExtendOvertravel),
(AlignWidth1 + GuideRadius),
AlignThick]); // alignment blocks
translate([-ExtendOvertravel,
(BatteryWidth - AlignWidth2),
BaseThick])
cube([(AlignDepth + ExtendOvertravel),
(AlignWidth2 + GuideRadius),
AlignThick]);
}
translate([(-ExtendOvertravel),
(CaseWidthOffset - Protrusion),
(CaseThickOffset + BatteryThick)])
cube([CaseLength,
(CaseWidth + 2*Protrusion),
(TopThick + Protrusion)]); // battery access
translate([(CaseLengthOffset - Protrusion),
(CaseWidthOffset - Protrusion),
(CaseThickOffset + BatteryThick)])
cube([(CaseLength + 2*Protrusion),
(CaseWidth + 2*Protrusion),
(TopThick + Protrusion)]); // battery insertion allowance
translate([(BatteryLength - Protrusion),
(CaseWidth/2 + CaseWidthOffset),
(CaseThickOffset + ThumbRadius)])
rotate([90,0,0])
rotate([0,90,0])
cylinder(r=ThumbRadius,
h=(WallThick + GuideRadius + 2*Protrusion),
$fn=22); // remove thumb notch
PinAssembly();
}
}
module Lid() {
difference() {
translate([0,0,(CaseThick/2 - BaseThick - BatteryThick)])
roundedBox([LidLength,
CaseWidth,CaseThick],CornerRadius);
translate([0,0,-(CaseThick/2)])
cube([(LidLength + 2*Protrusion),
(CaseWidth + 2*Protrusion),
(CaseThick)],center=true);
}
}
//-------------------
// Build it!
ShowPegGrid();
if (Layout == "Case")
Case();
if (Layout == "Lid")
Lid();
if (Layout == "Show") { // reveal pin assembly
difference() {
Case();
translate([(CaseLengthOffset - Protrusion),
(CaseWidthOffset - Protrusion + WallThick + ContactOffset + ContactOC),
(BaseThick + ContactHeight)])
cube([(-CaseLengthOffset + Protrusion),
(CaseWidth + 2*Protrusion),
CaseThick + BaseThick - ContactHeight + Protrusion]);
translate([(CaseLengthOffset - Protrusion),
(CaseWidthOffset - Protrusion),
-Protrusion])
cube([(-CaseLengthOffset + Protrusion),
(WallThick + GuideRadius + ContactOffset + Protrusion),
CaseThick]);
}
translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) { // pins
rotate([0,270,0]) {
%PinShape();
// translate([0,(2*ContactOC),0])
// %PinShape();
}
}
}
if (Layout == "Build") {
translate([-(CaseLength/2 + CaseLengthOffset),-(CaseWidthOffset - BuildOffset),0])
Case();
translate([0,(CaseLengthOffset/2 - BuildOffset),0])
rotate([0,0,90])
Lid();
}
if (Layout == "Fit") {
Case();
translate([(-LidLength/2 + ExtendRelax),
(CaseWidth/2 + CaseWidthOffset),
(BaseThick + BatteryThick)])
Lid();
translate([ExtendRelax,ContactOffset,CaseThickOffset + ContactHeight]) { // pins
rotate([0,270,0]) {
%PinShape();
translate([0,(2*ContactOC),0])
%PinShape();
}
}
}
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