Tag: M2

Using and tweaking a Makergear M2 3D printer

Juki TL-2010Q Needle LEDs: Simple Cable Clip

A straightforward cable clip:

TL-2010Q Needled COB LED - cable clip — TL-2010Q Needled COB LED – cable clip

It looks better than the previous hack bent from a snippet of PET clamshell:

Juki TL-2010Q Needle LEDs - cable clip — Juki TL-2010Q Needle LEDs – cable clip

Ream out the holes with suitable drills, clean out the slot using Tiny Bandsaw™, and it’s all good.

In retrospect, the slot isn’t worth the effort, because it doesn’t open wide enough to admit the cable and doesn’t provide any clamping force; a simple block with two holes would do as well. If the heatsink didn’t already have a 3 mm screw in play, I’d use an adhesive-backed clip from the early Kenmore LEDs.

The OpenSCAD source code isn’t much to look at:

//-----
// Cable clip
// Reoriented into build position, because we only need one

ClipWall = 3*ThreadWidth;
Clip = [15.0,10.0,CableOD + 2*ClipWall];

module CableClip(CableOD = 2.0) {

ClipSides = 4*3;
ClipRadius = Clip.y/2;
ScrewOD = 3.0;
ClipOC = Clip.x - ClipRadius - CableOD/2 - ClipWall;

  translate([0,0,Clip.y/2])
    rotate([90,0,90])
      translate([0,0,0*Clip.z/2])
        difference() {
          union() {
            rotate(180/ClipSides)
              cylinder(d=Clip.y/cos(180/ClipSides),h=Clip.z,$fn=ClipSides,center=true);
            translate([ClipRadius,0,0])
              cube([Clip.x - ClipRadius,Clip.y,Clip.z],center=true);
          }
          translate([0,0,-(Clip.z/2 + Protrusion)])
            rotate(180/8)
              PolyCyl(ScrewOD,Clip.z + 2*Protrusion,8);
          rotate([90,0,0])
            translate([ClipOC,0,-Clip.y])
              rotate(180/8)
              PolyCyl(CableOD,2*Clip.y,8);
          translate([ClipOC - Clip.x/2,0,0])
            cube([Clip.x,2*Clip.y,2*ThreadWidth],center=true);
        }
}

2019-03-04

SJCAM M20 Camera: Tour Easy Seat Mount

The general idea is to replace this:

M20 in waterproof case - Tour Easy seat — M20 in waterproof case – Tour Easy seat

With this:

SJCAM M20 Mount - Tour Easy side view — SJCAM M20 Mount – Tour Easy side view

Thereby solving two problems:

Pitifully small battery capacity
Wobbly camera support

The battery is an Anker PowerCore 13000 Power Bank plugged into the M20’s USB port. Given that SJCAM’s 1 A·h batteries barely lasted for a typical hour of riding, the 13 A·h PowerCore will definitely outlast my legs. The four blue dots just ahead of the strap around the battery show it’s fully charged and the blue light glowing through the case around the M20 indicates it’s turned on.

The solid model has four parts:

SJCAM M20 Mount - Fit layout — SJCAM M20 Mount – Fit layout

Which, as always, incorporates improvements based on the actual hardware on the bike.

A strap-and-buckle belt harvested from a defunct water pack holds the battery into the cradle and the cradle onto the rack, with a fuzzy velcro strip stuck to the bottom to prevent sliding:

SJCAM M20 Mount - Tour Easy rear view — SJCAM M20 Mount – Tour Easy rear view

The shell around the camera is basically a box minus the camera:

SJCAM M20 Mount - Show - shell — SJCAM M20 Mount – Show – shell

The shell builds as three separate slabs, with the center section having cutouts ahead of the camera’s projections to let it slide into place:

SJCAM M20 Mount - Show - shell sections — SJCAM M20 Mount – Show – shell sections

The new shell version is 30.5 mm thick, so a 40 mm screw will stick out maybe 5 mm beyond the nylon locknut. I trust the screws will get lost in the visual noise of the bike.

A peg sticking out behind the USB jack anchors the cable in place:

SJCAM M20 Mount - Show - shell sections - USB side — SJCAM M20 Mount – Show – shell sections – USB side

The front slab and center top have curves matching the M20 case:

SJCAM M20 Mount - Show - shell sections - button side — SJCAM M20 Mount – Show – shell sections – button side

The camera model has a tidy presentation option:

SJCAM M20 Mount - Show - M20 body — SJCAM M20 Mount – Show – M20 body

And an ugly option to knock the protruberances out of the shell:

SJCAM M20 Mount - Show - M20 body - knockouts — SJCAM M20 Mount – Show – M20 body – knockouts

The square-ish post on the base fits into an angled socket in the clamp around the seat rail:

SJCAM M20 Mount - Show - clamp — SJCAM M20 Mount – Show – clamp

The numbers correspond to the “Look Angle” of the socket pointing the camera toward overtaking traffic. The -20° in the first clamp shows a bit too much rack:

SJCAM M20 Mount - first ride - traffic - 2019-02-06 — SJCAM M20 Mount – first ride – traffic – 2019-02-06

It may not matter, though, as sometimes you want to remember what’s on the right:

SJCAM M20 Mount - first ride - 2019-02-06 — SJCAM M20 Mount – first ride – 2019-02-06

FWIW, the track veering off onto the grass came from a fat-tire bike a few days earlier. Most of the rail trail had cleared by the time we tried it, with some ice and snow in rock cuts and shaded areas.

Contrary to the first picture, I later remounted the camera under the seat rail with its top side downward. The M20 has a “rotate video” mode for exactly that situation, which I forgot to turn off in the fancy new mount, so I rotated the pix afterward.

A 3 mm screw extends upward through the hole in the socket to meet a threaded brass insert epoxied into the shell base, as shown in the uglified M20 model. Despite appearances, the hole is perpendicular to both the socket and the shell, so you can tweak the Look Angle without reprinting the shell.

All in all, the mount works well. We await better riding weather …

The OpenSCAD source code as a GitHub Gist:

	// SJCAM M20 Camera Mount for Tour Easy seat back rail
	// Ed Nisley – KE4ZNU
	// 2019-02

	/* [Layout Options] */

	Layout = "Fit"; // [Show,Fit,Build]

	Part = "Shell"; // [Cradle,Shell,Clamp,ShellSections,M20,Interposer,Battery,Buttons]

	LookAngle = [0,5,-25]; // camera angle, looking backwards


	/* [Extrusion Parameters] */

	ThreadWidth = 0.40;
	ThreadThick = 0.25;

	HoleWindage = 0.2;

	Protrusion = 0.1;

	//—–
	// Dimensions

	/* [Hidden] */

	ID = 0;
	OD = 1;
	LENGTH = 2;

	ClampScrew = [5.0,10.0,50.0]; // ID=thread OD=washer LENGTH=total
	ClampInsert = [5.0,7.5,10.5]; // brass insert

	MountScrew = [3.0,7.0,23]; // ID=thread OD=washer LENGTH=tune to fit clamp arch
	MountInsert = [3.0,4.95,8.0]; // ID=screw OD, OD=knurl dia

	EmbossDepth = 2*ThreadThick + Protrusion; // recess depth + Protrusion beyond surface

	DebossHeight = EmbossDepth; // text height + Protrusion into part

	Projection = 10; // stick-out to punch through shell sides & suchlike

	SupportColor = "Yellow";
	FadeColor = "Green";
	FadeAlpha = 0.25;

	//—–
	// Useful routines

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);

	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);
	}

	//—–
	// M20 Camera
	// Looks backwards from seat = usual right-hand coordinates work fine
	// X parallel to bike frame, Y parallel to seat strut, Z true vertical

	M20 = [24.5,40.5,54.0];

	M20tm = 4.0; // chord height at top of case
	M20tr = (pow(M20tm,2) + pow(M20.y,2)/4) / (2*M20tm); // … radius
	echo(str("Top radius: ",M20tr));

	M20TopSides = 334;
	echo(str(" … sides: ",M20TopSides));

	M20fm = 1.0; // chord height at front of case
	M20fr = (pow(M20fm,2) + pow(M20.y,2)/4) / (2*M20fm); // … radius
	echo(str("Front radius: ",M20fr));

	M20FrontSides = ceil(M20fr / M20tr * M20TopSides); // make arc sides match up
	echo(str(" … sides: ",M20FrontSides));

	Lens = [19.0,22.5,5.5]; // ID=optical element, OD=tube
	LensBezel = [23.0,24.5,2.5]; // ID=lens tube, OD=bezel
	LensOffset = [-M20fm,0,41.5]; // bottom of case to lens centerline

	LensCap = [Lens[OD],24.5,4.5]; // silicone lens cap

	Spkr = [0.75,M20.y,14.3]; // speaker recess below LCD

	Switch = [8.0,1.0,38.0]; // selection switches
	SwitchOffset = [9.0,0,0]; // from rear to center of switches

	Jack = [10.0,0.1,36.0]; // jack and MicroSD card access, slightly enlarged
	JackOffset = [10.0,0,30.0]; // rear, bottom to center of jack block

	USB = [JackOffset.x – Jack.x/2,20.0,10.0]; // strut under USB plug
	USBOffset = [0,0,33.5]; // bottom to center of jack

	SDCard = [2.0,0.1,12.0]; // SD Card slot
	SDOffset = [9.0,0,20.0]; // bottom, rear to center of slot

	Button = [8.5,10.5,M20tm]; // ID = button, OD = bezel
	ButtonOC = 18.0; // on-center Y separation, assume X centered

	Screen = [0.1,31,24]; // LCD on rear face
	ScreenOffset = [0,0,33];

	BarLEDs = [0.1 + M20fm,12.0,5.0]; // Bar LEDs on front face
	BarLEDsOffset = [-M20fm,0,12.5];

	PwrLED = [3.5,3.5,0.1 + M20tm]; // power LED on top
	PwrLEDOffset = [2.5,0,0];

	RearLEDs = [1.0,2.0,0.1]; // charge and power LED openings above LCD
	RearLEDsOffset = [0,13.0/2,M20tm + 3.0]; // .. from top center of case

	module Buttons(KO) {
	for (j = [-1,1])
	translate([0,j*ButtonOC/2,0]) {
	cylinder(d=Button[OD],h=Button[LENGTH],$fn=12);
	if (KO)
	translate([0,0,M20tm])
	cylinder(d1=Button[OD],d2=1.5*Button[OD],h=Button.z,$fn=12);
	}
	}

	module M20Shape(Knockout = false) {

	difference() {
	intersection() {
	translate([0,0,M20.z/2 – M20tr]) // top curve
	rotate([0,90,0]) rotate(180/M20TopSides)
	cylinder(r=M20tr,h=2*(M20.x + Protrusion),$fn=M20TopSides,center=true);
	translate([M20.x/2 – M20fr,0,0])
	rotate(180/M20FrontSides)
	cylinder(r=M20fr,h=2*M20.z,$fn=M20FrontSides,center=true);
	cube(M20,center=true);
	}
	translate([Spkr.x/2 – M20.x/2 – Protrusion,0,Spkr.z/2 – Protrusion/2 – M20.z/2])
	cube(Spkr + [Protrusion,2*Protrusion,Protrusion],center=true);
	}

	translate([M20.x/2,0,-M20.z/2] + LensOffset)
	rotate([0,90,0])
	cylinder(d=Lens[OD] + HoleWindage,h=(Knockout ? Projection : Lens[LENGTH]),$fn=443,center=false);

	translate([M20.x/2 + M20fm/2,0,-M20.z/2] + LensOffset) // lens bezel
	rotate([0,90,0])
	cylinder(d1=LensBezel[OD],d2=Lens[OD],h=LensBezel[LENGTH],$fn=443,center=false);

	translate([-M20.x/2 + SwitchOffset.x, // side switches
	-(Switch.y + M20.y – Protrusion)/2,
	0])
	cube(Switch + [0,Protrusion,0] + (Knockout ? [0,Projection,0] : [0,0,0]),center=true);

	if (Knockout)
	translate([(M20.x/2 – M20fm)/2,-M20.y/2,0]) // side switch slide-in clearance
	cube([M20.x/2 – M20fm,2*Switch.y,Switch.z],center=true);

	translate([-M20.x/2 + JackOffset.x,
	(Jack.y + M20.y – Protrusion)/2,
	JackOffset.z – M20.z/2])
	cube(Jack + [0,Protrusion,0] + (Knockout ? [0,Projection,0] : [0,0,0]),center=true);

	translate([0,0,M20.z/2 – M20tm]) // top control buttons
	Buttons(Knockout);

	if (Knockout)
	translate([(M20.x – M20fm)/4,0,M20.z/2 – M20tm + Button[LENGTH]/2]) // slide-in button clearance
	cube([(M20.x – M20fm)/2,ButtonOC + Button[OD],Button[LENGTH]],center=true);

	translate([-(M20.x + Screen.x – Protrusion)/2,0,-M20.z/2] + ScreenOffset)
	cube(Screen + [Protrusion,0,0] + (Knockout ? [Projection,0,0] : [0,0,0]),center=true);

	for (j = [-1,1])
	translate([-M20.x/2 + Protrusion,j*RearLEDsOffset.y,M20.z/2 – RearLEDsOffset.z])
	rotate([0,-90,0]) rotate(180/6)
	PolyCyl(RearLEDs[OD],Knockout ? Projection : RearLEDs[LENGTH],6);

	translate([M20.x/2 + BarLEDs.x/2,0,-M20.z/2] + BarLEDsOffset)
	cube(BarLEDs + (Knockout ? [Projection,0,0] : [0,0,0]),center=true);

	translate([0,0,M20.z/2 – M20tm] + PwrLEDOffset)
	rotate(180/8)
	PolyCyl(PwrLED[OD],(Knockout ? Projection : PwrLED[LENGTH]),8);

	if (Knockout) {
	translate([0,0,-M20.z/2])
	rotate([180,0,0]) { // mounting screw
	PolyCyl(MountScrew[ID],MountScrew[LENGTH],6);
	translate([0,0,MountScrew[LENGTH] – Protrusion])
	PolyCyl(MountScrew[OD],MountScrew[ID] + 4*ThreadThick,6); // SHCS head is about 1 ID long
	}

	translate([0,0,-(M20.z/2 + MountInsert[LENGTH] + 4*ThreadWidth – Protrusion)])
	PolyCyl(MountInsert[OD],MountInsert[LENGTH] + 4*ThreadWidth,6); // insert inside Interposer
	}

	}

	//—–
	// Shell
	// Wraps around camera

	NomWall = 3.0;

	ShellWall = [IntegerMultiple(NomWall,ThreadThick),
	IntegerMultiple(NomWall,ThreadWidth),
	IntegerMultiple(NomWall,ThreadWidth)];
	ShellRadius = ShellWall.x;
	ShellSides = 8;

	ShellOA = M20 + 2*ShellWall;
	echo(str("Shell OA: ",ShellOA));

	Interposer = [M20.x – M20fm,M20.x – M20fm,10.0]; // if you can't be smart, be square

	module Shell() {

	Screw = [3.0,6.75,30]; // ID=thread OD=washer LENGTH
	ScrewClear = 1.0; // additional washer clearance
	ScrewSides = 8;

	ScrewOC = M20 + [0,Screw[ID]/cos(180/ScrewSides),Screw[ID]/cos(180/ScrewSides)]; // use PolyCyl hole dia, ignore .x value

	difference() {
	union() {
	hull()
	for (i=[-1,1], j=[-1,1], k=[-1,1])
	translate([i(ShellOA.x – 2ShellRadius)/2,
	j(ShellOA.y – 2ShellRadius)/2,
	k(ShellOA.z – 2ShellRadius)/2])
	sphere(r=ShellRadius/cos(180/ShellSides),$fn=ShellSides); // fix low-poly approx radius

	for (j=[-1,1], k=[-1,1]) // screw bosses, full length
	translate([0,jScrewOC.y/2,kScrewOC.z/2])
	rotate([0,90,0]) rotate(180/ScrewSides)
	cylinder(d=Screw[OD] + ScrewClear,h=ShellOA.x,center=true,$fn=ScrewSides);

	translate([-(ShellOA.x – USB.x – ShellWall.x)/2, // USB plug support strut
	(M20.y + USB.y)/2 – ShellRadius,
	-M20.z/2] + USBOffset)
	hull()
	for (i=[-1,1], j=[-1,1], k=[-1,1])
	translate([i(USB.x + ShellWall.x – 2ShellRadius)/2,
	j(USB.y – 2ShellRadius)/2,
	k(USB.z – 2ShellRadius)/2])
	rotate(0*180/ShellSides) rotate([90,0,90])
	sphere(r=ShellRadius/cos(180/ShellSides),$fn=ShellSides);

	translate([-M20fm/2,0,-ShellOA.z/2 – Interposer.z + Protrusion/2])
	InterposerShape(Embiggen = false);
	}

	render(convexity=4) // remove camera shape from interior
	M20Shape(Knockout = true);

	for (j=[-1,1], k=[-1,1]) // screw bores
	translate([-ShellOA.x,jScrewOC.y/2,kScrewOC.z/2])
	rotate([0,90,0]) rotate(180/ScrewSides)
	PolyCyl(Screw[ID],2*ShellOA.x,ScrewSides);

	translate([ShellOA.x/2 – ThreadThick + Protrusion/2,0,-5]) // recess for legend
	cube([EmbossDepth,ShellOA.y – 12,7],center=true);

	translate([0,(M20.y + 1.5*SDCard.z)/2 + ThreadWidth,-M20.z/2 + SDOffset.z])
	resize([M20.x,0,0])
	sphere(d=1.5*SDCard.z,$fn=24);

	}

	translate([ShellOA.x/2 – DebossHeight,0,-5])
	rotate([90,0,90])
	linear_extrude(height=DebossHeight,convexity=20)
	text(text="KE4ZNU",size=5,spacing=1.20,font="Arial:style:Bold",halign="center",valign="center");


	// Totally ad-hoc support structures

	if (false)
	color(SupportColor) {
	for (j=[-1,1], k=[0,1])
	translate([-ShellOA.x/2 + Screw[LENGTH],jShellOA.y/2,kShellOA.z])
	rotate([0,90,0])
	SupportScrew(Dia=Screw[OD] + ScrewClear,Length=ShellOA.x – Screw[LENGTH],Num=ScrewSides);
	}
	}

	// Generate support structure for screw boss

	module SupportScrew(Dia,Length,Num = 6) {
	for (a=[0 : 360/Num : 360/2])
	rotate(a)
	translate([0,0,(Length + ThreadThick)/2])
	cube([Dia – 2ThreadWidth,2ThreadWidth,Length – ThreadThick],center=true);
	}

	// Generate interposer block
	// Origin at center bottom surface for E-Z rotation

	module InterposerShape(Embiggen = false) {

	translate([0,0,Interposer.z/2])
	if (Embiggen) {
	minkowski() {
	cube(Interposer,center=true);
	cube(HoleWindage,center=true);
	}
	}
	else
	cube(Interposer + [-Protrusion,0,Protrusion],center=true); // avoid slivers, merge with shell
	}

	// Cut shell sections for printing
	// "Front" = lens end, toward +X direction
	// origin centered on M20.xyz and ShellOA.xyz

	module ShellSection(Section="Front") {

	if (Section == "Front") // include front curve
	intersection() {
	Shell();
	translate([ShellOA.x – (M20fm + ShellWall.x),0,0])
	cube([ShellOA.x,2ShellOA.y,2ShellOA.z],center=true);
	}
	else if (Section == "Center") // exclude front curve for E-Z printing
	intersection() {
	Shell();
	translate([-M20fm/2,0,0])
	cube([M20.x – M20fm,2ShellOA.y,2ShellOA.z],center=true);
	}
	else if (Section == "Back") // flush with LCD on rear face
	intersection() {
	Shell();
	translate([-ShellOA.x + (ShellWall.x),0,0])
	cube([ShellOA.x,2ShellOA.y,2ShellOA.z],center=true);
	}

	}

	//—–
	// Clamp
	// Grips seat frame rail
	// Uses shell rounding values for tidiness
	// Adjust MountScrew[LENGTH] to put head more-or-less flush with clamp arch

	RailOD = 20.0; // slightly elliptical in bent section
	RailSides = 234;

	ClampOA = [60.0,40.0,ClampScrew[LENGTH]]; // set clamp size to avoid weird screw spacing
	echo(str("Clamp OA: ",ClampOA));

	ClampOffset = 0.0; // raise clamp to allow more room for mount

	ClampTop = ClampOA.z/2 + ClampOffset;
	InsertCap = 6*ThreadThick; // fill layers atop inserts

	Kerf = 2.0;

	module Clamp(Support = false) {

	RibThick = 2*ThreadWidth;
	NumRibs = IntegerMultiple(ceil(ClampOA.y / 4.0),2); // space ribs roughly 4 mm apart
	RibSpace = ClampOA.y / NumRibs;
	echo(str("Ribs: ",NumRibs," spaced: ",RibSpace));

	ClampScrewOC = IntegerMultiple(ClampOA.x – ClampScrew[OD] – 10*ThreadWidth,1.0);
	echo(str("ClampScrew OC: ",ClampScrewOC));

	difference() {
	hull()
	for (i=[-1,1], j=[-1,1], k=[-1,1])
	translate([i(ClampOA.x – 2ShellRadius)/2,
	j(ClampOA.y – 2ShellRadius)/2,
	k(ClampOA.z – 2ShellRadius)/2 + ClampOffset])
	sphere(r=ShellRadius/cos(180/ShellSides),$fn=ShellSides);

	cube([2ClampOA.x,2ClampOA.y,Kerf],center=true); // split across middle

	rotate([90,0,0]) // seat rail
	cylinder(d=RailOD,h=2*ClampOA.y,$fn=RailSides,center=true);

	for (i=[-1,1]) // clamp inserts
	translate([i*ClampScrewOC/2,0,0])
	rotate(180/6)
	PolyCyl(ClampInsert[OD],ClampTop – InsertCap,6);

	for (i=[-1,1]) // clamp screw clearance
	translate([i*ClampScrewOC/2,0,-(ClampOA.z/2 – ClampOffset) – InsertCap])
	rotate(180/6)
	PolyCyl(ClampScrew[ID],ClampOA.z,6);

	translate([0,0,ClampTop + 0.7*Interposer.z]) // mounting bolt hole
	rotate(LookAngle)
	translate([0,0,ShellOA.z/2]) {
	M20Shape(Knockout = true);
	translate([0,0,-ShellOA.z/2 – Interposer.z])
	InterposerShape(Embiggen = true);
	}

	translate([ClampOA.x/2 – (EmbossDepth – Protrusion)/2, // recess for LookAngle.z
	0,
	ClampOA.z/4 + ClampOffset])
	cube([EmbossDepth,17,8],center=true);

	translate([0.3*ClampOA.x, // recess for LookAngle.z
	-(ClampOA.y/2 – (EmbossDepth – Protrusion)/2),
	ClampOA.z/4 + ClampOffset])
	cube([10,EmbossDepth,8],center=true);

	translate([0,0,-ClampOA.z/2 + (EmbossDepth – Protrusion)/2]) // recess bottom legend
	cube([35,10,EmbossDepth],center=true);
	}

	translate([ClampOA.x/2 – DebossHeight,0,ClampOA.z/4 + ClampOffset]) // LookAngle.z legend
	rotate([90,0,90])
	linear_extrude(height=DebossHeight,convexity=20)
	text(text=str(LookAngle.z),size=6,spacing=1.20,
	font="Arial:style:Bold",halign="center",valign="center");

	translate([0.3*ClampOA.x,-ClampOA.y/2 + DebossHeight + Protrusion/2,ClampOA.z/4 + ClampOffset]) // LookAngle.y legend
	rotate([90,0,00])
	linear_extrude(height=DebossHeight,convexity=20)
	text(text=str(LookAngle.y),size=6,spacing=1.20,
	font="Arial:style:Bold",halign="center",valign="center");

	translate([0,0,-ClampOA.z/2])
	linear_extrude(height=DebossHeight,convexity=20)
	mirror([0,1,0])
	text(text="KE4ZNU",size=5,spacing=1.20,
	font="Arial:style:Bold",halign="center",valign="center");


	if (Support) {
	difference() {
	color(SupportColor)
	union() {
	for (j=[-NumRibs/2:NumRibs/2])
	translate([0,j*RibSpace,0])
	rotate([90,0,0])
	cylinder(d=RailOD – 2ThreadThick,h=RibThick,$fn=23*4,center=true);
	cube([RailOD – 4ThreadWidth,NumRibsRibSpace,Kerf + 2*ThreadThick],center=true);
	}
	cube([2ClampOA.x,2ClampOA.y,Kerf],center=true); // split across middle
	}
	}

	}


	//—–
	// Battery
	// Based on Anker PowerCore, simplified shapes
	// Includes port & button punchouts

	Battery = [97.5,80.0,22.5]; // X=length, Y includes rounded edges, Z = Y dia

	module BatteryShape() {

	USB = [Projection,38,10]; // clearance around USB output ports
	USBOffset = [0,25.5,0]; // from -Y edge to center of USB block

	ChargeBtn = [11.0 + 5.0,10,5.0 + 5.0]; // charge level check button, enlarged
	Btnc = ChargeBtn.z; // figure button recess into battery curve
	Btnr = Battery.z/2;
	Btnm = Btnr – sqrt(pow(Btnr,2) – pow(Btnc,2)/4);
	ChargeBtnOffset = [17.0,0,0]; // from +X edge to center, centered on Z

	BatterySides = 234;

	hull()
	for (j=[-1,1])
	translate([0,j*(Battery.y – Battery.z)/2,0])
	rotate([0,90,0])
	cylinder(d=Battery.z,h=Battery.x,$fn=BatterySides,center=true);
	translate([(Battery.x + USB.x)/2 – Protrusion,-Battery.y/2 + USBOffset.y,0])
	cube(USB,center=true);
	translate([Battery.x/2 – ChargeBtnOffset.x,Battery.y/2 + ChargeBtn.y/2 – 2*Btnm,0])
	cube(ChargeBtn,center=true);
	}

	//—–
	// Battery cradle

	RackWidth = 89.0; // flat width between rack rails

	CradleWall = [4.0,4.0,3.0]; // wall thickness
	CradleRadius = 2.0; // corner rounding

	CradlePad = 0.5; // cushion around battery
	BatteryBase = CradleWall.z + CradlePad; // actual bottom surface of battery

	CradleOA = [Battery.x + 2*CradleWall.x,
	min((Battery.y + 2*CradleWall.y),RackWidth),
	BatteryBase + Battery.z/3];
	echo(str("Cradle OA: ",CradleOA));

	module Cradle() {

	difference() {
	hull()
	for (i=[-1,1], j=[-1,1]) { // box with tidy rounded corners
	translate([i*(CradleOA.x/2 – CradleRadius),
	j*(CradleOA.y/2 – CradleRadius),
	1*(CradleOA.z – CradleRadius)])
	sphere(r=CradleRadius,$fn=6);
	translate([i*(CradleOA.x/2 – CradleRadius),
	j*(CradleOA.y/2 – CradleRadius),
	0*(CradleOA.z/2 – CradleRadius)])
	cylinder(r=CradleRadius,h=CradleOA.z/2,$fn=6);
	}

	translate([0,0,Battery.z/2 + BatteryBase]) // minus the battery
	minkowski(convexity=3) { // … slightly embiggened
	BatteryShape();
	cube(2*CradlePad,center=true);
	}

	if (false) // reveal insets for debug
	translate([0,0,-Protrusion])
	cube(CradleOA + [0,0,CradleOA.z],center=false);

	translate([0,0,CradleWall.z – ThreadThick + Protrusion/2]) // recess top legend
	cube([55,20,EmbossDepth],center=true);
	translate([0,0,(EmbossDepth – Protrusion)/2]) // recess bottom legend
	cube([70,15,EmbossDepth],center=true);
	}

	translate([0,4.0,CradleWall.z – DebossHeight – Protrusion])
	linear_extrude(height=DebossHeight,convexity=20)
	text(text="PowerCore",size=6,spacing=1.20,
	font="Arial:style:Bold",halign="center",valign="center");

	translate([0,-4.0,CradleWall.z – DebossHeight – Protrusion])
	linear_extrude(height=DebossHeight,convexity=20)
	text(text="13000",size=6,spacing=1.20,
	font="Arial:style:Bold",halign="center",valign="center");

	linear_extrude(height=DebossHeight,convexity=20)
	mirror([0,1,0])
	text(text="KE4ZNU",size=10,spacing=1.20,
	font="Arial:style:Bold",halign="center",valign="center");


	}


	//—–
	// Build things

	// Layouts for design & tweaking

	if (Layout == "Show")

	if (Part == "Battery")
	BatteryShape();

	else if (Part == "Buttons")
	Buttons();

	else if (Part == "Interposer")
	InterposerShape(Embiggen = false);

	else if (Part == "Shell")
	Shell();

	else if (Part == "M20")
	M20Shape(Knockout = false);

	else if (Part == "ShellSections") {
	translate([ShellOA.x,0,0])
	ShellSection(Section="Front");
	translate([0,0,0])
	ShellSection(Section="Center");
	translate([-ShellOA.x,0,0])
	ShellSection(Section="Back");
	}

	else if (Part == "Clamp") {
	Clamp(Support = false);
	color(FadeColor,FadeAlpha)
	rotate([90,0,0])
	cylinder(d=RailOD,h=2*ClampOA.y,$fn=RailSides,center=true);
	}

	else if (Part == "Cradle") {
	Cradle();
	translate([0,0,Battery.z/2 + CradleWall.z])
	color(FadeColor,FadeAlpha)
	BatteryShape();
	}

	// Build layouts for top-level parts

	if (Layout == "Build")

	if (Part == "Cradle")
	Cradle();

	else if (Part == "Clamp") {
	translate([0,0.7*ClampOA.y,0])
	difference() {
	translate([0,0,-Kerf/2])
	Clamp(Support = true);
	translate([0,0,-ClampOA.z])
	cube(2*ClampOA,center=true);
	}
	translate([0,-0.7*ClampOA.y,-0])
	difference() {
	translate([0,0,-Kerf/2])
	rotate([0,180,0])
	Clamp(Support = true);
	translate([0,0,-ClampOA.z])
	cube(2*ClampOA,center=true);
	}
	}

	else if (Part == "Shell") {
	translate([0,-1.2*ShellOA.y,ShellOA.x/2])
	rotate([0,90,180])
	ShellSection(Section="Front");
	translate([0,0,M20.x/2])
	rotate([0,-90,0])
	ShellSection(Section="Center");
	translate([0,1.4*ShellOA.y,ShellOA.x/2])
	rotate([0,-90,180])
	ShellSection(Section="Back");
	}

	// Ad-hoc arrangement to see how it all goes together

	if (Layout == "Fit") {
	rotate(180) {
	Cradle();
	translate([0,0,Battery.z/2 + CradleWall.z])
	color(FadeColor,FadeAlpha)
	BatteryShape();
	}
	translate([0,-100,0]) {
	Clamp();
	color(FadeColor,FadeAlpha)
	rotate([90,0,0])
	cylinder(d=RailOD,h=2*ClampOA.y,$fn=RailSides,center=true);
	}

	translate([0,-100,(ClampOA.z + ShellOA.z)/2 + Interposer.z])
	translate([0,0,-ShellOA.z/2 + Interposer.z])
	rotate(LookAngle)
	translate([0,0,ShellOA.z/2]) {
	Shell();
	color(FadeColor,FadeAlpha)
	M20Shape(Knockout = false);
	}
	}

view raw SJCAM M20 Mount.scad hosted with ❤ by GitHub

2019-02-20

Makergear M2: Z-Axis Platform Sensor Switch, Replacement Thereof
After nearly four years of dangling a bare millimeter above the nozzle, the lever on the relocated Z-Axis switch finally snagged a stray thread and got bent out of shape. I un-bent it, but finally decided it was time to get more air between the nozzle and the switch actuator.

The small shim reduces the actuation distance:

file:///mnt/bulkdata/Cameras/2019/Shop Projects/Makergear M2/Z-Axis Switch/IMG_20190204_185300 – M2 Z-Axis – microswitch exterior

Prying the ends outward with a thumbnail releases a pair of snaps and the cover pops off to reveal the innards:

M2 Z-Axis – microswitch interior

The spring-loaded innards will launch themselves into the far corners of your shop, so be gentle as you slide the lever out and reinstall the side plate with a pair of clicks.

I filed the screw holes in my homebrew brass angle plate into slots, so as to get some adjustability, remounted the switch on the X-axis gantry, and tuned for best clearance:

M2 Z-Axis – bare microswitch vs nozzle

It looks a bit more canted than it really is.

There’s about 1.6 mm of Z-axis distance between the nozzle and the switch, which should suffice for another few years.

The view from the front shows a slight angle, too:

M2 Z-Axis – activated

There’s a millimeter or so below the nuts holding the X-axis linear slide in place, because the original 18 mm M3 SHCS are now 16 mm long (having shotgunned the metric SHCS and BHCS situation some time ago) and the washers are gone.

They’re all nylon lock nuts except for the one just to the left of the switch, providing barely enough clearance for the Powerpole connectors on the hotrod platform:

M2 Z-Axis – platform connector clearance

With the nozzle off the platform to the far right side, Z-axis homing proceeded normally. Manually jogging to Z=+5.0 mm left 2.6 mm of air under the nozzle, so I reset the offset in EEPROM to -2.4 = (2.6 – 5.0) mm:
```
M206 Z-2.4
M500
```
The first calibration square came out at 2.91 mm, so I changed the offset to -2.3 mm, got a 2.80 mm square with a firmly squished first layer, changed it to -2.5 mm, and got a 3.00 mm square for my efforts.

An array of five squares showed the platform remains level to within +0.05 / -0.07 mm:

M2 Platform Alignment Check – 2019-02-06

I defined it to be Good Enough™ and quit while I was ahead.

The bottom two squares in the left pile have squished first layers. The rest look just fine:

M2 Z-Axis – switch offset calibration squares

The whole set-and-test process required about 45 minutes, most of which was spent waiting for the platform to reach 90 °C in the 14 °C Basement Laboratory.

Done!
2019-02-11
Vacuum Tube LEDs: Better Radome

A two-legged ~~spider~~ radome base definitely looks better than the four-legged version:

Arduino Pro Mini – NP-BX1 – radome

The radome base now has a hole punched in its bottom for the data lead, with the two power wires going out the sides as before:

Arduino Pro Mini Battery Holder – SK6812 radome base

The alert reader will notice the vertical strut on the far side doesn’t go directly into the center of its base fitting. I attempted a bit of cosmetic repair on the horizontal wire below the Pro Mini and discovered, not at all to my surprise, (re)soldering a connection to a 14 AWG copper wire an inch away from a 3D printed base doesn’t work well at all.

Doesn’t affect the function and, as nobody will ever notice, I’ll leave it be.

2019-02-04

Juki TL-2010Q: COB LED Light Bar

Mary needed more light under the arm of her Juki TL-2010Q sewing machine, so I proposed a 12 V 6 W COB LED module instead of the high-density LED strips I used on her Kenmore 158s:

Kenmore 158 Sewing Machine - Cool white LEDs - rear no flash — Kenmore 158 Sewing Machine – Cool white LEDs – rear no flash

Because the COB LEDs dissipate 6W, far more power than I’m comfortable dumping into a 3D printed structure, I redefined a length of aluminum shelf bracket extrusion to be a heatsink and epoxied the module’s aluminum back plate thereto:

Juki TL-2010Q COB LED - test lighting — Juki TL-2010Q COB LED – test lighting

Unlike the flexible LED strips, the COB LED modules have no internal ballast resistors and expect to run from a constant-current supply. Some preliminary testing showed we’d want less than the maximum possible light output, so a constant-voltage supply and a few ohms of ballast would suffice:

Juki TL-2010Q COB LED - ballast resistor test — Juki TL-2010Q COB LED – ballast resistor test

With all that in hand, the heatsink extrusion cried out for smooth endcaps to control the wires and prevent snagging:

TL-2010Q COB LED Light Bars - end caps - Show layout — TL-2010Q COB LED Light Bars – end caps – Show layout

The central hole in the left cap passes 24 AWG silicone wires from the power supply, with 28 AWG silicone wires snaking down through the L-shaped rectangular cutouts along the extrusion to the LED module’s solder pads.

The model includes built-in support:

TL-2010Q COB LED Light Bars - end caps - Build layout — TL-2010Q COB LED Light Bars – end caps – Build layout

Assuming the curved ends didn’t need support / anchors holding them down turned out to be completely incorrect:

Juki TL-2010Q COB LED - curled endcaps — Juki TL-2010Q COB LED – curled endcaps

Fortunately, those delicate potato chips lived to tell the tale and, after a few design iterations, everything came out right:

Juki TL-2010Q COB LED - heatsink endcap - internal connections — Juki TL-2010Q COB LED – heatsink endcap – internal connections

The “connector”, such as it is, serves to make the light bar testable / removable and the ballast resistor tweakable, without going nuts over the details. The left side is an ordinary pin header strip held in place with hot melt glue atop the obligatory Kapton tape, because the heatsink doesn’t get hot enough to bother the glue. The right side is a pair of two-pin header sockets, also intended for PCB use. The incoming power connects to one set and the ballast resistor to the other, thusly:

Juki TL-2010Q COB LED - light bar connector diagram — Juki TL-2010Q COB LED – light bar connector diagram

The diagram is flipped top-to-bottom from the picture, but you get the idea. Quick, easy, durable, and butt-ugly, I’d say.

The next step was to mount it on the sewing machine and steal some power, but that’s a story for another day.

The relevant dimensions for the aluminum extrusion:

Aluminum shelf bracket extrusion - dimensions — Aluminum shelf bracket extrusion – dimensions

The OpenSCAD source code as a GitHub Gist:

	// Juki TL-2010Q Sewing Machine – COB LED Light Bars
	// Ed Nisley – KE4ZNU
	// 2019-01

	/* [Layout Options] */

	Layout = "Build"; // [Bracket,Endcap,Show,Build]

	Wiring = [1,0]; // left and right wire holes

	BuildSupport = true;

	/* [Extrusion Parameters] */

	ThreadWidth = 0.40;
	ThreadThick = 0.20;

	HoleWindage = 0.2;

	Protrusion = 0.1;

	//—–
	// Shelf bracket used as LED heatsink

	/* [Hidden] */

	LEDPlate = [15.0,2.4]; // 2D coords from end of LED

	BktOuter = [15.9,12.6 + LEDPlate.y]; // 2D coords as seen from end of extrusion
	BktWalls = [1.3,2.2 + LEDPlate.y]; // … extend base to cover LED
	BktCap = [2.5,3.0];

	BracketPoints = [
	[0,0],
	[BktOuter.x,0],
	[BktOuter.x,BktOuter.y],
	[(BktOuter.x – BktCap.x),BktOuter.y],
	[(BktOuter.x – BktCap.x),(BktOuter.y – BktCap.y)],
	[(BktOuter.x – BktWalls.x),(BktOuter.y – BktCap.y)],
	[(BktOuter.x – BktWalls.x),BktWalls.y],
	[BktWalls.x,BktWalls.y],
	[BktWalls.x,(BktOuter.y – BktCap.y)],
	[BktCap.x,(BktOuter.y – BktCap.y)],
	[BktCap.x,BktOuter.y],
	[0,BktOuter.y],
	[0,0]
	];

	BracketPlugInsert = 10.0; // distance into bracket end

	WireOD = 1.6; // COB LED jumpers – 24 AWG silicone
	WireOC = BktOuter.x – 2*BktWalls.x – WireOD;
	echo(str("Wire OC: ",WireOC));

	CableOD = 4.0; // power entry cable

	CapSides = 234;

	//—–
	// 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);
	}

	//—–
	// Endcap with smooth rounding
	// Wires = true to punch holes for LED wires

	module Endcap(Wires = true) {

	// arc length to flatten inside of cap
	// not needed to build in normal orientation

	m = BktOuter.x/2 – sqrt(pow(BktOuter.x/2,2) – pow(BktOuter.x – 2*BktCap.x,2)/4);

	difference() {
	translate([0,0,BktOuter.y/2]) // basic endcap shape
	intersection() {
	cylinder(d=BktOuter.x,h=BktOuter.y,$fn=CapSides,center=true);
	rotate([90,0,0])
	rotate(180/CapSides)
	cylinder(d=BktOuter.y,h=BktOuter.x,$fn=CapSides,center=true);
	}

	translate([-BracketPlugInsert,0,0]) // extrusion + LED plate
	Bracket(BracketPlugInsert);

	if (false) // flatten inner end
	translate([-BktOuter.y + m,0,BktOuter.y/2])
	cube([BktOuter.y,BktOuter.x,BktOuter.y],center=true);

	if (Wires) {
	for (j=[-1,1]) // COB LED connections
	translate([WireOD – BktOuter.x/2,j*WireOC/2,(BktWalls.y + WireOD – Protrusion)/2])
	rotate([0,00,0])
	cube([BktOuter.x,WireOD + Protrusion,BktWalls.y + WireOD + Protrusion],center=true);
	translate([0,0,BktOuter.y/2]) // power entry / exit
	rotate([0,90,0])
	translate([0,0,-BktOuter.x])
	rotate(180/6)
	PolyCyl(CableOD,2*BktOuter.x,6);
	}
	}
	}

	// Totally ad-hoc support structures

	module Support(Wiring = false) {

	Spacing = 4*ThreadWidth;
	NumBars = floor((BktOuter.y/2) / Spacing);
	echo(str("Support bars: ",NumBars));

	color("Yellow") {
	render() difference() {
	union() {
	for (i=[1:NumBars]) // inside extrusion
	translate([-i*Spacing,0,(BktWalls.y + WireOD)/2])
	cube([2ThreadWidth,BktOuter.x – 0BktWalls.x,BktWalls.y + WireOD],center=true);

	if (true)
	for (j=[-1:1]) // reduce outside curve uplift
	translate([0.3BktOuter.y,jBktOuter.x/3,BktOuter.y/10])
	cube([BktOuter.y/3,2*ThreadWidth,BktOuter.y/5],center=true);
	}
	minkowski() { // all-around clearance
	Endcap(Wiring);
	cube(2.0*ThreadThick,center=true);
	}
	if (Wiring) {
	translate([0,0,BktOuter.y/2]) // remove rubble from wire bore
	rotate([0,90,0])
	translate([0,0,-BktOuter.x])
	rotate(180/6)
	PolyCyl(CableOD,2*BktOuter.x,6);
	}
	}

	if (false)
	translate([-(BktOuter.x/4 + ThreadWidth),0,ThreadThick/2]) // adhesion pad
	cube([BktOuter.x/2,BktOuter.x – BktWalls.x,ThreadThick],center=true);

	// translate([BktOuter.x/3,0,ThreadThick/2]) // adhesion pad
	// cube([0.3BktOuter.x,0.7BktOuter.x,ThreadThick],center=true);

	if (false)
	for (j = [-1:1]) // tie pad to bottom of cap
	translate([-(4ThreadWidth)/2,j(BktOuter.x – 2*ThreadWidth)/2,ThreadThick/2])
	cube([4ThreadWidth,2ThreadWidth,ThreadThick],center=true);
	}
	}

	//—–
	// Heatsink extrusion + LED plate
	// Centered on Y with Length extending in +X

	module Bracket(Length = 10)
	translate([0,-BktOuter.x/2,0])
	rotate([90,0,90])
	linear_extrude(height = Length,convexity=3)
	polygon(points=BracketPoints);

	//—–
	// Build things

	if (Layout == "Bracket")
	Bracket();

	if (Layout == "Endcap")
	Endcap();

	if (Layout == "Show") {
	translate([BktOuter.x,0,0])
	Endcap(Wiring[1]);
	translate([-BktOuter.x,0,0])
	rotate(180)
	Endcap(Wiring[0]);
	color("Yellow",0.35)
	translate([-BktOuter.x/2,0,0])
	Bracket(BktOuter.x);
	}

	if (Layout == "Build") {
	translate([BktOuter.y,0,0]) {
	Endcap(Wiring[0]);
	if (BuildSupport)
	Support(Wiring[0]);
	}
	translate([-BktOuter.y,0,0]) {
	Endcap(Wiring[1]);
	if (BuildSupport)
	Support(Wiring[1]);
	}
	}

view raw TL-2010Q COB LED Light Bars.scad hosted with ❤ by GitHub

2019-01-31

Vacuum Tube LEDs: Radome Prototype

Definitely not a vacuum tube:

Arduino Pro Mini – NP-BX1 cell – SK6812 – blue phase

It’s running the same firmware, though, with the Arduino Pro Mini and the LEDs drawing power from the (mostly) defunct lithium battery.

The LED holder is identical to the Pirhana holder, with a 10 mm diameter recess punched into it for the SK6812 PCB:

Astable Multivibrator Battery Holder – Neopixel PCB – Slic3r

Those embossed legends sit in debossed rectangles for improved legibility. If I repeat it often enough, I’m sure I’ll remember which is which.

The 3.6 V (and declining) power supply may not produce as much light from the SK6812 LEDs, but it’s entirely adequate for anything other than a well-lit room. The 28 AWG silicone wires require a bit of careful dressing to emerge from the holes in the radome holder:

SK6812 LED PCB – Pirhana holder wiring

The firmware cycles through all the usual colors:

Arduino Pro Mini – NP-BX1 cell – SK6812 – orange phase

A pair of tensilized 22 AWG copper wires support the Pro Mini between the rear struts. The whole affair looks a bit heavier than I expected, though, so I should reduce the spider to a single pair of legs with a third hole in the bottom of the LED recess for the data wire.

The OpenSCAD source code needs some refactoring and tweaking, but the Pirhana LED solid model version of the battery holder should give you the general idea.

2019-01-29

Astable Multivibrator: Monochrome Pirhana LED

The LED parts box disgorged some single-color Pirhana-style LEDs:

Astable - 2N7000 - Mono Pirhana LED — Astable – 2N7000 – Mono Pirhana LED

Didn’t quite catch the blink, but the ~~Ping-Pong ball~~ radome lights up just as you’d expect.

The radome sits on a stripped-down RGB LED spider:

Astable Multivibrator Battery Holder - mono LED Spider - fit view — Astable Multivibrator Battery Holder – mono LED Spider – fit view

The circuitry is the same as the First Light version, with a 1 MΩ resistor stabilizing the LED ballast resistor:

Astable - 2N7000 - Mono Pirhana LED - detail — Astable – 2N7000 – Mono Pirhana LED – detail

Those are 1 µF ceramic caps in the astable section, so I’m no longer abusing electrolytics, and a stylin’ 100 nF film cap metering out the LED pulse up above.

Just for pretty, I’ve been using yellow / black wires for the battery connections and matching the LED color with its cathode lead.

The OpenSCAD source code as a GitHub Gist:

	// Holder for Li-Ion battery packs
	// Ed Nisley KE4ZNU January 2013
	// 2018-11-15 Adapted for 1.5 mm pogo pins, battery data table
	// 2018-12 RGB LED spider, general cleanups

	/* [Layout options] */

	BatteryName = "NP-BX1"; // [NP-BX1,NB-5L,NB-6L]

	RGBCircuit = false; // false = 1 strut pair, true = 2 pairs

	Layout = "Spider"; // [Build,Show,Fit,Case,Lid,Pins,RGBSpider,Spider]

	/* [Extrusion parameters] – must match reality! */
	// Print with +2 shells and 3 solid layers

	ThreadThick = 0.25;
	ThreadWidth = 0.40;

	HoleWindage = 0.2;

	function IntegerMultiple(Size,Unit) = Unit * ceil(Size / Unit);
	function IntegerLessMultiple(Size,Unit) = Unit * floor(Size / Unit);

	Protrusion = 0.1; // make holes end cleanly

	/* [Hidden] */

	inch = 25.4;

	BuildOffset = 3.0; // clearance for build layout

	Gap = 2.0; // separation for Fit parts

	//- Basic dimensions

	WallThick = 4*ThreadWidth; // holder sidewalls

	BaseThick = 6*ThreadThick; // bottom of holder to bottom of battery
	TopThick = 6*ThreadThick; // top of battery to top of holder

	//- Battery dimensions – rationalized from several samples
	// Coordinate origin at battery corner with contacts, key openings downward

	T_NAME = 0; // Name must fit recess, so don't get loquacious
	T_SIZE = 1;
	T_CONTACTS = 2;
	T_KEYS = 3;

	BatteryData = [
	["NP-BX1",[43.0,30.0,9.5],[[-0.75,6.0,6.2,"+"],[-0.75,16.0,6.2,"-"]],[[1.70,3.70,2.90],[1.70,3.60,2.90]]],
	["NB-5L", [45.0,32.0,8.0],[[-0.82,4.5,3.5,"-"],[-0.82,11.0,3.5,"+"]],[[2.2,0.75,2.0],[2.2,2.8,2.0]]],
	["NB-6L",[42.5,35.5,7.0],[[-0.85,5.50,3.05,"-"],[-0.85,11.90,3.05,"+"]],[[2.0,0.70,2.8],[2.0,2.00,2.8]]],
	];

	echo(str("Battery: ",BatteryName));

	BatteryIndex = search([BatteryName],BatteryData,1,0)[0];
	echo(str(" Index: ",BatteryIndex));

	BatterySize = BatteryData[BatteryIndex][T_SIZE]; // X = length, Y = width, Z = thickness
	echo(str(" Size: ",BatterySize));

	Contacts = BatteryData[BatteryIndex][T_CONTACTS]; // relative to battery edge, front, and bottom
	echo(str(" Contacts: ",Contacts));

	ContactOC = Contacts[1].y – Contacts[0].y; // + and – terminals for pogo pin contacts
	ContactCenter = Contacts[0].y + ContactOC/2;

	KeyBlocks = BatteryData[BatteryIndex][T_KEYS]; // recesses in battery face set X position
	echo(str(" Keys: ",KeyBlocks));

	//- Pin dimensions

	ID = 0;
	OD = 1;
	LENGTH = 2;

	PinShank = [1.5,2.0,6.5]; // shank, flange, compressed length
	PinFlange = [1.5,2.0,0.5]; // flange, length included in PinShank
	PinTip = [0.9,0.9,2.5]; // extended spring-loaded tip

	WireOD = 1.7; // wiring from pins to circuitry

	PinChannel = WireOD; // cut behind flange for solder overflow
	PinRecess = 3.0; // recess behind pin flange end for epoxy fill

	echo(str("Contact tip dia: ",PinTip[OD]));
	echo(str(" .. shank dia: ",PinShank[ID]));

	OverTravel = 0.5; // space beyond battery face at X origin

	//- Holder dimensions

	GuideRadius = ThreadWidth; // friction fit ridges
	GuideOffset = 7; // from compartment corners

	LidOverhang = 2.0; // atop of battery for retention
	LidClearance = LidOverhang * (BatterySize.z/BatterySize.x); // … clearance above battery for tilting
	echo(str("Lid clearance: ",LidClearance));

	CaseSize = [BatterySize.x + PinShank[LENGTH] + OverTravel + PinRecess + GuideRadius + WallThick,
	BatterySize.y + 2WallThick + 2GuideRadius,
	BatterySize.z + BaseThick + TopThick + LidClearance];
	echo(str("Case size: ",CaseSize));

	CaseOffset = [-(PinShank[LENGTH] + OverTravel + PinRecess),-(WallThick + GuideRadius),0]; // position around battery

	ThumbRadius = 10.0; // thumb opening at end of battery

	CornerRadius = 3*ThreadThick; // nice corner rounding

	LidSize = [-CaseOffset.x + LidOverhang,CaseSize.y,TopThick];

	LidOffset = [0.0,CaseOffset.y,0];

	//- Wire struts

	StrutDia = 1.6; // AWG 14 = 1.6 mm
	StrutSides = 3*4;

	StrutBase = [StrutDia,StrutDia + 4*WallThick,CaseSize.z – TopThick]; // ID = wire, OD = buildable

	//StrutOC = [IntegerLessMultiple(BatterySize.x – StrutBase[OD],5.0), // set easy OC wire spacing
	// IntegerMultiple(CaseSize.y + StrutBase[OD],5.0)];
	StrutOC = [IntegerLessMultiple(CaseSize.x – 2CornerRadius -2StrutBase[OD],5.0),
	IntegerMultiple(CaseSize.y + StrutBase[OD],5.0)];

	StrutOffset = [CaseSize.x/2 + CaseOffset.x,BatterySize.y/2]; // from case centerlines

	StrutAngle = atan(StrutOC.y/StrutOC.x);

	echo(str("Strut OC: ",StrutOC));

	//- RGB / Pirhana / Neopixel-ish LEDs

	RGBBody = [8.0,8.0,5.0]; // Z = body height

	PixelPCB = [4.0,10.0,3.0]; // Neopixel-ish PCBs, ID = chip window

	RGBPin = 5.0; // pin length
	RGBPinsOC = [5.0,5.0]; // pin layout

	RGBRecess = RGBBody.z + RGBPin/2; // maximum LED recess depth

	BallOD = 40.0; // radome sphere
	BallSides = 4*StrutSides; // nice number of sides

	BallPillar = [norm([RGBBody.x,RGBBody.y]),
	norm([RGBBody.x,RGBBody.y]) + 4*WallThick,
	StrutBase[OD] + RGBBody.z];
	BallChordM = BallOD/2 – sqrt(pow(BallOD/2,2) – (pow(BallPillar[OD],2))/4);
	echo(str("Ball chord depth: ",BallChordM));

	//———————-
	// 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);
	}

	//——————-
	//– Guides for tighter friction fit

	module Guides() {
	translate([GuideOffset,-GuideRadius,0])
	PolyCyl(2*GuideRadius,(BatterySize.z – Protrusion),4);
	translate([GuideOffset,(BatterySize.y + GuideRadius),0])
	PolyCyl(2*GuideRadius,(BatterySize.z – Protrusion),4);
	translate([(BatterySize.x – GuideOffset),-GuideRadius,0])
	PolyCyl(2*GuideRadius,(BatterySize.z – Protrusion),4);
	translate([(BatterySize.x – GuideOffset),(BatterySize.y + GuideRadius),0])
	PolyCyl(2*GuideRadius,(BatterySize.z – Protrusion),4);
	translate([(BatterySize.x + GuideRadius),GuideOffset/2,0])
	PolyCyl(2*GuideRadius,(BatterySize.z – Protrusion),4);
	translate([(BatterySize.x + GuideRadius),(BatterySize.y – GuideOffset/2),0])
	PolyCyl(2*GuideRadius,(BatterySize.z – Protrusion),4);

	}

	//– Contact pins
	// Rotated to put them in their natural oriention
	// Aligned to put tip base / end of shank at Overtravel limit

	module PinShape() {

	translate([-(PinShank[LENGTH] + OverTravel),0,0])
	rotate([0,90,0])
	rotate(180/6)
	union() {
	PolyCyl(PinTip[OD],PinShank[LENGTH] + PinTip[LENGTH],6);
	PolyCyl(PinShank[ID],PinShank[LENGTH] + Protrusion,6); // slight extension for clean cuts
	PolyCyl(PinFlange[OD],PinFlange[LENGTH],6);
	}
	}

	// Position pins to put end of shank at battery face
	// Does not include recess access into case

	module PinAssembly() {

	union() {
	for (p = Contacts)
	translate([0,p.y,p.z])
	PinShape();

	translate([-(PinShank[LENGTH] + OverTravel) + PinChannel/2, // solder space
	ContactCenter,
	Contacts[0].z])
	cube([PinChannel,
	(Contacts[1].y – Contacts[0].y + PinFlange[OD]),
	PinFlange[OD]],center=true);

	for (j=[-1,1]) // wire channels
	translate([-(PinShank[LENGTH] + OverTravel – PinChannel/2),
	j*ContactOC/4 + ContactCenter,
	Contacts[0].z – PinFlange[OD]/2])
	rotate(180/6)
	PolyCyl(WireOD,CaseSize.z,6);
	}
	}

	//– Case with origin at battery corner

	module Case() {

	difference() {

	union() {

	difference() {
	union() {
	translate([(CaseSize.x/2 + CaseOffset.x), // basic case shape
	(CaseSize.y/2 + CaseOffset.y),
	(CaseSize.z/2 – BaseThick)])
	hull()
	for (i=[-1,1], j=[-1,1], k=[-1,1])
	translate([i*(CaseSize.x/2 – CornerRadius),
	j*(CaseSize.y/2 – CornerRadius),
	k*(CaseSize.z/2 – CornerRadius)])
	sphere(r=CornerRadius/cos(180/8),$fn=8); // cos() fixes undersize spheres!

	for (i= RGBCircuit ? [-1,1] : -1) { // strut bases
	hull()
	for (j=[-1,1])
	translate([iStrutOC.x/2 + StrutOffset.x,jStrutOC.y/2 + StrutOffset.y,-BaseThick])
	rotate(180/StrutSides)
	cylinder(d=StrutBase[OD],h=StrutBase[LENGTH],$fn=StrutSides);

	translate([i*StrutOC.x/2 + StrutOffset.x,StrutOffset.y,StrutBase[LENGTH]/2 – BaseThick])
	cube([2*StrutBase[OD],StrutOC.y,StrutBase[LENGTH]],center=true); // blocks for fairing

	for (j=[-1,1]) // hemisphere caps
	translate([i*StrutOC.x/2 + StrutOffset.x,
	j*StrutOC.y/2 + StrutOffset.y,
	StrutBase[LENGTH] – BaseThick])
	rotate(180/StrutSides)
	sphere(d=StrutBase[OD]/cos(180/StrutSides),$fn=StrutSides);

	}
	}

	translate([-OverTravel,-GuideRadius,0])
	cube([(BatterySize.x + GuideRadius + OverTravel),
	(BatterySize.y + 2*GuideRadius),
	(BatterySize.z + LidClearance + Protrusion)]); // battery space

	translate([BatterySize.x/2,BatterySize.y/2,0]) // recess around battery name
	cube([0.8BatterySize.x,8,2ThreadThick],center=true);

	translate([CaseOffset.x + CaseSize.x/2,BatterySize.y/2,-BaseThick + ThreadThick – Protrusion]) // recess around battery name
	cube([0.75CaseSize.x,8,2ThreadThick],center=true);
	}

	Guides(); // improve friction fit

	translate([-OverTravel,-GuideRadius,0]) // battery keying blocks
	cube(KeyBlocks[0] + [OverTravel,GuideRadius,0],center=false);
	translate([-OverTravel,(BatterySize.y – KeyBlocks[1].y),0])
	cube(KeyBlocks[1] + [OverTravel,GuideRadius,0],center=false);

	translate([BatterySize.x/2,BatterySize.y/2,-ThreadThick])
	linear_extrude(height=2*ThreadThick,convexity=10)
	text(text=BatteryName,size=5,spacing=1.20,font="Arial:style:Bold",halign="center",valign="center");

	translate([CaseOffset.x + CaseSize.x/2,BatterySize.y/2,-BaseThick])
	linear_extrude(height=2*ThreadThick + Protrusion,convexity=10)
	mirror([0,1,0])
	text(text="KE4ZNU",size=6,spacing=1.20,font="Arial:style:Bold",halign="center",valign="center");
	}

	translate([2*CaseOffset.x, // battery top access
	(CaseOffset.y – Protrusion),
	BatterySize.z + LidClearance])
	cube([2CaseSize.x,(CaseSize.y + 2Protrusion),2*TopThick]);

	for (i2 = RGBCircuit ? [-1,1] : -1) { // strut wire holes and fairing
	for (j=[-1,1])
	translate([i2StrutOC.x/2 + StrutOffset.x,jStrutOC.y/2 + StrutOffset.y,0])
	rotate(180/StrutSides)
	PolyCyl(StrutBase[ID],2*StrutBase[LENGTH],StrutSides);

	for (i=[-1,1], j=[-1,1])
	translate([iStrutBase[OD] + (i2StrutOC.x/2 + StrutOffset.x),
	j*StrutOC.y/2 + StrutOffset.y,
	-(BaseThick + Protrusion)])
	rotate(180/StrutSides)
	PolyCyl(StrutBase[OD],StrutBase[LENGTH] + 2*Protrusion,StrutSides);
	}

	translate([(BatterySize.x – Protrusion), // remove thumb notch
	(CaseSize.y/2 + CaseOffset.y),
	(ThumbRadius)])
	rotate([90,0,0])
	rotate([0,90,0])
	cylinder(r=ThumbRadius,
	h=(WallThick + GuideRadius + 2*Protrusion),
	$fn=22);

	PinAssembly(); // pins and wiring

	translate([CaseOffset.x + PinRecess + Protrusion,(Contacts[1].y + Contacts[0].y)/2,Contacts[0].z])
	translate([-PinRecess,0,0])
	cube([2*PinRecess,
	(Contacts[1].y – Contacts[0].y + PinFlange[OD]/cos(180/6) + 2*HoleWindage),
	2*PinFlange[OD]],center=true); // pin insertion hole

	}

	}

	// Lid position offset to match case
	// The polarity indicator recesses are pure bodges

	module Lid() {

	union() {
	difference() {
	translate([-LidSize.x/2 + LidOffset.x + LidOverhang,LidSize.y/2 + LidOffset.y,0])
	difference() {
	hull()
	for (i=[-1,1], j=[-1,1], k=[-1,1])
	translate([i*(LidSize.x/2 – CornerRadius),
	j*(LidSize.y/2 – CornerRadius),
	k*(LidSize.z – CornerRadius)]) // double thickness for flat bottom
	sphere(r=CornerRadius,$fn=8);

	translate([0,0,-LidSize.z/2]) // remove bottom
	cube([(LidSize.x + 2Protrusion),(LidSize.y + 2Protrusion),LidSize.z],center=true);

	translate([LidSize.x/8,0,0])
	cube([LidSize.x/4,0.75LidSize.y,4ThreadThick],center=true); // epoxy recess
	}

	translate([0,0,-(Contacts[0].z + PinFlange[OD])]) // punch wire holes
	PinAssembly();

	for (n=[0,1]) // polarity recesses
	translate([-LidOverhang/2 – 0.40,Contacts[n].y,LidSize.z – ThreadThick/2])
	cube([4,4.5,ThreadThick + Protrusion],center=true);

	}

	for (n=[0,1]) // polarity indicators
	translate([-LidOverhang/2,Contacts[n].y,LidSize.z – 1*ThreadThick]) // … proud of surface
	rotate(90)
	linear_extrude(height=2*ThreadThick,convexity=10)
	text(text=Contacts[n][3],size=5,font="Arial:style:Bold",halign="center",valign="center");
	}

	}

	// Spider for RGB LED + radome atop vertical struts

	module RGBSpider() {

	difference() {
	union() {
	for (i=[-1,1], j=[-1,1]) {
	translate([iStrutOC.x/2,jStrutOC.y/2,StrutBase[OD]/2])
	rotate(180/StrutSides) // doesn't quite match crosspieces; close enough
	sphere(d=StrutBase[OD]/cos(180/StrutSides),$fn=StrutSides);
	translate([iStrutOC.x/2,jStrutOC.y/2,0])
	rotate(180/StrutSides)
	cylinder(d=StrutBase[OD],h=StrutBase[OD]/2,$fn=StrutSides);
	}

	for (m=[-1,1]) // connecting bars
	rotate(m*StrutAngle)
	translate([0,0,StrutBase[OD]/4])
	cube([norm(StrutOC),StrutBase[OD],StrutBase[OD]/2],center=true);

	translate([0,0,0]) // pillar for RGB LED and ball
	cylinder(d=BallPillar[OD],h=BallPillar[LENGTH],$fn=BallSides);
	}

	for (i=[-1,1], j=[-1,1]) // strut wires
	translate([iStrutOC.x/2,jStrutOC.y/2,-Protrusion])
	rotate(0)
	PolyCyl(StrutBase[ID],StrutBase[OD]/2,6);

	for (m=[-1,1], n=[0,1]) // RGBA wires through bars
	rotate(mStrutAngle + n180)
	translate([StrutOC.x/3,0,-Protrusion])
	PolyCyl(StrutBase[ID],StrutBase[OD],6);

	translate([0,0,BallOD/2 + BallPillar[LENGTH] – BallChordM]) // ball inset
	sphere(d=BallOD);

	translate([0,0,2*RGBBody.z + (BallPillar[LENGTH] – BallChordM) – RGBRecess]) // LED inset
	cube(RGBBody + [HoleWindage,HoleWindage,3*RGBBody.z],center=true); // XY clearance + huge height for E-Z cut

	translate([0,0,StrutBase[OD]/2]) // Neopixel recess
	PolyCyl(PixelPCB[OD],3*RGBBody.z,BallSides/2);

	for (m=[-1,1]) // RGBA wires through pillar
	rotate(m*StrutAngle)
	translate([0,0,StrutBase[OD]/2 + WireOD/2 + 0*Protrusion])
	cube([norm(StrutOC)/2,WireOD,WireOD],center=true);

	}
	}

	// Spider for single LED atop struts, with the ball
	// Aligned to struts at terminal end of battery on Y axis

	module Spider() {

	difference() {
	union() {
	for (j=[-1,1]) {
	translate([-StrutOC.x/2,j*StrutOC.y/2,StrutBase[OD]/2])
	rotate(180/StrutSides)
	sphere(d=StrutBase[OD]/cos(180/StrutSides),$fn=StrutSides);
	translate([-StrutOC.x/2,j*StrutOC.y/2,0])
	rotate(180/StrutSides)
	cylinder(d=StrutBase[OD],h=StrutBase[OD]/2,$fn=StrutSides);
	}

	translate([-StrutOC.x/2,0,StrutBase[OD]/4]) // connecting bars
	cube([StrutBase[OD]*cos(180/StrutSides),StrutOC.y,StrutBase[OD]/2],center=true);

	translate([-StrutOC.x/2,0,0]) // pillar for RGB LED and ball
	cylinder(d=BallPillar[OD],h=BallPillar[LENGTH],$fn=BallSides);
	}

	for (j=[-1,1]) // strut wires
	translate([-StrutOC.x/2,j*StrutOC.y/2,-Protrusion])
	rotate(0)
	PolyCyl(StrutBase[ID],StrutBase[OD]/2,6);

	translate([-StrutOC.x/2,0,0]) // wires through bars
	for (n=[-1,1])
	rotate(n*90)
	translate([StrutOC.x/3,0,-Protrusion])
	PolyCyl(StrutBase[ID],StrutBase[OD],6);

	translate([-StrutOC.x/2,0,-Protrusion]) // center hole for Neopixel
	rotate(180/6)
	PolyCyl(StrutBase[ID],StrutBase[OD],6);

	translate([-StrutOC.x/2,0,BallOD/2 + BallPillar[LENGTH] – BallChordM]) // ball inset
	sphere(d=BallOD);

	translate([-StrutOC.x/2,0,2*RGBBody.z + (BallPillar[LENGTH] – BallChordM) – RGBRecess]) // LED inset
	cube(RGBBody + [HoleWindage,HoleWindage,3*RGBBody.z],center=true); // XY clearance + huge height for E-Z cut

	translate([-StrutOC.x/2,0,StrutBase[OD]/2]) // Neopixel recess
	PolyCyl(PixelPCB[OD],3*RGBBody.z,BallSides/2);

	translate([-StrutOC.x/2,0,StrutBase[OD]/2 + WireOD/2 + 0*Protrusion]) // wire channels
	cube([WireOD,StrutOC.y/2,WireOD],center=true);

	}
	}

	//——————-
	// Build it!

	if (Layout == "Case")
	Case();

	if (Layout == "Lid")
	Lid();

	if (Layout == "RGBSpider") {
	RGBSpider();
	}

	if (Layout == "Spider") {
	Spider();
	}

	if (Layout == "Pins") {
	color("Silver",0.5)
	PinShape();
	PinAssembly();
	}

	if (Layout == "Fit") { // reveal pin assembly
	difference() {
	Case();

	translate([(CaseOffset.x – Protrusion),
	Contacts[1].y,
	Contacts[1].z])
	cube([(-CaseOffset.x + Protrusion),CaseSize.y,CaseSize.z]);

	translate([(CaseOffset.x – Protrusion),
	(CaseOffset.y – Protrusion),
	0])
	cube([(-CaseOffset.x + Protrusion),
	Contacts[0].y + Protrusion – CaseOffset.y,
	CaseSize.z]);
	}

	translate([0,0,BatterySize.z + Gap])
	Lid();

	color("Silver",0.15)
	PinAssembly();

	if (RGBCircuit) {
	translate([StrutOC.x/2,BatterySize.y/2,2*BatterySize.z])
	difference() {
	RGBSpider();
	rotate(180-StrutAngle)
	translate([0,0,-Protrusion])
	cube([norm(StrutOC),StrutBase[OD],2*BallPillar.z],center=false);
	}
	color("Green",0.35)
	translate([StrutOC.x/2,BatterySize.y/2,2*BatterySize.z + BallOD/2 + BallPillar[LENGTH] – BallChordM])
	sphere(d=BallOD);
	}
	else {
	difference() {
	translate([StrutOC.x/2,BatterySize.y/2,2*BatterySize.z])
	Spider();
	translate([-BallPillar[OD],BatterySize.y/2,2*BatterySize.z – Protrusion])
	cube([BallPillar[OD],StrutOC.y,2*BallPillar.z],center=false);
	}
	color("Green",0.35)
	translate([0,BatterySize.y/2,2*BatterySize.z + BallOD/2 + BallPillar[LENGTH] – BallChordM])
	sphere(d=BallOD);
	}
	}

	if (Layout == "Build") {
	rotate(90) {
	translate([-BatterySize.x/2,-BatterySize.y/2,BaseThick])
	Case();
	translate([-CaseSize.x + LidSize.x,-(LidSize.y/2 + LidOffset.y),0])
	Lid();
	if (RGBCircuit)
	translate([StrutOC.x + BatterySize.x/2,0,0])
	RGBSpider();
	else
	translate([StrutOC.x + BatterySize.x/2,0,0])
	Spider();
	}
	}

	if (Layout == "Show") {
	Case();
	translate([0,0,(BatterySize.z + Gap)])
	Lid();
	color("Silver",0.25)
	PinAssembly();
	if (RGBCircuit) {
	translate([StrutOC.x/2,BatterySize.y/2,2*BatterySize.z])
	RGBSpider();
	color("Green",0.35)
	translate([StrutOC.x/2,BatterySize.y/2,2*BatterySize.z + BallOD/2 + BallPillar[LENGTH] – BallChordM])
	sphere(d=BallOD);
	}
	else {
	translate([StrutOC.x/2,BatterySize.y/2,2*BatterySize.z])
	Spider();
	color("Green",0.35)
	translate([0,BatterySize.y/2,2*BatterySize.z + BallOD/2 + BallPillar[LENGTH] – BallChordM])
	sphere(d=BallOD);
	}
	}

view raw Astable Multivibrator Battery Holder.scad hosted with ❤ by GitHub

2019-01-17

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