prepared body with all holes except mounting holes

7 files changed, 292 insertions, 60 deletions

diff --git a/body/body.scad b/body/body.scad
index 127d005..1db4742 100644
--- a/body/body.scad
+++ b/body/body.scad
@@ -1,3 +1,4 @@
+include <body_config.scad>
 include <design.scad>
 include <helpers.scad>
 include <holes.scad>
@@ -8,24 +9,6 @@ include <noctua_nf_a4x20.scad>
 include <radxa_zero_3e.scad>
 include <veye_imx287.scad>
 
-// main frame size
-// in scanner coords
-// inner height is a bit random
-// TODO: choose constant size to use one frame for
-// many similar ranges
-main_frame_height_y = 150;
-main_frame_width_x = 34;
-main_frame_depth_z = 56;
-
-// wall and wall thickness
-$sbfwo = $scannerBodyFrontWallOffsetMm;
-$wawt = -$scannerBodyFrontWallOffsetMm + $scannerBodyWallThicknessMm;
-wt = $scannerBodyWallThicknessMm;
-wzo = $scannerBodyFrontWallOffsetMm;
-
-// scanner coords
-fan_y_offset = 80;
-
 module cam_and_lense_new()
 {
     lhs = laser_holder_size();
@@ -559,35 +542,72 @@ module scanner_main_frame()
         }
     }
     
+    // back wall, bottom
+    translate([0, bwo, 10])
+    hole_holder_hot_inserts(hs = hole_side_back);
+    
+    // back wall, top
+    translate([0, bwo, 120])
+    hole_holder_hot_inserts(hs = hole_side_back);
+    
+    // top wall
+    translate([0, 0, two])
+    hole_holder_hot_inserts(hs = hole_side_top);
+    
+    // front wall, bottom
+    translate([0, fwo, 12])
+    hole_holder_hot_inserts(hs = hole_side_front);
+    
+    // front wall, top
+    translate([0, fwo, 83])
+    hole_holder_hot_inserts(hs = hole_side_front);
+    
     // TODO: and now add some stands for screwing left/right covers
     // TODO: simplify inner cut cube after implementing this:
     // rounded corners won't be needed anymore
 
     // chinese fan
     //translate([0, -$scannerBodyFrontWallOffsetMm, 40])
-    translate([0, -wzo - id, fan_y_offset])
+    *translate([0, bwo, fan_y_offset])
     ld3007ms();
 }
 
-module m12_connectors()
+// s - scale
+module m12_connectors(s = [1, 1, 1])
 {
-    // inner height, width, depth and radius
+    // inner height, width, depth and radius (scanner coords)
     ih = main_frame_height_y;
     iw = main_frame_width_x;
     id = main_frame_depth_z;
     ir = wt;
     
+    // scanner coords
+    bottom_connector_y = 28;
+    bcy = bottom_connector_y;
+    
+    m12tpd = m12_male_conn_body_thick_part_d;
+    
     {
         // add outer m12 connectors
         //scale([1.05, 1, 1.05])
-        translate([0, -wzo - id + $tiny_padding, 20 + m12_male_conn_body_thick_part_d + 5])
+        //     scale([1.1, 1, 1.1])
+        translate([0, bwo + $tiny_padding, bcy + m12tpd + 5])
+        scale(s)
         m12_female_connector();
         
-        translate([0, -wzo - id + $tiny_padding, 20])
+        translate([0, bwo + $tiny_padding, bcy])
+        scale(s)
         m12_male_connector();
     }
 }
 
+module m12_connectors_to_cut()
+{
+    //translate([0, $tiny_padding * 50, 0])
+    
+    m12_connectors([1.05, 1, 1.05]);
+}
+
 module laser_with_holder()
 {
     translate([0, -$laserZOffsetMm, 0])
@@ -600,20 +620,33 @@ module laser_with_holder()
 module body_fan_holes()
 {
     id = main_frame_depth_z;
-    translate([0, -wzo - id, fan_y_offset])
+    translate([0, fwo, fan_y_offset])
     ld3007ms_holes();
 }
 
 module radxa()
 {
     translate([0, 0, 20])
-    translate([
-        0,
-        -$scannerBodyFrontWallOffsetMm - 5,
-        radxa_zero_3e_pcb_h - 10])
+    translate([0, fwo - 13, radxa_zero_3e_pcb_h - 5])
     rotate([90, 0, 0])
     //radxa_zero_3e_with_protoboard();
-    radxa_zero_3e_with_protoboard_and_connectors();
+    {
+        radxa_zero_3e_with_protoboard_and_connectors();
+        %radxa_zero_3e_mount_plate_with_holes();
+    }
+}
+
+module radxa_body_cutter()
+{
+    translate([0, 0, 20])
+    translate([0, fwo - 13, radxa_zero_3e_pcb_h - 5])
+    rotate([90, 0, 0])
+    *radxa_zero_3e_mount_plate_holes();
+    
+    translate([0, 0, 20])
+    translate([0, fwo, radxa_zero_3e_pcb_h - 5])
+    rotate([90, 0, 0])
+    radxa_zero_3e_mount_plate_outer_holes();
 }
 
 module other()
@@ -638,7 +671,7 @@ module other()
 // visual block
 
 // visualize camera
-union()
+*union()
 {
     translate([0, 0, $lenseYPosMm])
     %rotate([-$opticalAxisAngleDegrees, 0, 0])
@@ -658,7 +691,7 @@ union()
     }
 }
 
-union()
+*union()
 {
     other();
 
@@ -671,10 +704,14 @@ union()
         camera_hole();
         laser_glass_hole();
         laser_holder_screw_holes();
-        m12_connectors();
+        m12_connectors_to_cut();
+        //m12_connectors_to_cut();
         cam_lense_holder_screw_holes();
-        body_fan_holes();
+        //body_fan_holes();
+        radxa_body_cutter();
     }
+    %m12_connectors();
+    //m12_connectors_to_cut();
 }
 
 // printing cam/lense holder
@@ -690,17 +727,24 @@ union()
 }
 
 // printing body
-*difference()
+difference()
 {
     scanner_main_frame();
     camera_hole();
     laser_glass_hole();
     laser_holder_screw_holes();
-    m12_connectors();
+    //m12_connectors();
+    m12_connectors_to_cut();
+    //body_fan_holes();
+    radxa_body_cutter();
 }
 
 *translate([0, -$laserZOffsetMm, 0])
 {
     %laser_body();
     laser_holder();
-}
\ No newline at end of file
+}
+
+//m12_connectors();
+//m12_connectors_to_cut();
+//radxa_body_cutter();
\ No newline at end of file
diff --git a/body/holes.scad b/body/holes.scad
index a764dc7..5074ddc 100644
--- a/body/holes.scad
+++ b/body/holes.scad
@@ -1,5 +1,6 @@
 include <design.scad>
 include <helpers.scad>
+include <body_config.scad>
 
 // `Heat` in module name means heat brass threaded insert
 
@@ -14,11 +15,15 @@ hole_side_bottom = [0, 0, 0];
 hole_side_left = [0, 90, 0];
 hole_side_right = [0, -90, 0];
 
-hole_insert_height = 4;
 m2_head_diameter = 3.75;
 m2_head_height = 1.9;
 m2 = 2;
 
+// some default values
+// TODO: propagate everywhere
+hole_insert_height = 4;
+hole_insert_diameter = 4;
+
 padding_around_insert = 2;
 
 // gw - glass width
@@ -138,21 +143,19 @@ module screw_hole(m, id, il, hd, hh, hs, wt = $scannerBodyWallThicknessMm)
             // full head diameter
             fhd = hd + hdd;
             fhh = hh + hhd;
-            echo("hh:", hh);
-            echo("fhh:", fhh);
             translate([0, 0, wt - fhh - $tiny_padding])
             cylinder($fn = dToFn(fhd), d = fhd, h = fhh + $tiny_padding * 2);
         }
     }
 }
 
-function padded_hole_d(hd = 4) =
+function padded_hole_d(hd = hole_insert_diameter) =
     hd + padding_around_insert * 2;
 
 // h - height
 // hd - hole diameter
 // TODO: support usual holes, not only hot inserts
-module hole_holder(h, hd = 4)
+module hole_holder(h, hd = hole_insert_diameter)
 {
     d = padded_hole_d(hd);
     cube_size = [d * 2, d / 2, h];
@@ -182,14 +185,17 @@ module hole_holder(h, hd = 4)
 // h - height
 // hd - hole (insert) diameter
 // hs - hole side, see values above for details
-module hole_holder_hot_inserts(h, hd = 4, hs)
+module hole_holder_hot_inserts(
+    h = main_frame_width_x,
+    hd = hole_insert_diameter,
+    hs)
 {
     d = hd + padding_around_insert * 2;
 
     rotate(hs)
     difference()
     {
-        hole_holder(h = 40, hd = 4);
+        hole_holder(h = h, hd = hd);
 
         // holes for hot inserts
         union()
@@ -215,11 +221,14 @@ module hole_holder_hot_inserts(h, hd = 4, hs)
     }
 }
 
-hole_holder_hot_inserts(h = 40, hd = 4, hs = hole_side_top);
+*hole_holder_hot_inserts(
+    h = main_frame_width_x,
+    hd = hole_insert_diameter,
+    hs = hole_side_top);
 
 *screw_hole(
     m = m2,
-    id = 4,
+    id = hole_insert_diameter,
     il = hole_insert_height * 2,
     hd = m2_head_diameter,
     hh = m2_head_height,
diff --git a/body/laser.scad b/body/laser.scad
index b4dc8aa..32658e9 100644
--- a/body/laser.scad
+++ b/body/laser.scad
@@ -1,8 +1,10 @@
 include <design.scad>
 include <helpers.scad>
+include <body_config.scad>
 
-default_laser_d = 14;
-default_laser_l = 45;
+// up to 0.7 inside measurement range, but can be bigger outside.
+// non-ideal printing/manufacturing is also possible
+laser_ray_thickness = 1;
 
 // create a body of laser with diameter `d` and
 // length `l`.
diff --git a/body/laser_holder.scad b/body/laser_holder.scad
index f5c4562..8416db9 100644
--- a/body/laser_holder.scad
+++ b/body/laser_holder.scad
@@ -1,16 +1,6 @@
 include <helpers.scad>
 include <laser.scad>
 
-default_laser_holder_padding = [4, 1.5, 1.5];
-
-// d - laser body diameter
-// l - laser body length
-// padding - see `laser_holder_wo_holes` for details
-function laser_holder_size(
-    d = default_laser_d,
-    l = 45,
-    padding = default_laser_holder_padding) = ([d, l / 2, d] + padding * 2);
-
 // create a holder for laser with diameter `d` and
 // length `l`. no holes
 // with one-side `padding` for each axis
diff --git a/body/m12_connectors.scad b/body/m12_connectors.scad
index 3916b96..ec3a816 100644
--- a/body/m12_connectors.scad
+++ b/body/m12_connectors.scad
@@ -12,7 +12,7 @@ m12_female_conn_body_outer_part_length = 16;
 m12_female_conn_body_outer_part_d = 15.1;
 m12_female_conn_body_outer_part_flat_w = 13.4;
 
-m12_female_conn_body_wires_length = 20;
+m12_female_conn_body_wires_length = 12;
 m12_female_conn_body_wires_d = 8;
 
 // male
@@ -23,7 +23,7 @@ m12_male_conn_body_outer_part_length = 16;
 m12_male_conn_body_outer_part_d = 12;
 m12_male_conn_body_outer_part_flat_w = 10.6;
 
-m12_male_conn_body_wires_length = 20;
+m12_male_conn_body_wires_length = 12;
 m12_male_conn_body_wires_d = 8;
 
 // wl - wires length
diff --git a/body/noctua_nf_a4x20.scad b/body/noctua_nf_a4x20.scad
index f6a1945..5d3a2a0 100644
--- a/body/noctua_nf_a4x20.scad
+++ b/body/noctua_nf_a4x20.scad
@@ -1,4 +1,5 @@
 include <holes.scad>
+include <body_config.scad>
 
 noctua_nf_a4x20_h = 40;
 noctua_nf_a4x20_w = 40;
diff --git a/body/radxa_zero_3e.scad b/body/radxa_zero_3e.scad
index 731f883..b5eca5f 100644
--- a/body/radxa_zero_3e.scad
+++ b/body/radxa_zero_3e.scad
@@ -1,12 +1,21 @@
 include <helpers.scad>
+include <noctua_nf_a4x20.scad>
 
 radxa_zero_3e_pcb_w = 30;
 radxa_zero_3e_pcb_h = 65;
 radxa_zero_3e_pcb_thickness = 1.6;
 
+radxa_zero_3e_pcb_screw_offset = 3.5;
+radxa_zero_3e_pcb_distance_between_holes_w = 23;
+radxa_zero_3e_pcb_distance_between_holes_h = radxa_zero_3e_pcb_h - radxa_zero_3e_pcb_screw_offset * 2;
+
 rpi_protoboard_connectors_h = 12;
 rpi_protoboard_z_offset = 15;
 
+radxa_zero_3e_fan_hole_offset = 28;
+radxa_zero_3e_mount_plate_screw_holder_height = 4;
+radxa_zero_3e_mount_plate_h = 2;
+
 function radxa_zero_3e_pcb_size() = [
     radxa_zero_3e_pcb_w,
     radxa_zero_3e_pcb_h,
@@ -80,9 +89,186 @@ module radxa_zero_3e_with_protoboard_and_connectors()
     radxa_zero_3e_rj45_male();
 }
 
+module radxa_zero_3e_mount_plate()
+{
+    // outer screw holder diameter. there is no more space there,
+    // so only round 6 mm screw holders will fit under radxa
+    oshd = 6;
+    // screw holder height
+    shh = radxa_zero_3e_mount_plate_screw_holder_height;
+    
+    dbhw = radxa_zero_3e_pcb_distance_between_holes_w;
+    dbhh = radxa_zero_3e_pcb_distance_between_holes_h;
+    so = radxa_zero_3e_pcb_screw_offset;
+    
+    outer_cyl_delta = so - oshd / 2;
+    ocd = outer_cyl_delta;
+    bph = radxa_zero_3e_mount_plate_h;
+    hih = hole_insert_height;
+    hid = hole_insert_diameter;
+    
+    echo("radxa_zero_3e_pcb_distance_between_holes_h: ", radxa_zero_3e_pcb_distance_between_holes_h);
+    echo("dbhh: ", dbhh);
+        
+    difference()
+    {
+        union()
+        {
+            // hole holders
+            translate([0, 0, -shh / 2])
+            for (xo = [-dbhw / 2, dbhw / 2], yo = [-so, -so - dbhh])
+            {
+                //translate([-dbhw / 2, -so, 0])
+                translate([xo, yo, 0])
+                cylinder($fn = dToFn(oshd), d = oshd, h = shh, center = true);
+            }
+            
+            // outer hole holders
+            *translate([0, 0, -shh / 2])
+            for (xo = [-dbhw / 2 - ocd, dbhw / 2 + ocd], yo = [-so + ocd, -so - dbhh - ocd])
+            {
+                translate([xo, yo, 0])
+                cylinder($fn = dToFn(oshd), d = oshd, h = shh, center = true);
+            }
+            
+            // bottom plate
+            hull()
+            translate([0, 0, -shh - bph / 2])
+            for (xo = [-dbhw / 2, dbhw / 2], yo = [-so, -so - dbhh])
+            {
+                //translate([-dbhw / 2, -so, 0])
+                translate([xo, yo, 0])
+                cylinder($fn = dToFn(oshd), d = oshd + 1, h = bph, center = true);
+            }
+            
+            // fan: distance between holes
+            fdbh = ld3007ms_distance_between_holes;
+
+            // fan/plate hole holders
+            fan_plate_hole_holder_h = hih - bph;
+            fphhh = fan_plate_hole_holder_h;
+            translate([0, 0, -shh / 2])
+            translate([0, -radxa_zero_3e_fan_hole_offset / 2 - (oshd - hid), -fphhh / 2])
+            for (xo = [-fdbh / 2, fdbh / 2], yo = [0, 0 - fdbh])
+            {
+                //translate([-dbhw / 2, -so, 0])
+                translate([xo, yo, 0])
+                cylinder($fn = dToFn(oshd), d = oshd, h = fphhh, center = true);
+            }
+        }
+    }
+}
+
+// with screw holes and fan holes
+// TODO: production: create a new one with normal holes and w/o fan holes
+module radxa_zero_3e_mount_plate_holes()
+{   
+    // fan hole diameter, put under CPU
+    fan_hole_d = ld3007ms_w - 2;
+    fhd = fan_hole_d;
+    fan_hole_h = 10;
+    fhh = fan_hole_h;
+    
+    // screw holder height
+    shh = radxa_zero_3e_mount_plate_screw_holder_height;
+    
+    // TODO: deduplicate, move to a global var
+    bottom_plate_h = 2;
+    bph = bottom_plate_h;
+    
+    dbhw = radxa_zero_3e_pcb_distance_between_holes_w;
+    dbhh = radxa_zero_3e_pcb_distance_between_holes_h;
+    so = radxa_zero_3e_pcb_screw_offset;
+    hid = hole_insert_diameter;
+    
+    // fan holes
+    translate([0, -radxa_zero_3e_fan_hole_offset, 0])
+    hull()
+    {
+        // top
+        translate([0, 0, -shh + $tiny_padding])
+        cylinder($fn = dToFn(fhd), d = fhd - 2, h = 0.001, center = true);
+        
+        // bottom
+        translate([0, 0, -shh - bph + $tiny_padding])
+        //cylinder($fn = dToFn(fhd), d = fhd, h = fhh, center = true);
+        cylinder($fn = dToFn(fhd), d = fhd, h = 0.001, center = true);
+        
+        // prolongate to cut scanner main frame
+        translate([0, 0, -20])
+        //cylinder($fn = dToFn(fhd), d = fhd, h = fhh, center = true);
+        cylinder($fn = dToFn(fhd), d = fhd, h = 0.001, center = true);
+    }
+    
+    // fan screw holders holes
+    translate([0, 0, -bph - shh - $tiny_padding])
+    radxa_zero_3e_mount_plate_outer_holes();
+    
+    // radxa hot inserts holes
+    translate([0, 0, -shh / 2])
+    for (xo = [-dbhw / 2, dbhw / 2], yo = [-so, -so - dbhh])
+    {
+        //translate([-dbhw / 2, -so, 0])
+        translate([xo, yo, $tiny_padding])
+        cylinder($fn = dToFn(hid), d = hid, h = shh, center = true);
+    }
+}
+
+module radxa_zero_3e_mount_plate_with_holes()
+{
+    shh = radxa_zero_3e_mount_plate_screw_holder_height;
+    bph = radxa_zero_3e_mount_plate_h;
+    
+    //color("green", 0.1)
+    difference()
+    {
+        radxa_zero_3e_mount_plate();
+        radxa_zero_3e_mount_plate_holes();
+    }
+    
+    translate([0, -radxa_zero_3e_fan_hole_offset, -shh - bph])
+    rotate([-90, 0, 0])
+    *%ld3007ms();
+}
+
+// these holes should be positioned by a module which knows
+// radxa position in body, so putting them at z==0 for now
+module radxa_zero_3e_mount_plate_outer_holes()
+{
+    shh = radxa_zero_3e_mount_plate_screw_holder_height;
+    bph = radxa_zero_3e_mount_plate_h;
+    
+    translate([0, -radxa_zero_3e_fan_hole_offset, 0])
+    rotate([90, 0, 0])
+    ld3007ms_holes();
+}
+
 //radxa_zero_3e();
 //rpi_zero_protoboard();
 
 //radxa_zero_3e_with_protoboard();
 //%radxa_zero_3e_rj45_male();
-//radxa_zero_3e_with_protoboard_and_connectors();
\ No newline at end of file
+*%radxa_zero_3e_with_protoboard_and_connectors();
+
+*translate([0, 0, -6 - $tiny_padding])
+*radxa_zero_3e_mount_plate_outer_holes();
+
+*radxa_zero_3e_mount_plate();
+*radxa_zero_3e_mount_plate_with_holes();
+*radxa_zero_3e_mount_plate_outer_holes();
+//translate([0, fwo, 0])
+//translate([0, 0, 20])
+translate([0, 0, -10])
+//translate([0, 0, radxa_zero_3e_pcb_h - 5])
+//rotate([90, 0, 0])
+*%radxa_zero_3e_mount_plate_outer_holes();
+
+// debug, visualize 1 mm
+*union()
+{
+    translate([15 - 0.5, -28, -6])
+    cube([1, 1, 1], center = true);
+
+    translate([15 - 0.5, -28, -3])
+    cube([1, 1, 1], center = true);
+}
\ No newline at end of file