minor component fixes

model/common.scad

@@ -1,45 +1,266 @@
+include <BOSL2/std.scad>
+
 BASE_MODEL_SCALE = [1.1, 1, 1.1];
 BASE_MODEL_TRANSLATE = [-0.4, 0, 16.978];
+EPS = 0.01;
+$fn = 50;
 
-module main_display(){
-    // Outer dimensions, height currently unknown
-    cube([55.04, 89.3, 10]);
+module pin_header(cols = 4, rows = 1, anchor = BOTTOM, spin = 0, orient = UP) {
+  // Standard pin header dimensions (in mm)
+  base_height = 2.54; // Height of the plastic base
+  pin_width = 0.64; // Width/thickness of the square pin
+  pin_length = 6.0; // Length of pin sticking up
+  pitch = 2.54;
+
+  // 1. The Plastic Base is the Parent
+  // It directly receives your anchor, spin, and orient arguments.
+  color("darkgrey")
+    cuboid([cols * pitch, rows * pitch, base_height], anchor=anchor, spin=spin, orient=orient) {
+
+      // 2. Metal Pins are the Children
+      // Placed relative to the center of the plastic base
+      color("silver")
+        xcopies(spacing=pitch, n=cols) {
+          ycopies(spacing=pitch, n=rows) {
+            up(base_height / 2)
+              cuboid([pin_width, pin_width, pin_length], anchor=BOTTOM);
+          }
+        }
+
+      // Allows attaching other objects to this header if needed
+      children();
+    }
 }
 
-module pad(){
+module main_display(pin_header = false) {
+  // Outer dimensions
+  width = 55.04;
+  length = 89.35;
+  height = 2.7;
+
+  display_height = 3;
+  display_length = 77.6;
+  display_inset = 5.7;
+
+  sd_width = 26.6;
+  sd_height = 3;
+  sd_length = 16.6;
+  sd_inset = 29.4;
+
+  hole_diameter = 3;
+  hole_inset = 1.5;
+
+  difference() {
+    cuboid([length, width, height]) {
+      position(TOP + RIGHT)
+        left(display_inset)
+          color("black")
+            cuboid([display_length, width, display_height], anchor=BOTTOM + RIGHT);
+
+      position(BOTTOM + RIGHT + FRONT)
+        left(sd_inset)
+          cuboid([sd_width, sd_length, sd_height], anchor=TOP + RIGHT + FRONT);
+
+      position(BOTTOM + LEFT)
+        xrot(180)
+          pin_header(14, spin=90, anchor=BOTTOM + BACK);
+    }
+
+    xcopies(length - (2 * hole_inset) - hole_diameter) {
+      ycopies(width - (2 * hole_inset) - hole_diameter) {
+        zcyl(d=hole_diameter, h=height + EPS);
+      }
+    }
+  }
+}
+
+module pad() {
   // A button has 4.2 x 6 mm -> At least ~20x20 are required for the PCB
   cube([20, 20, 10]);
 }
 
-module small_display_below_main()
-{
+module secondary_display(pin_header = false) {
   // https://de.aliexpress.com/item/1005003753680706.html
-    cube([45.8, 20, 11.3]);
-    // old i2c variant:
-    //cube([43.5, 19.44, 4.5]);
+  length = 45.8;
+  width = 20;
+  height = 3.7;
 
-    // initial dimension ideas
-    // cube([38,16,4]);
-    // translate([150,0,0]) cube([22,5.5,4]);
+  hole_diameter = 2;
+  hole_inset = 1.5;
+
+  difference() {
+    cuboid([length, width, height]) {
+      if (pin_header)
+        position(LEFT + TOP)
+          pin_header(7, spin=90, anchor=BACK + BOTTOM);
+    }
+
+    right(length / 2 - hole_inset) {
+      ycopies(width - (2 * hole_inset) - hole_diameter) {
+        zcyl(d=hole_diameter, h=height + EPS, anchor=RIGHT);
+      }
+    }
+  }
 }
 
-module tertiary_display()
-{
-    // https://de.aliexpress.com/item/1005006034531826.html
-    cube([80, 36, 10]);
-}
-
-module battery() {
+module battery(anchor = BOTTOM) {
   // 18650
-    rotate([0,90,0]) cylinder(d=18, h=65);
+  rotate([0, 90, 0]) cylinder(d=18, h=65, anchor=anchor);
 }
 
-module microcontroller() {
-    // width 32 including USB-C port
-    length = 91.5;
-    height = 20;
+/// USB-C port and switch not 100% dimensionally accurate, take care!
+module micro_controller(battery_holder = false, battery = false) {
+  pcb_length = 91.5;
+  pcb_height = 6.5; // including components, highest point: jst connector, followed by uC
+  pcb_height_no_components = 1.1;
+  pcb_width = 28.8;
+
+  hole_diameter = 2.5;
+  hole_inset = 1;
+  usb_protrusion = 1.7;
+  usb_width = 9;
+  usb_inset_from_pcb_end = 5;
+  power_switch_protrusion = 2.1;
+  power_switch_inset_from_pcb_end = 8.1;
+  power_switch_width = 4;
+
+  battery_holder_height = 15;
+  battery_holder_width = 21;
+  battery_holder_length = 77.3;
+
   battery_length = 65;
-    delta = length - battery_length;
-    cube([length, 32, height]);
-    translate([delta / 2,16, 15]) battery();
+  battery_protrusion = 4.5;
+
+  difference() {
+    cuboid([pcb_length, pcb_width, pcb_height], rounding=2, edges="Z") {
+      if (battery_holder)
+        position(TOP)
+          cube([battery_holder_length, battery_holder_width, battery_holder_height], anchor=BOTTOM + CENTER) {
+            if (battery)
+              position(TOP)
+                up(battery_protrusion)
+                  battery(anchor=CENTER + LEFT);
+          }
+      position(RIGHT + BOTTOM) {
+        position(FRONT)
+          left(usb_inset_from_pcb_end)
+            cube([usb_width, usb_protrusion, pcb_height - pcb_height_no_components], orient=FRONT, anchor=RIGHT + BOTTOM + FRONT);
+        position(BACK)
+          left(power_switch_inset_from_pcb_end)
+            cube([power_switch_width, power_switch_protrusion, pcb_height - pcb_height_no_components], orient=FRONT, anchor=RIGHT + TOP + FRONT);
+      }
+    }
+
+    xcopies(pcb_length - (2 * hole_inset) - hole_diameter) {
+      ycopies(pcb_width - (2 * hole_inset) - hole_diameter) {
+        cyl(d=hole_diameter, h=pcb_height + EPS, orient=UP);
+      }
+    }
+  }
+}
+
+module nfc(pin_header = true) {
+  length = 43;
+  width = 40.5;
+  height = 4;
+
+  pin_protrusion = 2.2;
+
+  hole_diameter = 3;
+  hole_inset = 6;
+
+  x_span = length - (2 * hole_inset) - hole_diameter;
+  y_span = width - (2 * hole_inset) - hole_diameter;
+
+  color("red")
+    difference() {
+      cuboid([length, width, height], rounding=2, edges="Z") {
+        // pin header is lower than highest other component -> in the cube.
+        if (pin_header)
+          right(6 - pin_protrusion) // ugly: 6mm is the pin height
+            position(LEFT + TOP)
+              yrot(-90)
+                pin_header(7, spin=90, anchor=FRONT + TOP);
+      }
+
+      move_copies(
+        [
+          [x_span / 2, -y_span / 2], // Bottom-Left corner
+          [-x_span / 2, y_span / 2], // Top-Right corner
+        ]
+      ) {
+        zcyl(d=hole_diameter, h=height + EPS);
+      }
+    }
+}
+
+module tertiary_display(pin_headers = true) {
+  // https://de.aliexpress.com/item/1005006034531826.html
+
+  pcb_length = 81;
+  pcb_width = 36.1;
+  pcb_height = 3.7;
+
+  hole_diameter = 2.8;
+  hole_inset = 1;
+
+  display_length = 71.2;
+  display_width = 24.4;
+  display_height = 7;
+
+  piggy_length = 41.8;
+  piggy_width = 19.1;
+  piggy_height = 8.5 - 2.6;
+  piggy_inset = 6.2;
+
+  jumper_protrusion = 6.6;
+  pin_protrusion = 6.2;
+
+  color("green")
+    difference() {
+      cuboid([pcb_length, pcb_width, pcb_height]) {
+        position(TOP)
+          cuboid([display_length, display_width, display_height], anchor=BOTTOM);
+      }
+
+      xcopies(pcb_length - (2 * hole_inset) - hole_diameter) {
+        ycopies(pcb_width - (2 * hole_inset) - hole_diameter) {
+          zcyl(d=hole_diameter, h=pcb_height + 1);
+        }
+      }
+    }
+
+  // Replaces position(BOTTOM + BACK + LEFT) so that difference cannot mess with color.
+  translate([-pcb_length / 2 + piggy_inset, pcb_width / 2, -pcb_height / 2]) {
+    color("black")
+      cuboid([piggy_length, piggy_width, piggy_height], anchor=TOP + BACK + LEFT);
+
+    if (pin_headers) {
+      // Replaces position(LEFT + BOTTOM) so that parent child cannot mess with color.
+      translate([0, -piggy_width / 2, -piggy_height])
+        right(6 - pin_protrusion)
+          yrot(-90)
+            pin_header(4, spin=90, anchor=BACK + TOP);
+
+      // Replaces position(RIGHT + BOTTOM) so that parent child cannot mess with color.
+      translate([piggy_length, -piggy_width / 2, -piggy_height])
+        left(6 - pin_protrusion)
+          yrot(90)
+            back(1.6)
+              pin_header(2, spin=-90, anchor=BACK + TOP);
+
+      // Replaces position(BACK + TOP) so that parent child cannot mess with color.
+      translate([piggy_length / 2, -EPS, 0])
+        pin_header(16, anchor=BACK + TOP);
+    }
+  }
+}
+
+// show different components as overview
+if (false) {
+  back(30) tertiary_display(true);
+  back(80) yrot(180) secondary_display(true);
+  right(100) zrot(90) main_display(true);
+  fwd(20) micro_controller(true, true);
+  fwd(60) nfc(true);
 }