BSB Case: v2.0

diff --git a/bsb/case/case.scad b/bsb/case/case.scad
index ed377983793c9a5741a2ffc8e1315ad1e1b05a4e..d8f19cee8505db394518ef3013496e19c22a2fbe 100644 (file)
--- a/bsb/case/case.scad
+++ b/bsb/case/case.scad
@@ -7,18 +7,27 @@ front_panel_thickness = 1.35;
 // Measured between PCB screws
 pcb_width = 66;                // x
 pcb_length = 58.4;     // y
-screw_inside_diam = 2.5;
-screw_outside_diam = 5;
 
 // From screws to PCB edges
 pcb_left = 5;
 pcb_right = 5;
 pcb_front = 5.2;
 pcb_back = 10;
+pcb_thickness = 1.5;
 
 // Interior dimensions relative to z=0
 box_height = 26;
-box_depth = 10;
+box_depth = 4;
+
+// Screw dimensions
+screw_inside_diam = 2.5;
+screw_outside_diam = 3.2;
+screw_head_diam = 6;
+screw_head_height = 1.4;
+screw_length = 14;             // really 12, but make the hole deeper
+
+// Screw holders
+holder_size = 3*2.5;
 
 // Cable hole
 cable_x = 9;
@@ -38,18 +47,13 @@ usb_right = ref_x - 17;
 usb_bottom = 13.5;
 usb_top = 17.5;
 
-// Lid holders
-holder_width = 10;
-holder_depth = 6;
-holder_tail_depth = 14;
-
 // Lid
-lid_thickness = 2;
-lid_screw_thickness = 3.2;
-lid_screw_head_diam = 6;
-lid_screw_head_height = 2.8;
-lid_screw_holder_height = 4;   // includes lid_thickness
-// we want lid_screw_holder_height + (holder_depth + holder_tail_depth)/2 >= screw length (13 mm)
+lid_smaller = 0.2;
+lid_left = pcb_left - lid_smaller;
+lid_right = pcb_right - lid_smaller;
+lid_front = pcb_front - lid_smaller;
+lid_back = pcb_back - lid_smaller;
+lid_thickness = 1.8;
 text_depth = 1;
 
 over = 0.1;
@@ -60,27 +64,20 @@ module led_hole() {
                cylinder(h = front_panel_thickness + 2*over, d = led_diameter);
 }
 
-module screw_hole() {
-       translate([0, 0, -box_depth])
-               difference() {
-                       translate([0, 0, -over])
-                               cylinder(h = box_depth + over, d = screw_outside_diam);
-                       cylinder(h = box_depth + over, d = screw_inside_diam);
-               }
+module screw_holder() {
+       translate([-holder_size/2, -holder_size/2, -box_depth - over])
+               cube([holder_size, holder_size, box_depth + over]);
 }
 
-module lid_holder() {
-       difference() {
-               rotate([90, 0, 0])
-                       linear_extrude(height = holder_width, center = true)
-                               polygon(points = [[0,0], [0,-holder_tail_depth], [holder_width,-holder_depth], [holder_width,0]]);
-
-               translate([holder_width/2, 0, -holder_depth])
-                       cylinder(h = holder_depth + over, d = screw_inside_diam);
-       }
+module screw_hole() {
+       translate([0, 0, -box_depth - wall_thickness - over])
+               union() {
+                       cylinder(h = box_depth + wall_thickness + 2*over, d = screw_outside_diam);
+                       cylinder(h = screw_head_height, d1 = screw_head_diam, d2 = screw_outside_diam);
+               }
 }
 
-module bottom() {
+module bottom_base() {
        union() {
                difference() {
                        // Exterior
@@ -112,40 +109,29 @@ module bottom() {
                                rotate([-90, 0, 0])
                                        cylinder(h = wall_thickness + 2*over, d = cable_diameter);
                }
+       }
+}
+
+module bottom() {
+       difference() {
+               union() {
+                       bottom_base();
+
+                       // Screw holder
+                       screw_holder();
+                       translate([pcb_width, 0, 0]) screw_holder();
+                       translate([0, pcb_length, 0]) screw_holder();
+                       translate([pcb_width, pcb_length, 0]) screw_holder();
+               }
 
                // Screw holes
                screw_hole();
                translate([pcb_width, 0, 0]) screw_hole();
                translate([0, pcb_length, 0]) screw_hole();
                translate([pcb_width, pcb_length, 0]) screw_hole();
-
-               // Lid holders
-               lh = box_height - lid_screw_holder_height;
-               translate([-pcb_left, 0, lh])
-                       lid_holder();
-               translate([-pcb_left, pcb_length, lh])
-                       lid_holder();
-               translate([pcb_width + pcb_right, 0, lh])
-                       rotate([0, 0, 180])
-                               lid_holder();
-               translate([pcb_width + pcb_right, pcb_length, lh])
-                       rotate([0, 0, 180])
-                               lid_holder();
        }
 }
 
-module lid_screw_holder() {
-       translate([-holder_width/2, -holder_width/2, -lid_screw_holder_height])
-               cube([holder_width, holder_width, lid_screw_holder_height]);
-}
-
-module lid_screw_hole() {
-       translate([0, 0, -lid_screw_holder_height - over])
-               cylinder(h = lid_screw_holder_height + 2*over, d = lid_screw_thickness);
-       translate([0, 0, -lid_screw_head_height])
-               cylinder(h = lid_screw_head_height + over, d1 = lid_screw_thickness, d2 = lid_screw_head_diam);
-}
-
 module lid_text(overshoot = 0) {
        translate([pcb_width / 2, 10, -text_depth/2])
        rotate(0)
@@ -154,37 +140,38 @@ module lid_text(overshoot = 0) {
                text("USB – BSB", font = "Liberation Serif", halign="center");
 }
 
+module lid_screw_hole() {
+       translate([0, 0, -box_height + pcb_thickness])
+               difference() {
+                       translate([-holder_size/2, -holder_size/2, 0])
+                               cube([holder_size, holder_size, box_height - pcb_thickness - lid_thickness + over]);
+                       translate([0, 0, -over])
+                               cylinder(h = screw_length - pcb_thickness - box_depth - wall_thickness + over, d = screw_inside_diam);
+               }
+}
+
 module lid() {
        difference() {
                union() {
-                       translate([-pcb_left, -pcb_front, -lid_thickness])
-                               cube([pcb_left + pcb_width + pcb_right, pcb_front + pcb_length + pcb_back, lid_thickness]);
-
-                       translate([0, 0, 0])
-                               lid_screw_holder();
-                       translate([0, pcb_length, 0])
-                               lid_screw_holder();
-                       translate([pcb_width, 0, 0])
-                               lid_screw_holder();
-                       translate([pcb_width, pcb_length, 0])
-                               lid_screw_holder();
-               }
-
-               // Screw holes
-               translate([0, 0, 0])
-                       lid_screw_hole();
-               translate([0, pcb_length, 0])
-                       lid_screw_hole();
-               translate([pcb_width, 0, 0])
-                       lid_screw_hole();
-               translate([pcb_width, pcb_length, 0])
+                       translate([-lid_left, -lid_front, -lid_thickness])
+                               cube([lid_left + pcb_width + lid_right, lid_front + pcb_length + lid_back, lid_thickness]);
                        lid_screw_hole();
+                       translate([pcb_width, 0, 0]) lid_screw_hole();
+                       translate([0, pcb_length, 0]) lid_screw_hole();
+                       translate([pcb_width, pcb_length, 0]) lid_screw_hole();
+               }
 
                // Text
                lid_text(over);
        }
 }
 
+module pcb() {
+       translate([-pcb_left, -pcb_front, 0])
+               cube([pcb_left + pcb_width + pcb_right, pcb_front + pcb_length + pcb_back, pcb_thickness]);
+}
+
 bottom();
-// color([1, 0, 0]) translate([0, 0, box_height]) lid();
+// color([1, 0, 1]) pcb();
+color([1, 0, 0]) translate([0, 0, box_height]) lid();
 // color([0, 0, 1]) translate([0, 0, box_height]) lid_text(0);