sumorobot-frame/sumorobot-remote.scad

WIDTH = 114;
HEIGHT = 63;
DEPTH = 30;

R = 30;
THICKNESS = 2;

BORDER_RADIUS = 4;
JOYSTICK_AXIS_DIAMETER = 31;
JOYSTICK_TO_BUTTONS = 45.72;
BUTTON_DIAMETER = 11.5;
T = 0.2;
BUTTON_PLACEMENT_DIAMETER = 22.86;
BUTTON_PLACEMENT_LEFT = WIDTH / 2 - JOYSTICK_TO_BUTTONS / 2;
JOYSTICK_LEFT = WIDTH / 2 + JOYSTICK_TO_BUTTONS / 2;
JOYSTICK_TOP = HEIGHT / 2;
BUTTON_SINK = 13.5;

TRAY_WIDTH = 35;
TRAY_HEIGHT = 52;
TRAY_DEPTH = 6;
TRAY_THICKNESS = 1;


SWITCH_POSITION = WIDTH - 27;
SWITCH_HEIGHT = 12.7;
SWITCH_WIDTH = 19.3;

SCREW_HOLE = 6.3;

STANDOFF_H = 20;
STANDOFF_D2 = 4.65;
STANDOFF_D = STANDOFF_D2 / 0.866;

module box(width, height, depth, h1 = STANDOFF_D, h2 = STANDOFF_D, hd = STANDOFF_H, hr=6) {
    difference() {
        translate([0, 0, -THICKNESS]) {
            // Bottom
            translate([-BORDER_RADIUS, 0, 0]) cube([width + BORDER_RADIUS * 2, HEIGHT, THICKNESS]);
            translate([0, -BORDER_RADIUS, 0]) cube([width, height + BORDER_RADIUS * 2, THICKNESS]);

            // Walls
            translate([0, -BORDER_RADIUS, 0]) cube([width, THICKNESS, depth + THICKNESS]);
            translate([-BORDER_RADIUS, 0, 0]) cube([THICKNESS, height, depth + THICKNESS]);
            translate([0, height + BORDER_RADIUS - THICKNESS, 0]) cube([width, THICKNESS, depth + THICKNESS]);
            translate([width + BORDER_RADIUS - THICKNESS, 0, 0]) cube([THICKNESS, height, depth + THICKNESS]);


            // Screw hole cylinders
            cylinder(r = BORDER_RADIUS, h = depth + THICKNESS, $fn = R);
            translate([WIDTH, 0, 0]) cylinder(r = BORDER_RADIUS, h = depth + THICKNESS, $fn = R);
            translate([0, HEIGHT, 0]) cylinder(r = BORDER_RADIUS, h = depth + THICKNESS, $fn = R);
            translate([WIDTH, HEIGHT, 0]) cylinder(r = BORDER_RADIUS, h = depth + THICKNESS, $fn = R);
        }

        // Screw hole
        translate([0, 0, depth - hd - T]) {
            cylinder(d1 = h1+T, d2 = h2+T, h = hd+T+T, $fn = hr);
            translate([WIDTH, 0, 0]) cylinder(d1 = h1+T, d2 = h2+T, h = hd+T+T, $fn = hr);
            translate([0, HEIGHT, 0]) cylinder(d1 = h1+T, d2 = h2+T, h = hd+T+T, $fn = hr);
            translate([WIDTH, HEIGHT, 0]) cylinder(d1 = h1+T, d2 = h2+T, h = hd+T+T, $fn = hr);

        }
    }
}

// Cover
translate([0, -THICKNESS - BORDER_RADIUS * 2, 0]) {
    mirror([0, 1, 0]) {
        difference() {
          box(WIDTH, HEIGHT, 0, h1 = 5.4, h2 = 2.8, hr=R, hd = THICKNESS);
          translate([WIDTH/2-5, -BORDER_RADIUS+THICKNESS+T+1, -THICKNESS-T])
          cube([10, 4, 10]);
        }

        // Switch fixer
        translate([SWITCH_POSITION + T, -BORDER_RADIUS, 0]) {
            cube([SWITCH_WIDTH - T - T, BORDER_RADIUS, DEPTH - SWITCH_HEIGHT - T]);
        }

        // Charger mount
        translate([WIDTH/2-19/2-3, -BORDER_RADIUS+THICKNESS+T, 0]) {
            difference() {
              cube([19+3+3, 7, DEPTH - SWITCH_HEIGHT - T]);
              translate([+3, 0, 0])
              cube([19, 3, 20]);

              translate([7.5, 0, 0])
              cube([10, 5, 20]);
            }
        }

    }
}


module screw_hole(dia=SCREW_HOLE) {
    difference() {
        cylinder(h = 11, d = 8, $fn = R);
        translate([0, 0, TRAY_DEPTH])
        cylinder(h = TRAY_DEPTH + T, d = dia, $fn = R);

    }
}

module button() {
    cylinder(d1 = BUTTON_DIAMETER + THICKNESS * 2 + T, d2 = BUTTON_DIAMETER + T, h = THICKNESS + T * 2, $fn = R);
}

module case () {
    difference() {
        union() {
            box(WIDTH, HEIGHT, DEPTH);


            // Switch holder
            translate([SWITCH_POSITION - 5, -BORDER_RADIUS + T + T, 0]) {
                cube([SWITCH_WIDTH + 10, BORDER_RADIUS, DEPTH]);
                translate([-85+6, 0,0 ])
                cube([85, 5,3.5]);
            }




        }

        // Switch cutout
        translate([SWITCH_POSITION, -BORDER_RADIUS - T, 0]) {
            cube([SWITCH_WIDTH, THICKNESS, HEIGHT]);
            translate([-1, THICKNESS, 0])
            cube([SWITCH_WIDTH + 2, BORDER_RADIUS, HEIGHT]);
        }


        union() {

            translate([JOYSTICK_LEFT, JOYSTICK_TOP, 5]) {
                sphere(JOYSTICK_AXIS_DIAMETER / 2);
            }

            translate([BUTTON_PLACEMENT_LEFT, JOYSTICK_TOP, -THICKNESS]) {
                translate([BUTTON_PLACEMENT_DIAMETER / 2, 0, -T]) button();
                translate([0, BUTTON_PLACEMENT_DIAMETER / 2, -T]) button();
                translate([-BUTTON_PLACEMENT_DIAMETER / 2, 0, -T]) button();
                translate([0, -BUTTON_PLACEMENT_DIAMETER / 2, -T]) button();
            }
        }




    }


    /* PCB mounting holes */
    translate([BUTTON_PLACEMENT_LEFT, JOYSTICK_TOP, 0]) {
        translate([-18.9, BUTTON_PLACEMENT_DIAMETER / 2, 0]) {
            screw_hole(1.9);
            translate([0, -28, 0]) {
                screw_hole(1.9);
            }
        }
    }


    translate([BUTTON_PLACEMENT_LEFT + JOYSTICK_TO_BUTTONS, JOYSTICK_TOP, 0]) {

        translate([+12.2 + 1.5, +24.7 + 1.5, 0]) {
            screw_hole(1.9);
        }

    }

}



case ();