lauri/sumorobot-frame
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Lauri Võsandi 2019-05-06 19:53:11 +03:00
commit 6cc0cc496c
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/* Error tolerance for cutouts */
T = 0.2;
/* Arc smoothness */
R = 100;
/* PCB dimensions */
PCB_WIDTH = 66.5;
PCB_DEPTH = 66.5;
PCB_THICKNESS = 1.6;
PCB_OFFSET = 6;
/* Robot dimensions */
THICKNESS = 3;
WIDTH = 100;
HEIGHT = 90;
DEPTH = 100;
OFFSET = 34;
TILT = -8;
/* Ultrasonic sensor parameters */
ULTRASONIC_SENSOR_PLACEMENT = 47;
ULTRASONIC_SENSOR_SPAN = 26.5;
ULTRASONIC_SENSOR_HOLE = 16;
/* Line sensor parameters */
LINE_SENSOR_PLACEMENT = 13.5;
LINE_SENSOR_HOLES = 3;
LINE_SENSOR_SPAN = 38;
/* How far from eachother servo mount surfaces are placed */
SERVO_AXLE_LENGTH = 58;
COVER_WIDTH = 70;
COVER_HEIGHT = 76;
/* Servo parameters */
SERVO_MOUNT_PLACEMENT = 65;
SERVO_MOUNT_OFFSET = 33.5;
/* Magnet parameters */
MAGNET_HEIGHT = 0.8;
MAGNET_DIAMETER = 5;
/* Show placeholders for battery, wheels, PCB, etc */
DEBUG = false;
/* Helper function for mirror-copying object */
module mirror_copy() {
children();
mirror() {
children();
}
}
/* Mount holes for servos */
module mount_hole() {
cylinder(h = 100, d = LINE_SENSOR_HOLES + T, $fn = R);
}
/* Standard servo cutout helper */
module servo_cutout() {
translate([-34.5, 5, 0]) mount_hole();
translate([-34.5, -5, 0]) mount_hole();
translate([15, 5, 0]) mount_hole();
translate([15, -5, 0]) mount_hole();
translate([-31, -10, 0]) cube([40 + T * 2 + 2, 20 + T * 2, 100]);
}
module face() {
difference() {
union() {
/* Front face */
cube([WIDTH / 2, HEIGHT * 2, THICKNESS]);
/* Ultrasonic sensor mount */
rotate([TILT, 0, 0]) {
translate([ULTRASONIC_SENSOR_SPAN / 2, ULTRASONIC_SENSOR_PLACEMENT, 0]) {
cylinder(h = 20, d = ULTRASONIC_SENSOR_HOLE + THICKNESS, $fn = R);
}
}
}
/* Line following sensor mounting holes */
translate([0, LINE_SENSOR_PLACEMENT, -T]) {
translate([LINE_SENSOR_SPAN, 0, 0]) {
cylinder(h = THICKNESS + T * 2, d2 = LINE_SENSOR_HOLES + T, d1 = LINE_SENSOR_HOLES * 2 + T, $fn = R);
}
cylinder(h = THICKNESS + T * 2, d2 = LINE_SENSOR_HOLES + T, d1 = LINE_SENSOR_HOLES * 2 + T, $fn = R);
}
/* Ultrasonic sensor cutout */
rotate([TILT, 0, 0]) {
translate([0, ULTRASONIC_SENSOR_PLACEMENT, 0]) {
translate([ULTRASONIC_SENSOR_SPAN / 2, 0, -1]) {
cylinder(h = 100, d = ULTRASONIC_SENSOR_HOLE + T, $fn = R);
}
translate([0, 0, 15]) {
cube([ULTRASONIC_SENSOR_SPAN / 2, ULTRASONIC_SENSOR_SPAN / 2, 30]);
}
}
}
}
}
module frame() {
/* Front face to top face support arcs */
rotate([0, 90, 0]) {
translate([-90, 0, -WIDTH / 2]) {
difference() {
cylinder(d = 300, h = T + WIDTH/2 - COVER_WIDTH/2, $fn = R);
translate([0, 0, -THICKNESS])
cylinder(d = 176, h = WIDTH-COVER_WIDTH, $fn = R);
/* Clear out line sensor holes */
cube([200, 30, 20]);
translate([-200, -200, -1]) {
cube([200, 400, 20]);
}
}
}
}
difference() {
translate([-COVER_WIDTH / 2, HEIGHT - OFFSET, 0]) {
/* PCB compartment walls */
cube([THICKNESS, OFFSET, DEPTH]);
/* PCB rails */
translate([0, OFFSET - PCB_OFFSET - THICKNESS * 3, 0]) {
cube([6, PCB_OFFSET + THICKNESS * 3, DEPTH]);
}
}
/* PCB cutout */
translate([-PCB_WIDTH / 2, HEIGHT - 9, DEPTH - PCB_DEPTH - THICKNESS + T]) {
cube([PCB_WIDTH + T, PCB_THICKNESS + T, PCB_DEPTH]);
translate([0, -PCB_THICKNESS, -2]) {
cube([PCB_WIDTH + T, PCB_THICKNESS + T, PCB_DEPTH]);
}
}
}
/* Servo mounting walls */
translate([-SERVO_AXLE_LENGTH / 2, 0, 0]) {
cube([THICKNESS, HEIGHT - OFFSET, DEPTH]);
}
rotate([90, 0, 0]) {
/* Bottom face */
translate([0, 0, -HEIGHT + COVER_HEIGHT]) {
cube([SERVO_AXLE_LENGTH / 2, DEPTH, THICKNESS]);
}
/* Bottom support columnns */
translate([SERVO_AXLE_LENGTH / 2 - 12, 0, -HEIGHT + COVER_HEIGHT - 4]) {
cube([10, DEPTH, 18]);
}
/* Battery compartment separator */
translate([0, 0, -HEIGHT + OFFSET]) {
difference() {
cube([COVER_WIDTH / 2, DEPTH, THICKNESS]);
translate([0, 0, -T]) {
cube([SERVO_AXLE_LENGTH / 2, 20, THICKNESS + T * 2]);
translate([0, 20, 0]) {
/* Arc to ease 3D printing */
cylinder(h = THICKNESS * 2, d = SERVO_AXLE_LENGTH - THICKNESS * 2, $fn = R);
translate([0, 80, 0])
cylinder(h = THICKNESS * 2, d = SERVO_AXLE_LENGTH - THICKNESS * 2, $fn = R);
}
}
}
}
}
/* Top face */
translate([0, HEIGHT - THICKNESS, 0]) {
cube([WIDTH / 2, THICKNESS, DEPTH]);
}
}
module half() {
difference() {
union() {
face();
difference() {
rotate([TILT, 0, 0]) {
frame();
}
/* Line following sensor wires */
translate([0, 32, THICKNESS]) {
rotate([0, -90, 0]) {
cylinder(d = 26, h = 30, $fn = R);
}
rotate([90, 0, 0]) {
cylinder(d = 26, h = 100, $fn = R);
}
}
rotate([TILT]) {
rotate([0, -90, 0]) {
/* Bottom arc */
translate([50, -86, -50]) {
cylinder(d = 195, h = 100, $fn = R);
}
/* Servo mount */
translate([SERVO_MOUNT_PLACEMENT, SERVO_MOUNT_OFFSET, 0]) {
servo_cutout();
}
}
}
}
}
/* Front face cutoff */
translate([-100, -100, -100]) {
cube([200, 300, 100]);
}
/* Bottom face cutoff */
translate([-100, -100, -100]) {
cube([300, 100, 300]);
}
/* Top face cutoff */
rotate([TILT, 0, 0]) {
translate([-100, HEIGHT, -100]) {
cube([200, 200, 200]);
}
translate([-COVER_WIDTH / 2 - T, HEIGHT - COVER_HEIGHT - THICKNESS, DEPTH - THICKNESS]) {
cube([COVER_WIDTH + T, 200, 200]);
}
}
}
}
module magnet_hole() {
cylinder(d = MAGNET_DIAMETER + T, h = MAGNET_HEIGHT + T, $fn = R);
}
module magnet_holes() {
mirror_copy() {
/* Top holes */
translate([+COVER_WIDTH / 2 - MAGNET_DIAMETER / 2 - 0.5, HEIGHT - 3, -MAGNET_HEIGHT]) {
magnet_hole();
}
/* Bottom holes */
translate([SERVO_AXLE_LENGTH / 2 - MAGNET_DIAMETER / 2 - 0.5, HEIGHT - COVER_HEIGHT + MAGNET_DIAMETER / 2 - THICKNESS + 0.5, -MAGNET_HEIGHT]) {
magnet_hole();
}
}
}
module sumorobot() {
difference() {
mirror_copy() {
half();
}
rotate([TILT, 0, 0]) {
translate([0, 0, DEPTH - THICKNESS]) {
magnet_holes();
}
}
}
}
module cover() {
translate([0, 100, 0]) {
difference() {
union() {
translate([-27, COVER_HEIGHT-20, 0])
cube([35,12,THICKNESS*2]);
mirror_copy() {
// Battery/servo compartment cover
translate([0, 0, 0]) {
cube([SERVO_AXLE_LENGTH / 2, COVER_HEIGHT, THICKNESS]);
}
// PCB compartment cover
translate([0, COVER_HEIGHT - OFFSET, 0]) {
cube([COVER_WIDTH / 2, OFFSET + THICKNESS, THICKNESS]);
}
// PCB locking mechanism
translate([PCB_WIDTH/2-T-6, COVER_HEIGHT-6, 0]) {
cube([6, PCB_THICKNESS-T, THICKNESS+3*PCB_THICKNESS]);
cube([PCB_THICKNESS, 5, THICKNESS+3*PCB_THICKNESS]);
}
}
}
translate([0, COVER_HEIGHT - HEIGHT + THICKNESS, THICKNESS]) {
magnet_holes();
}
translate([-COVER_WIDTH/2+THICKNESS-0.5, COVER_HEIGHT+THICKNESS-0.5-PCB_THICKNESS, -T]) {
translate([10.7, -13.1, 0]) {
cylinder(d2=5, d1=5+THICKNESS, h=THICKNESS+T*2, $fn=R);
cylinder(d=5, h=10, $fn=R);
}
translate([36.2, -13.1, 0]) cylinder(d=5, h=THICKNESS*3+T*2, $fn=R);
translate([17.8-T*2, -19.46, 0]) cube([12.1+T*4, 10.5+T*4, 20]);
}
}
}
}
module plow_hole() {
translate([0, 0, -T])
cylinder(d1=LINE_SENSOR_HOLES+T, d2=LINE_SENSOR_HOLES*3, h=THICKNESS+T+T, $fn=R);
translate([0, 0, THICKNESS]) {
cylinder(d=LINE_SENSOR_HOLES*3, h=WIDTH, $fn=R);
}
}
module plow() {
translate([0, -40, 0]) {
mirror_copy() {
difference() {
rotate([TILT, 0, 0]) {
cube([WIDTH/2, LINE_SENSOR_PLACEMENT*2-6, 50]);
}
rotate([-TILT, 0, 0])
translate([-T, LINE_SENSOR_PLACEMENT*2-6, -6])
cube([100, 100, 100]);
translate([-T, 0, -100]) {
cube([100, 100, 100]);
}
translate([0, LINE_SENSOR_PLACEMENT-3]) {
translate([LINE_SENSOR_SPAN, 0]) {
plow_hole();
}
plow_hole();
}
translate([0, -1, 50]) {
rotate([-90, 0, 0]) {
cylinder(d=WIDTH-10, h=50, $fn=R);
}
}
}
}
}
}
sumorobot();
cover();
plow();
if (DEBUG) {
color([1, 0, 0]) {
rotate([TILT, 0, 0]) {
rotate([90, 0, 0]) {
/* PCB board mockup */
translate([0, 0, -HEIGHT + PCB_OFFSET + T]) {
translate([-PCB_WIDTH / 2, DEPTH - PCB_DEPTH, 0]) {
cube([PCB_WIDTH, PCB_DEPTH + 5, 1.6]);
}
translate([-PCB_WIDTH / 2 + 5, DEPTH - PCB_DEPTH, 0]) {
cube([PCB_WIDTH - 10, PCB_DEPTH - 5, 20]);
}
}
/* Battery mockup */
translate([-25, 30, -24]) {
translate([0, 0, 0]) {
cube([50, 60, 5.5]);
}
translate([10, 0, 0]) {
cube([30, 50, 10]);
}
}
}
}
translate([WIDTH / 2 + 28 / 2, HEIGHT - 47, 0]) {
cylinder(h = 12, d = 15, $fn = R);
}
/* Wheel mockups */
rotate([TILT]) {
rotate([0, -90, 0]) {
translate([SERVO_MOUNT_PLACEMENT, SERVO_MOUNT_OFFSET, SERVO_AXLE_LENGTH/2 + 10]) {
difference() {
cylinder(d=70, h=11);
cylinder(d=3, h=12);
}
}
}
}
/* Line sensor mockups */
difference() {
translate([0, LINE_SENSOR_PLACEMENT - 5.2, THICKNESS]) {
translate([WIDTH / 2 - (+12 + 8.9), 0, 0]) cube([17.8, 15.2, 5.2]);
translate([-8.9, 0, 0]) cube([17.8, 15.2, 5.2]);
translate([-WIDTH / 2 + 12 - 8.9, 0, 0]) cube([17.8, 15.2, 5.2]);
}
cylinder(d = 3, h = 20, $fn = R);
translate([38, 0, 0]) cylinder(d = 3, h = 20, $fn = R);
}
}
}

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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 ();