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Add "DisplayCaseTopLarge" variant for use of OLED displays with a slightly larger pcb #78

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Binary file added export/DisplayCase/DisplayCaseTopLarge.stl
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238 changes: 238 additions & 0 deletions src/DisplayCase/DisplayCaseTopLarge.scad
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Original file line number Diff line number Diff line change
@@ -0,0 +1,238 @@
include <../../variables.scad>

use <../../lib/Round-Anything/polyround.scad>
use <../../lib/utils.scad>

// $fn=128;

module essCurve(r1, r2, w, h) {
a = acos(1 - w / (r1 + r2));
l = sin(a) * (r1 + r2);
c = [w - r1 + cos(a) * r1, sin(a) * r1];

intersection() {
cube([w, l, h]);
difference() {
union() {
translate([w-r1, 0, 0])
cylinder(r=r1, h=h);

linear_extrude(h)
polygon([[0, 0], [r1, 0], c, [0, l]]);
}

translate([r2, l, -1])
cylinder(r=r2, h=h+2);
}
}
}

module tripleEssCurve() {
w = 9;
h = 8;
r1 = 5;
r2 = 5;
r3 = 2;
d1 = r1 + r2;
d2 = r2 + r3;
d3 = sqrt((w-r3)^2 + (h-r1)^2);
a2 = acos((d3^2-d1^2-d2^2) / (-2 * d1 * d2));
a4 = acos((d2^2-d1^2-d3^2) / (-2 * d1 * d3));
a5 = acos((d1^2-d2^2-d3^2) / (-2 * d2 * d3));
a6 = atan((w-r3) / (h-r1));
a7 = atan((h-r1) / (w-r3));
a3 = 180 - a5 - a7;
a1 = 180 - a4 - a6;
p1 = [-w, -r1];
p2 = [-r3+d2*cos(a3), -h+d2*sin(a3)];
p3 = [-r3, -h];
t1 = [(p1.x*r2+p2.x*r1)/(r1+r2), (p1.y*r2+p2.y*r1)/(r1+r2)];
t2 = [(p2.x*r3+p3.x*r2)/(r2+r3), (p2.y*r3+p3.y*r2)/(r2+r3)];

difference() {
intersection() {
union () {
translate(p1)
circle(r1);

translate(p3)
circle(r3);

polygon([[-w, 0], t1, t2, [0, -h], [-w, -h]]);
}

translate([-w, -h])
square([w, h]);
}

translate(p2)
circle(r2);
}
translate([-w-2, -h])
square([2, h]);
}

module DisplayCaseBasicShape(height=20, magnet_depth) {
difference() {
union() {
difference() {
hull() {
translate([DisplayCase_outer_radius, -DisplayCase_outer_radius, 0])
cylinder(r=DisplayCase_outer_radius, h=height);

#translate([DisplayCase_outer_width-4, -DisplayCase_outer_radius, 0])
cylinder(r=DisplayCase_outer_radius, h=height);

translate([DisplayCase_outer_width - DisplayCase_outer_large_radius, -45, 0])
cylinder(r=DisplayCase_outer_large_radius, h=height);

intersection() {
translate([20, -30, 0])
cylinder(r=20, h=height);

translate([0, -45, 0])
cube([DisplayCase_outer_width, 45, height]);
}
}
translate([DisplayCase_outer_width+DisplayCase_magnet_housing_width-9, -8, -1])
cube([9, 8, height+2]);
}

linear_extrude(height)
translate([DisplayCase_outer_width+DisplayCase_magnet_housing_width, 0, 0])
tripleEssCurve();

translate([DisplayCase_outer_width, -8-DisplayCase_magnet_length, 0])
mirror([0, 1])
essCurve(2, 5, DisplayCase_magnet_housing_width, height);

translate([DisplayCase_outer_width, -8-DisplayCase_magnet_length, 0])
cube([DisplayCase_magnet_housing_width, DisplayCase_magnet_length, height]);
}

translate([DisplayCase_outer_width-default_clearance, -8-DisplayCase_magnet_length, height-magnet_depth])
cube([DisplayCase_magnet_thickness*2+default_clearance, DisplayCase_magnet_length+default_clearance, height]);
}
}

module DisplayCaseHolePattern() {
translate([DisplayCase_outer_radius, -DisplayCase_outer_radius])children();
translate([DisplayCase_outer_width-4, -DisplayCase_outer_radius])children();
translate([DisplayCase_outer_radius+2, -(DisplayCase_outer_radius+DisplayCaseTop_pcb_height+DisplayCaseTop_hole_diameter+1)])rotate([0, 0, 180])children();
}

module DisplayCaseTop() {
pcb_depth = DisplayCaseTop_height-DisplayCaseTop_window_depth;

standoff_width = (DisplayCaseTop_large_pcb_width-DisplayCaseTop_cable_clearance)/2;
standoff_height = 3.35;

union () {
difference() {
mirror([1, 0, 0])
DisplayCaseBasicShape(DisplayCaseTop_height, DisplayCaseTop_magnet_depth);

mirror([1, 0, 0])
DisplayCaseHolePattern() {
difference() {
union () {
translate([0, 0, -100])
cylinder(d=m3_screw_diameter_loose, h=200);

translate([0, 0, 0])
cylinder(d=m3_screw_head_diameter, h=2.7);

translate([-m3_screw_diameter_loose/2, -m3_screw_diameter_loose, 8-3.3])
cube([m3_screw_diameter_loose, m3_screw_diameter_loose, 20]);
}

if(enable_easy_print)
translate([0, 0, 2.7])
EasyPrintHoleShink(3.3, m3_screw_head_diameter, 2);
}
}

// hole for PCB
translate(DisplayCaseTop_large_pcb_origin) {
cube([DisplayCaseTop_large_pcb_width, DisplayCaseTop_large_pcb_height, pcb_depth*2], center=true);
}

// window
translate([DisplayCaseTop_pcb_origin.x, DisplayCaseTop_pcb_origin.y-DisplayCaseTop_window_offset, 0]) {
d = DisplayCaseTop_window_depth/2;
union () {
hull() {
translate([0, 0, d-0.1])
linear_extrude(0.1)
polygon(roundedRectangle(DisplayCaseTop_window_width, DisplayCaseTop_window_height, DisplayCaseTop_window_radius));

translate([0, 0, -d])
linear_extrude(d)
polygon(roundedRectangle(DisplayCaseTop_window_width+d*2, DisplayCaseTop_window_height+d*2, DisplayCaseTop_window_radius+d));
}

translate([0, 0, d])
linear_extrude(d*2)
polygon(roundedRectangle(DisplayCaseTop_window_width, DisplayCaseTop_window_height, DisplayCaseTop_window_radius));
}
}

// hole for button
translate([-DisplayCase_outer_width+DisplayCase_outer_large_radius, -45, 0]) {
difference() {
union () {
translate([0, 0, -1])
cylinder(d=DisplayCaseTop_button_diameter, h=20);
translate([0, 0, -pcb_depth+DisplayCaseTop_pcb_standoff+DisplayCaseTop_large_pcb_origin.z])
cylinder(h=5,d=DisplayCaseTop_button_nut_diameter);

translate([0, 0, -1])
cylinder(d=DisplayCaseTop_button_outside_diameter, h=1+DisplayCaseTop_button_outside_depth);
}

if(enable_easy_print)
translate([0, 0, DisplayCaseTop_button_outside_depth])
EasyPrintHoleShink(DisplayCaseTop_button_diameter, DisplayCaseTop_button_outside_diameter, 3);
}
};

translate(DisplayCaseTop_large_pcb_origin - [0, DisplayCaseTop_large_pcb_height / 2-epsilon,pcb_depth-DisplayCaseTop_pcb_standoff]) linear_extrude(4)
polygon(polyRound([
[-10.5,0,0],
[-8.5, 0, 2],
[-8.5, -6, 0],
[0,-4.4,0],
[9.9,-4.4,2],
[9.9,0,2],
[12.9,0,0]
]));
}

translate(DisplayCaseTop_large_pcb_origin)
mirrorCopy([0, 1, 0])
mirrorCopy([1, 0, 0])
translate([-DisplayCaseTop_large_pcb_width/2, -DisplayCaseTop_large_pcb_height/2, -pcb_depth])
linear_extrude(DisplayCaseTop_pcb_standoff)
polygon(polyRound([
[0, 0, 0],
[standoff_width, 0, 0],
[standoff_width, standoff_height, 1],
[0, standoff_height, 0],
]));
}
}

module EasyPrintHoleShink(inner_diameter, outer_diameter, n=2, lh=layer_height) {
mirror([0, 0, 1])
intersection() {
cylinder(h=lh*2, d=outer_diameter);

union()for(z=[0,1])for(i=[1:n]) {
rotate([0, 0, 360/n*(i+z*0.5)])
translate([inner_diameter/2, -100, 0])
cube([(outer_diameter-inner_diameter)/2, 200, (z+1)*lh]);
}
}
}

DisplayCaseTop();
3 changes: 3 additions & 0 deletions variables.scad
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Expand Up @@ -219,6 +219,8 @@ DisplayCaseTop_window_offset = 2; // to bottom
DisplayCaseTop_window_radius = 1.5;
DisplayCaseTop_pcb_width = 26.5;
DisplayCaseTop_pcb_height = 27.2;
DisplayCaseTop_large_pcb_width = 28.0; // large pcb variant (DisplayCaseTopLarge)
DisplayCaseTop_large_pcb_height = 28.0; // large pcb variant (DisplayCaseTopLarge)
DisplayCaseTop_pcb_standoff = 1.7;
DisplayCaseTop_hole_diameter = 3.3;
DisplayCaseTop_cable_clearance = 12.5;
Expand All @@ -227,6 +229,7 @@ DisplayCaseTop_button_nut_diameter = 16.3;
DisplayCaseTop_button_outside_diameter = 18;
DisplayCaseTop_button_outside_depth = 3;
DisplayCaseTop_pcb_origin = [-DisplayCase_outer_width/2, -DisplayCase_outer_radius-DisplayCaseTop_hole_diameter/2-DisplayCaseTop_pcb_height/2, DisplayCaseTop_height];
DisplayCaseTop_large_pcb_origin = [-DisplayCase_outer_width/2, -DisplayCase_outer_radius-DisplayCaseTop_hole_diameter/2-DisplayCaseTop_pcb_height/2 - 0.4, DisplayCaseTop_height]; // large pcb variant (DisplayCaseTopLarge

DisplayCaseBottom_height = 11;
DisplayCaseBottom_magnet_depth = 10.4 - DisplayCaseTop_magnet_depth;
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